Methods for processing condensate feedstocks

Abstract

A condensate feedstock may be processed by a method that includes passing the condensate feedstock to a first separation unit, and separating the condensate feedstock into at least a light fraction stream and a heavy fraction stream. The method may further include cracking the light fraction stream in a light fraction FCC reactor to form a first FCC effluent, and cracking the heavy fraction stream in a heavy fraction FCC reactor to from a second FCC effluent. The light fraction FCC reactor may operate with more severe cracking conditions than the heavy fraction FCC reactor.

What is claimed is: 
     
         1 . A method for processing a condensate feedstock, the method comprising:
 passing the condensate feedstock to a first separation unit, and separating the condensate feedstock into at least a light fraction stream and a heavy fraction stream, wherein:
 the light fraction stream has a maximum boiling point that is about equal to a minimum boiling point of the heavy fraction stream; 
 the light fraction stream has a maximum boiling point of from 230° C. to 380° C. and the heavy fraction stream has a minimum boiling point of from 230° C. to 380° C.; and 
 at least 90 wt. % of the condensate feedstock is contained in the combination of the light fraction stream and the heavy fraction stream; 
   cracking the light fraction stream in a light fraction FCC reactor to form a first FCC effluent;   cracking the heavy fraction stream in a heavy fraction FCC reactor to from a second FCC effluent, wherein the light fraction FCC reactor operates with more severe cracking conditions than the heavy fraction FCC reactor;   passing the first FCC effluent and the second FCC effluent to a second separation unit and forming a plurality of downstream separated streams.   
     
     
         2 . The method of  claim 1 , wherein one or more of:
 the condensate feedstock has an API gravity of from 45 degrees to 55 degrees;   the condensate feedstock has a final boiling point of from 550 to 650° C.; or   the condensate feedstock has less than or equal to 5 wt. % boiling above 565° C.   
     
     
         3 . The method of  claim 1 , wherein:
 the light fraction stream has a maximum boiling point of from 230° C. to 260° C. and the heavy fraction stream has a minimum boiling point of from 230° C. to 260° C.; or   the light fraction stream has a maximum boiling point of from 350° C. to 380° C. and the heavy fraction stream has a minimum boiling point of from 350° C. to 380° C.   
     
     
         4 . The method of  claim 1 , further comprising removing at least a portion of salt from the condensate feedstock prior to passing the condensate feedstock to the first separation unit. 
     
     
         5 . The method of  claim 1 , wherein the light fraction FCC reactor operates at a higher temperature than the heavy fraction FCC reactor. 
     
     
         6 . The method of  claim 1 , wherein the light fraction FCC reactor operates with a greater catalyst to feed ratio than the heavy fraction FCC reactor. 
     
     
         7 . The method of  claim 1 , wherein the light fraction FCC reactor operates with a greater residence time than the heavy fraction FCC reactor. 
     
     
         8 . The method of  claim 1 , wherein:
 the light fraction FCC reactor is a riser and the heavy fraction FCC reactor is a riser;   the light fraction FCC reactor is a downer and the heavy fraction FCC reactor is a downer;   the light fraction FCC reactor is a riser and the heavy fraction FCC reactor is a downer; or   the light fraction FCC reactor is a downer and the heavy fraction FCC reactor is a riser.   
     
     
         9 . The method of  claim 1 , wherein all of the condensate feedstock is contained in the combination of the light fraction stream and the heavy fraction stream. 
     
     
         10 . The method of  claim 1 , wherein a greater amount of mesoporous zeolite is utilized in the light fraction FCC reactor than in the heavy fraction FCC reactor. 
     
     
         11 . The method of  claim 1 , wherein the plurality of downstream separated streams comprise:
 a fuel gas stream;   a stream comprising C 3 -C 4  paraffins and C 3 -C 4  light olefins, wherein at least the C 3 -C 4  paraffins are passed to a mixed feed steam cracker unit;   a cat-cracked naphtha stream that is passed to a saturation unit;   a light cycle oil stream that is passed to a diesel preparation unit; and   a heavy cycle oil stream.   
     
     
         12 . The method of  claim 1 , wherein the plurality of downstream separated streams comprise:
 a fuel gas stream;   a stream comprising C 3 -C 4  paraffins and C 3 -C 4  light olefins that is passed to an olefin separation unit;   a cat-cracked naphtha stream that is passed to a gasoline preparation unit;   a light cycle oil stream that is passed to a diesel preparation unit; and   a heavy cycle oil stream.   
     
     
         13 . A method for processing a condensate feedstock, the method comprising:
 passing the condensate feedstock to a first separation unit, and separating the condensate feedstock into at least a light fraction stream, an intermediate fraction stream, and a heavy fraction stream, wherein:
 the light fraction stream has a maximum boiling point that is about equal to a minimum boiling point of the intermediate fraction stream, and the intermediate fraction stream has a maximum boiling point that is about equal to a minimum boiling point of the heavy fraction stream; 
 the light fraction stream has a maximum boiling point of from 150° C. to 200° C. and the intermediate fraction stream has a minimum boiling point of from 150° C. to 200° C.; 
 the intermediate fraction stream has a maximum boiling point of from 230° C. to 380° C. and the heavy fraction stream has a minimum boiling point of from 230° C. to 380° C.; and 
 at least 90 wt. % of the condensate feedstock is contained in the combination of the light fraction stream, the intermediate fraction stream, and the heavy fraction stream; 
   cracking the light fraction stream in a light fraction FCC reactor to form a first FCC effluent;   cracking the heavy fraction stream in a heavy fraction FCC reactor to from a second FCC effluent, wherein the light fraction FCC reactor operates with more severe cracking conditions than the light fraction FCC reactor;   passing the first FCC effluent and the second FCC effluent to a second separation unit and forming a plurality of downstream separated streams.   
     
     
         14 . The method of  claim 13 , wherein the condensate feedstock has an API gravity of from 45 degrees to 55 degrees. 
     
     
         15 . The method of  claim 13 , wherein:
 the intermediate fraction stream has a maximum boiling point of from 230° C. to 260° C. and the heavy fraction stream has a minimum boiling point of from 230° C. to 260° C.; or   the intermediate fraction stream has a maximum boiling point of from 350° C. to 380° C. and the heavy fraction stream has a minimum boiling point of from 350° C. to 380° C.   
     
     
         16 . The method of  claim 13 , wherein the light fraction FCC reactor operates at a higher temperature than the heavy fraction FCC reactor. 
     
     
         17 . The method of  claim 13 , wherein the light fraction FCC reactor operates with a greater catalyst to feed ratio than the heavy fraction FCC reactor. 
     
     
         18 . The method of  claim 13 , wherein the light fraction FCC reactor operates with a greater residence time than the heavy fraction FCC reactor. 
     
     
         19 . The method of  claim 13 , wherein:
 the light fraction FCC reactor is a riser and the heavy fraction FCC reactor is a riser;   the light fraction FCC reactor is a downer and the heavy fraction FCC reactor is a downer;   the light fraction FCC reactor is a riser and the heavy fraction FCC reactor is a downer; or   the light fraction FCC reactor is a downer and the heavy fraction FCC reactor is a riser.   
     
     
         20 . The method of  claim 13 , wherein the plurality of downstream separated streams comprise:
 a fuel gas stream;   a stream comprising C 3 -C 4  paraffins and C 3 -C 4  light olefins that is passed to a mixed feed stream cracker unit;   a cat-cracked naphtha stream that is passed to a saturation unit;   a light cycle oil stream that is passed to a diesel preparation unit; and   a heavy cycle oil stream.