A process for processing plastic waste comprising converting plastic waste to hydrocarbon liquid and a first C.sub.1-4 gas; contacting hydrocarbon liquid with a first hydroprocessing catalyst in hydroprocessing unit to yield a second C.sub.1-4 gas and a first hydrocarbon product comprising C.sub.5+ liquid hydrocarbons; introducing the first hydrocarbon product to a first separating unit to produce treated hydrocarbon stream comprising C.sub.5-8 hydrocarbons and a first heavies stream comprising C9+ hydrocarbons; contacting the first heavies stream with a second hydroprocessing catalyst in hydrodealkylating unit to yield a second hydrocarbon product comprising C.sub.5+ liquid hydrocarbons and a third C.sub.1-4 gas; conveying the second hydrocarbon product to the first separating unit; feeding treated hydrocarbon stream to steam cracker to produce steam cracker product; separating steam cracker product into olefin gas, saturated hydrocarbons gas, aromatics, and a second heavies stream; and conveying the second heavies stream to hydroprocessing unit.

A process for processing plastic waste comprising converting plastic waste to hydrocarbon liquid and a first C.sub.1-4 gas; contacting hydrocarbon liquid with a first hydroprocessing catalyst in hydroprocessing unit to yield a second C.sub.1-4 gas and a first hydrocarbon product comprising C.sub.5+ liquid hydrocarbons; introducing the first hydrocarbon product to a first separating unit to produce treated hydrocarbon stream comprising C.sub.5-8 hydrocarbons and a first heavies stream comprising C9+ hydrocarbons; contacting the first heavies stream with a second hydroprocessing catalyst in hydrodealkylating unit to yield a second hydrocarbon product comprising C.sub.5+ liquid hydrocarbons and a third C.sub.1-4 gas; conveying the second hydrocarbon product to the first separating unit; feeding treated hydrocarbon stream to steam cracker to produce steam cracker product; separating steam cracker product into olefin gas, saturated hydrocarbons gas, aromatics, and a second heavies stream; and conveying the second heavies stream to hydroprocessing unit.

The invention provides a pyrolysis reaction system, the system comprising: a pyrolysis chamber comprising a feed inlet, a gas inlet and a product outlet, wherein the pyrolysis chamber is configured i) to receive a pyrolysable organic feed and an inert gas via the feed inlet and gas inlet respectively, ii) to pyrolyse the organic feed at a pyrolysis temperature to produce a carbonaceous pyrolysis product and a pyrolysis gas, wherein the pyrolysis gas will combine with the inert gas to form a gas mixture having a pyrolysis chamber pressure in the pyrolysis chamber, and iii) to discharge the carbonaceous pyrolysis product via the product outlet; a gas reactor configured to react the pyrolysis gas by combustion and/or carbon deposition at a gas reaction temperature and a gas reactor pressure; and a first partition defining a boundary between the pyrolysis chamber and the gas reactor, the first partition comprising a plurality of first apertures to provide fluid communication between the pyrolysis chamber and the gas reactor, wherein the pyrolysis reaction system is operable with the gas reactor pressure less than the pyrolysis chamber pressure such that the gas mixture flows from the pyrolysis chamber to the gas reactor through the first apertures, thereby providing at least a portion of the pyrolysis gas for reaction in the gas reactor.

The invention provides a pyrolysis reaction system, the system comprising: a pyrolysis chamber comprising a feed inlet, a gas inlet and a product outlet, wherein the pyrolysis chamber is configured i) to receive a pyrolysable organic feed and an inert gas via the feed inlet and gas inlet respectively, ii) to pyrolyse the organic feed at a pyrolysis temperature to produce a carbonaceous pyrolysis product and a pyrolysis gas, wherein the pyrolysis gas will combine with the inert gas to form a gas mixture having a pyrolysis chamber pressure in the pyrolysis chamber, and iii) to discharge the carbonaceous pyrolysis product via the product outlet; a gas reactor configured to react the pyrolysis gas by combustion and/or carbon deposition at a gas reaction temperature and a gas reactor pressure; and a first partition defining a boundary between the pyrolysis chamber and the gas reactor, the first partition comprising a plurality of first apertures to provide fluid communication between the pyrolysis chamber and the gas reactor, wherein the pyrolysis reaction system is operable with the gas reactor pressure less than the pyrolysis chamber pressure such that the gas mixture flows from the pyrolysis chamber to the gas reactor through the first apertures, thereby providing at least a portion of the pyrolysis gas for reaction in the gas reactor.

