A process for production of useful hydrocarbon materials from plastic waste and reaction system therefor is provided. The process includes frequentatively thermolyzing of high molecular weight hydrocarbons such as plastic waste to produce useful medium molecular weight hydrocarbons and low molecular weight hydrocarbons. The process utilizes low molecular weight hydrocarbons as solution reactants which helps in reducing the viscosity of the material for more effective heat transfer. The process also includes addition of one or more low molecular weight olefins and solution reactants to high molecular weight hydrocarbons to augment the free radical environment. The process also includes hydrogenating and oxidizing the high molecular weight hydrocarbons. The process enables production of the useful, predominantly hydrocarbon materials such as waxes, lube oil base-stocks, refinery feedstocks, intermediates or fuel additives. The present invention also provides a reaction system comprising thermolysis reactor including a primary zone and an optional secondary zone for production of useful hydrocarbon materials from plastic waste.

Provided in one embodiment is a continuous process for converting waste plastic into recycle for polyethylene 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 pyrolysis oil and optionally wax comprising a naphtha/diesel and heavy fraction, and char. The pyrolysis oil and wax is passed to a refinery FCC unit from which a liquid petroleum gas C.sub.3-C.sub.5 olefin/paraffin mixture fraction is recovered. The liquid petroleum gas C.sub.3-C.sub.5 olefin/paraffin mixture fraction is passed to a refinery alkylation unit, with a propane and butane fraction recovered from the alkylation unit. The propane and butane fraction is then passed to a steam cracker for ethylene production. In another embodiment, a naphtha fraction (C.sub.5-C.sub.8) is recovered from the alkylation unit and passed to the steam cracker. In another embodiment, a propane/propylene fraction (C.sub.3-C.sub.3.sup.=) is recovered from the FCC and passed to the steam cracker.

Provided is a continuous process for converting waste plastic into recycle for polyethylene polymerization or for normal alpha olefins. 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 separated into offgas, a naphtha/diesel fraction, a heavy fraction, and char. The naphtha/diesel fraction is passed to a crude unit in a refinery from which is recovered a straight run naphtha fraction (C.sub.5-C.sub.8) or a propane/butane (C.sub.3-C.sub.4) fraction. The straight run naphtha fraction, or propane and butane (C.sub.3-C.sub.4) fraction, is passed to a steam cracker for ethylene production. The ethylene is converted to normal alpha olefin and/or polyethylene. Also, a heavy fraction from the pyrolysis reactor can be combined with a heavy fraction of normal alpha olefin stream recovered from the steam cracker. The combined heavy fraction and heavy fraction of normal alpha olefin stream can be passed to a wax hydrogenation zone to produce wax.

A continuous process for converting waste plastic into recycle for polypropylene polymerization is provided. The process integrates refinery operations to provide an effective and efficient recycle process. The process comprises selecting waste plastics containing polyethylene and 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 separated into offgas, a naphtha/diesel fraction, a heavy fraction, and char. The naphtha/diesel fraction is passed to a refinery FCC unit, from which is recovered a liquid petroleum gas C.sub.3 olefin/paraffin mixture. The C.sub.3 paraffins and C.sub.3 olefins are separated into different fractions with a propane/propylene splitter. The C.sub.3 olefin fraction is passed to a propylene polymerization reactor. The C.sub.3 paraffin fraction is optionally passed to a dehydrogenation unit to produce additional propylene and then the resulting C.sub.3 olefin is passed to a propylene polymerization reactor. The heavy fraction of pyrolyzed oil is passed to an isomerization dewaxing unit to produce a lubricating base oil.

Processes and systems for making recycle content hydrocarbons, including olefins, from recycled waste material. Recycle waste material may be pyrolyzed to form recycle content pyrolysis oil composition (r-pyoil), at least a portion of which may then be cracked to form a recycle content olefin composition (r-olefin). The r- olefin may then be further separated into product streams in a separation zone downstream of the cracker furnace. In some cases, presence of recycle content hydrocarbons may facilitate more efficient operation of one or more distillation columns in the separation zone, including the demethanizer.

Processes and systems for making recycle content hydrocarbons, including olefins, from recycled waste material. Recycle waste material may be pyrolyzed to form recycle content pyrolysis oil composition (r-pyoil), at least a portion of which may then be cracked to form a recycle content olefin composition (r-olefin). In some cases, a heavy fraction from the cracker effluent may be used to form a recycle content pyrolysis gasoline composition (r-pyrolysis gasoline).

Processes and systems for making recycle content hydrocarbons, including olefins, are provided that integrate a cracker unit with one or more other processing units. For example, in some cases, a pyrolysis unit and cracking unit may share a common energy exchange zone so that energy from one unit may be transferred to the other. The energy exchange may be direct or indirect and may be present at one or more locations between the units.

A process for converting pyrolysis effluent stream into hydrocarbon products. Waste plastics are pyrolyzed at high temperature in a pyrolysis reactor to obtain a plastic pyrolysis effluent stream. The plastic pyrolysis effluent stream is further sent to a steam cracking unit for the separation of plastic pyrolysis effluent stream into a C5+ hydrocarbon stream and a C4 hydrocarbon stream. The pyrolysis reactor is operated at a to obtain hydrocarbon products of high value.

An installation for the production of oil, gas and char for carbon black, from elastomers, characterized in that, it has a screw dispenser (3) with a shaft (1), which from the loading side is closed hydraulically with a lock (2) by a nitrogen, a reactor (4), which is divided into zones A, B, C, corresponding to the subsequent stages of the pyrolysis process: zone A—the beginning of depolymerization (350° C.), zone B—carbonization (350-400° C.) and zone C—aromatic compounds cracking (400-650° C.), while a bubbler (5) hydraulically closed with a siphon (6) and a separator (7) with a hydraulic closure (8) and an oil separator (9) equipped with a transport screw (10) and an afterburner chamber (20) are installed outside the reactor (4), wherein the oil separator (9) is closed at the outlet by an accumulation shaft (12) and from the side of receiving a solid product—with a shaft (13), which is connected by an U-shaped screw conveyor (14) with economizers (11) and (15). wherein the installation is provided with a scrubber (16).

Systems and methods are provided for co-processing of plastic waste in a coking environment or other thermal conversion environment. The co-processing of plastic waste in a coking environment can be performed by performing four types of processes on the plastic waste. The plastic waste can be conditioned by classifying and sizing of the plastic waste to improve the suitability of the plastic waste for co-processing. The conditioned plastic waste particles can be entrained and/or dissolved into a solvent and/or the base feed. The solution and/or slurry of plastic waste can be passed into a coking environment, such as a fluidized coking environment or a delayed coking environment. The plastic waste can then be co-processed in the coking environment to generate liquid product.