A method and associated system for producing refined hydrocarbons from waste plastics. The method and associated system provide for pretreating waste plastics; a producing a pyrolysis gas by introducing the waste plastics pretreated in the pretreatment process into a pyrolysis reactor; producing in a lightening process a pyrolysis oil by introducing the pyrolysis gas into a hot filter; dehydrating a first mixed solution, obtained by mixing the produced pyrolysis oil with washing water and a demulsifier, by applying a voltage to the first mixed solution; hydrotreating a second mixed solution obtained by mixing the dehydrated first mixed solution with a sulfur source to produce a refined pyrolysis oil from which impurities are removed; and coking the refined pyrolysis oil, wherein a liquid condensed in the hot filter is re-introduced into the pyrolysis reactor.

A method and associated system for producing refined hydrocarbons from waste plastics. The method and associated system provide for pretreating waste plastics; a producing a pyrolysis gas by introducing the waste plastics pretreated in the pretreatment process into a pyrolysis reactor; producing in a lightening process a pyrolysis oil by introducing the pyrolysis gas into a hot filter; dehydrating a first mixed solution, obtained by mixing the produced pyrolysis oil with washing water and a demulsifier, by applying a voltage to the first mixed solution; hydrotreating a second mixed solution obtained by mixing the dehydrated first mixed solution with a sulfur source to produce a refined pyrolysis oil from which impurities are removed; and coking the refined pyrolysis oil, wherein a liquid condensed in the hot filter is re-introduced into the pyrolysis reactor.

Methods and systems for hydroprocessing heavy oil feedstocks to form an upgraded material involve the use of a colloidal or molecular catalyst dispersed within a heavy oil feedstock, a pre-coking hydrocracking reactor, a separator, and a coking reactor. The colloidal or molecular catalyst promotes upgrading reactions that reduce the quantity of asphaltenes or other coke forming precursors in the feedstock, increase hydrogen to carbon ratio in the upgraded material, and decrease boiling points of hydrocarbons in the upgraded material. The methods and systems can be used to upgrade vacuum tower bottoms and other low grade heavy oil feedstocks. The result is one or more of increased conversion level and yield, improved quality of upgraded hydrocarbons, reduced coke formation, reduced equipment fouling, processing of a wider range of lower quality feedstocks, and more efficient use of supported catalyst if used in combination with the colloidal or molecular catalyst, as compared to a conventional hydrocracking process or a conventional thermal coking process.

Methods and systems for hydroprocessing heavy oil feedstocks to form an upgraded material involve the use of a colloidal or molecular catalyst dispersed within a heavy oil feedstock, a pre-coking hydrocracking reactor, a separator, and a coking reactor. The colloidal or molecular catalyst promotes upgrading reactions that reduce the quantity of asphaltenes or other coke forming precursors in the feedstock, increase hydrogen to carbon ratio in the upgraded material, and decrease boiling points of hydrocarbons in the upgraded material. The methods and systems can be used to upgrade vacuum tower bottoms and other low grade heavy oil feedstocks. The result is one or more of increased conversion level and yield, improved quality of upgraded hydrocarbons, reduced coke formation, reduced equipment fouling, processing of a wider range of lower quality feedstocks, and more efficient use of supported catalyst if used in combination with the colloidal or molecular catalyst, as compared to a conventional hydrocracking process or a conventional thermal coking process.

A process for producing coke that may include: heating a coker feedstock to a coking temperature to produce a heated coker feedstock; feeding the heated coker feedstock to a coking drum; feeding a coking additive, such as at least one hydroconversion or hydrocracking catalyst, to the coking drum; and subjecting the heated coker feedstock to thermal cracking in the coking drum to crack a portion of the coker feedstock to produce a cracked vapor product and produce a coke product.

A process for producing coke that may include: heating a coker feedstock to a coking temperature to produce a heated coker feedstock; feeding the heated coker feedstock to a coking drum; feeding a coking additive, such as at least one hydroconversion or hydrocracking catalyst, to the coking drum; and subjecting the heated coker feedstock to thermal cracking in the coking drum to crack a portion of the coker feedstock to produce a cracked vapor product and produce a coke product.

An automatic batch sequence computer control system is configured to automatically operate process valves in a delayed coker for a complete coke drum cycle. Double verification of the movement of the process valves is used to confirm advancing to the next step. Primary verification is achieved by using position sensors on the valves. Secondary verification is achieved by using monitored process conditions and confirming the measured conditions correlate with expected process conditions for an arrangement of valve positions at a given sequence in the coke drum cycle. A safety interlock system may be integrated with the control system.

An automatic batch sequence computer control system is configured to automatically operate process valves in a delayed coker for a complete coke drum cycle. Double verification of the movement of the process valves is used to confirm advancing to the next step. Primary verification is achieved by using position sensors on the valves. Secondary verification is achieved by using monitored process conditions and confirming the measured conditions correlate with expected process conditions for an arrangement of valve positions at a given sequence in the coke drum cycle. A safety interlock system may be integrated with the control system.

A method of depolymerizing coal includes preparing a high temperature depolymerizing medium consisting of heavy hydrocarbon oils and mixing it with coal to form a mixture, performing an optional first distillation at a temperature below 250 C. to recover naphthalene, heating the mixture to a temperature between 350 C. and 450 C. to create a digested coal, centrifuging the digested coal to remove ash and obtain a centrate, and distillation of the centrate into separate fractions. The high temperature depolymerizing medium may be a heavy hydrocarbon with a hydrogen to carbon (H/C) ratio higher than 7.0% and may include liquids chosen from the group consisting of: coal tar distillate, decant oil, anthracene oil, and heavy aromatic oils. The high temperature depolymerizing medium may be blended with an oil, preferably with H/C ratio higher than 10.0%, such as soybean oil, other biomass derived oil, lignin, petroleum oil, pyrolysis oil such that the overall hydrogen-to-carbon mass ratio in a digestion reactor is over 7.0% for the mixture of depolymerizing medium and coal. The depolymerized coal is an aromatic liquid that can itself be, either wholly or in part, a depolymerizing medium so that the process can be repeated.

A method of depolymerizing coal includes preparing a high temperature depolymerizing medium consisting of heavy hydrocarbon oils and mixing it with coal to form a mixture, performing an optional first distillation at a temperature below 250 C. to recover naphthalene, heating the mixture to a temperature between 350 C. and 450 C. to create a digested coal, centrifuging the digested coal to remove ash and obtain a centrate, and distillation of the centrate into separate fractions. The high temperature depolymerizing medium may be a heavy hydrocarbon with a hydrogen to carbon (H/C) ratio higher than 7.0% and may include liquids chosen from the group consisting of: coal tar distillate, decant oil, anthracene oil, and heavy aromatic oils. The high temperature depolymerizing medium may be blended with an oil, preferably with H/C ratio higher than 10.0%, such as soybean oil, other biomass derived oil, lignin, petroleum oil, pyrolysis oil such that the overall hydrogen-to-carbon mass ratio in a digestion reactor is over 7.0% for the mixture of depolymerizing medium and coal. The depolymerized coal is an aromatic liquid that can itself be, either wholly or in part, a depolymerizing medium so that the process can be repeated.