The present disclosure generally relates to the utilization of a fine mineral matter in the process of upgrading the liquid products obtained by thermolysis or pyrolysis of solid plastic waste or biomass or from cracking, coking or visbreaking of petroleum feedstocks. More particularly, the present disclosure is directed to a process of stabilization of the free-radical intermediates formed during thermal or catalytic cracking of hydrocarbon feedstocks including plastic waste and on a process of catalytic in-situ heavy oil upgrading. The fine mineral matter may be derived from natural sources or from synthetic sources.

A process for processing plastic waste comprising converting plastic waste to hydrocarbon liquid and a first C.sub.1-4 gas; contacting hydrocarbon liquid with a first hydroprocessing catalyst in hydroprocessing unit to yield a second C.sub.1-4 gas and a first hydrocarbon product comprising C.sub.5+ liquid hydrocarbons; introducing the first hydrocarbon product to a first separating unit to produce treated hydrocarbon stream comprising C.sub.5-8 hydrocarbons and a first heavies stream comprising C9+ hydrocarbons; contacting the first heavies stream with a second hydroprocessing catalyst in hydrodealkylating unit to yield a second hydrocarbon product comprising C.sub.5+ liquid hydrocarbons and a third C.sub.1-4 gas; conveying the second hydrocarbon product to the first separating unit; feeding treated hydrocarbon stream to steam cracker to produce steam cracker product; separating steam cracker product into olefin gas, saturated hydrocarbons gas, aromatics, and a second heavies stream; and conveying the second heavies stream to hydroprocessing unit.

A process for processing plastic waste comprising converting plastic waste to hydrocarbon liquid and a first C.sub.1-4 gas; contacting hydrocarbon liquid with a first hydroprocessing catalyst in hydroprocessing unit to yield a second C.sub.1-4 gas and a first hydrocarbon product comprising C.sub.5+ liquid hydrocarbons; introducing the first hydrocarbon product to a first separating unit to produce treated hydrocarbon stream comprising C.sub.5-8 hydrocarbons and a first heavies stream comprising C9+ hydrocarbons; contacting the first heavies stream with a second hydroprocessing catalyst in hydrodealkylating unit to yield a second hydrocarbon product comprising C.sub.5+ liquid hydrocarbons and a third C.sub.1-4 gas; conveying the second hydrocarbon product to the first separating unit; feeding treated hydrocarbon stream to steam cracker to produce steam cracker product; separating steam cracker product into olefin gas, saturated hydrocarbons gas, aromatics, and a second heavies stream; and conveying the second heavies stream to hydroprocessing unit.

A plastic catalytic pyrolysis process that can produce high yields of ethylene, propylene and other light olefins from waste plastics is disclosed. The catalytic product stream is quenched to below catalytic pyrolysis temperature quickly after exiting the reactor or bulk separation from the catalyst. Quench preserves selectivity of light olefinic monomers. The catalytic pyrolysis process can be operated in a single stage or a two-stage process.

A plastic catalytic pyrolysis process that can produce high yields of ethylene, propylene and other light olefins from waste plastics is disclosed. The catalytic product stream is quenched to below catalytic pyrolysis temperature quickly after exiting the reactor or bulk separation from the catalyst. Quench preserves selectivity of light olefinic monomers. The catalytic pyrolysis process can be operated in a single stage or a two-stage process.

A method for decomposing an organic raw material, comprising: a raw material supply step of supplying an organic raw material containing biomass and/or organic polymer waste, and an artificial carbon particle to a fluidized-bed-type decomposition apparatus, and a decomposition step of decomposing the organic raw material into a non-solid decomposition component and a solid residue while fluidizing the artificial carbon particle with introducing a carrier gas to the fluidized-bed-type decomposition apparatus, to discharge the non-solid decomposition component with the carrier gas as well as to discharge the solid residue separately from the non-solid decomposition component.