Provided is a continuous process for converting waste plastic into a feedstock for polyethylene polymerization. The process comprises selecting waste plastics containing polyethylene and/or polypropylene, and then passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is then separated into offgas, a pyrolysis oil comprising a naphtha/diesel/heavy fraction, and char. The pyrolysis oil is passed to a crude unit in a refinery from which a naphtha fraction (C.sub.5-C.sub.8), or a propane and butane (C.sub.3-C.sub.4) fraction, is recovered. The naphtha fraction, or propane and butane (C.sub.3-C.sub.4) fraction, is then passed to a steam cracker for ethylene production.

Provided is a continuous process for converting waste plastic into recycle for polypropylene polymerization. The process comprises selecting waste plastics containing polyethylene and/or polypropylene and passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is separated into offgas, a naphtha/diesel fraction, a heavy fraction, and char. Pyrolysis oil and wax, comprising the naphtha/diesel fraction and heavy fraction, is sent to a refinery FCC unit. A liquid petroleum gas C.sub.3-C.sub.5 olefin/paraffin mixture is recovered from the FCC unit and passed to a refinery alkylation unit. A propane fraction is recovered from the alkylation unit and passed to a dehydrogenation unit to produce propylene. The propylene is passed to a propylene polymerization reactor.

Provided is a continuous process for converting waste plastic into recycle for polypropylene polymerization. The process comprises selecting waste plastics containing polyethylene and/or polypropylene and passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is separated into offgas, a naphtha/diesel fraction, a heavy fraction, and char. Pyrolysis oil and wax, comprising the naphtha/diesel fraction and heavy fraction, is sent to a refinery FCC unit. A liquid petroleum gas C.sub.3-C.sub.5 olefin/paraffin mixture is recovered from the FCC unit and passed to a refinery alkylation unit. A propane fraction is recovered from the alkylation unit and passed to a dehydrogenation unit to produce propylene. The propylene is passed to a propylene polymerization reactor.

Provided is a dehydrogenating catalyst that is capable of preventing or reducing coking and improving the yield of an olefin in a pyrolysis reaction of a hydrocarbon raw material. A dehydrogenating catalyst (4A) for production of an olefin contains, as a catalyst component, at least one of La and Ce, wherein, when the dehydrogenating catalyst (4A) does not contain Ce, the dehydrogenating catalyst (4A) contains at least one element selected from the group consisting of Ba, Fe, and Mn, or wherein, when the dehydrogenating catalyst (4A) contains Ce, the dehydrogenating catalyst (4A) contains at least one of Fe and Mn.

Disclosed herein are methods of preparing dehydrogenation catalysts using non-halogen containing metal sources. The methods generally comprise the steps of providing a first solution comprising anions of a first metal selected from Group 14 of the Periodic Table of Elements, and impregnating an inorganic support with the first solution to obtain a first impregnated inorganic support, wherein the first solution has a pH value of less than the isoelectric point of the inorganic support. The dehydrogenation catalysts prepared in accordance with the methods of the present disclosure are typically free or substantially free of halogen species. Such catalysts may be particularly useful in the dehydrogenation of a feed comprising cyclohexane and/or methylcyclopentane.

A process for dehydrogenating alkane or alkylaromatic compounds comprising contacting the given compound and a dehydrogenation catalyst in a fluidized bed. The dehydrogenation catalyst is prepared from an at least partially deactivated platinum/gallium catalyst on an alumina-based support that is reconstituted by impregnating it with a platinum salt solution, then calcining it at a temperature from 400° C. to 1000° C., under conditions such that it has a platinum content ranging from 1 to 500 ppm, based on weight of catalyst; a gallium content ranging from 0.2 to 2.0 wt %; and a platinum to gallium ratio ranging from 1:20,000 to 1:4. It also has a Pt retention that is equal to or greater than that of a fresh catalyst being used in a same or similar catalytic process.

An apparatus to decompose a hydrocarbon reactant into a gaseous product and a solid product includes a reactor volume, a reservoir of liquid material, a plurality of nozzles connected to the reservoir of liquid material, the plurality of nozzles configured to distribute the liquid material into the reactor volume from the reservoir as a liquid mist, a gas inlet connected to a hydrocarbon gas source to receive hydrocarbon gas reactant, a distributor connected to the inlet to distribute the hydrocarbon gas reactant into the reactor volume, a heat source located adjacent the reactor volume configured to heat the reactor volume, a separator to separate the solid product from the liquid material, a re-circulation path connected between the reactor volume and the reservoir to re-circulate the liquid material from the reactor volume to the reservoir, a gas outlet connected to the reactor volume configured to outlet hydrogen gas from the reactor volume, and at least one filter connected to the gas outlet to remove entrained solid product from the hydrogen gas.

A method to decompose a hydrocarbon reactant into a gaseous product and a solid product includes generating a mist of a liquid material within a reactor volume, heating the reactor volume, introducing a hydrocarbon reactant into the reactor volume to produce a solid product and a gaseous product, separating the solid product from the liquid material, removing the solid product and gaseous product from the reactor volume, and recirculating the liquid material be re-introduced to the reactor volume.

A process for converting naphtha to light olefins comprises contacting a naphtha stream with a zeolitic catalyst to produce a light paraffin stream at conditions which dehydrogenate the naphtha to olefins, interconvert the olefins to lighter olefins and hydrogenate the lighter olefins to produce a light paraffin stream comprising ethane and propane. The catalyst may comprise a zeolite and a metal.

Processes and systems for dehydrogenating ethylbenzene may include mixing a steam stream and an ethylbenzene stream to form a feed mixture. The ethylbenzene/steam feed mixture may then be fed to a dehydrogenation reactor containing an alkali metal promoted catalyst. A liquid, selected from an alkali metal liquid, an alkali metal compound liquid, or a liquid solution comprising an alkali metal, may be injected into a feed stream, such as the steam stream, the ethylbenzene stream, or the ethylbenzene/steam feed mixture. Following injection, the liquid vaporizes and disperses into the feed stream upstream of the dehydrogenation reactor. The liquid may be maintained as a liquid from a point upstream of injection to an injection nozzle. The liquid is dispersed through the injection nozzle, in liquid form, to form droplets of liquid dispersed in the feed stream, which evaporate and/or dissolve into the vaporous feed stream.