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.

Methods and systems are provided for the conversion of waste plastics into various useful downstream recycle-content products. More particularly, the present system and method involves integrating a pyrolysis facility with a cracker facility by introducing at least a stream of r-pyrolysis gas into the cracker facility, in the cracker facility, the r-pyrolysis gas may be separated to form one or more recycle content products, and can enhance the operation of the facility.

A thermal cracking treatment train, comprising: a rotatable kiln reactor; the rotatable kiln reactor being configured to receive a polymeric feed material, the reactor defining at least one interior wall that bounds an interior volume of the reactor, the interior volume defining an entrance and an exit along a direction of feed material travel, the rotatable kiln reactor comprising a section that comprises one or more sweeping features configured to sweep, with rotation of the kiln, a portion of the at least one interior wall, the kiln comprising a section that comprises one or more lifter features extending from the at least one interior wall and configured to, with rotation of the kiln, encourage material disposed on the one or more features to fall into the interior volume of the interior kiln; a combustor configured to provide a heated gas to the rotatable kiln reactor; and a devolatilization train.

A thermal cracking treatment train, comprising: a rotatable kiln reactor; the rotatable kiln reactor being configured to receive a polymeric feed material, the reactor defining at least one interior wall that bounds an interior volume of the reactor, the interior volume defining an entrance and an exit along a direction of feed material travel, the rotatable kiln reactor comprising a section that comprises one or more sweeping features configured to sweep, with rotation of the kiln, a portion of the at least one interior wall, the kiln comprising a section that comprises one or more lifter features extending from the at least one interior wall and configured to, with rotation of the kiln, encourage material disposed on the one or more features to fall into the interior volume of the interior kiln; a combustor configured to provide a heated gas to the rotatable kiln reactor; and a devolatilization train.

A process is provided for producing a liquid hydrocarbon material suitable for use as a fuel or as a blending component in a fuel. The process includes co-processing a pyrolysis oil derived from a waste plastic raw material and a biorenewable feedstock comprising triglycerides in a catalytic cracking process in a presence of a solid catalyst at catalytic cracking conditions to provide a cracking product. The cracking product may be fractionated to provide at least one of a gasoline fraction and a middle distillate fraction.

Provided are a method of producing a lubricating base oil composition including a) reacting at least a part of waste plastic pyrolysis oil having a boiling point in a range higher than 340° C. to remove impurities and structurally isomerizing the oil; and b) hydroisomerizing at least a part of the product of step a), and a lubricating base oil composition produced therefrom. A lubricating base oil, which has more methyl branches than petroleum-based lubricating base oil, to have improved low-temperature properties may be provided.

Provided are a method of producing a Lube base oil composition including a) reacting at least a part of waste plastic pyrolysis oil having a boiling point in a range of 180 to 340° C. to remove impurities and oligomerize the oil; and b) hydroisomerizing at least a part of the product of step a). A lube base oil composition is also produced therefrom.

The present invention relates to automated waste recovering system and method which is not limited to a specific type of waste only. The system comprises a reactor for pyrolysis, a condensing unit connected to a water-cooled chiller to obtain liquid phase products and non-condensable gas, a gas treatment unit, a series of gas filtration unit to obtain clean gas, a storage and a control unit. The system also comprises a gas mixer unit to mix the non-condensable gas with hydrogen to obtain hydrocarbon rich gas, an artificial fuel condensing unit for condensing the hydrocarbon rich gas to obtain artificial fuel and water, which subsequently separated in a phase separator unit. The present invention provides a means to achieve constant yield by controlling conditions in the reactor and further increase the yield by producing artificial fuel.

The present invention relates to automated waste recovering system and method which is not limited to a specific type of waste only. The system comprises a reactor for pyrolysis, a condensing unit connected to a water-cooled chiller to obtain liquid phase products and non-condensable gas, a gas treatment unit, a series of gas filtration unit to obtain clean gas, a storage and a control unit. The system also comprises a gas mixer unit to mix the non-condensable gas with hydrogen to obtain hydrocarbon rich gas, an artificial fuel condensing unit for condensing the hydrocarbon rich gas to obtain artificial fuel and water, which subsequently separated in a phase separator unit. The present invention provides a means to achieve constant yield by controlling conditions in the reactor and further increase the yield by producing artificial fuel.

A method of continuously recovering hydrocarbons from carbon ores can include providing first and second vessels containing rubblized carbon ore. A cooling fuel gas can be introduced into the first vessel. The cooling fuel gas can include oxygen and a recycle gas from the second vessel, which includes hydrocarbons and oxidation products. The oxygen can be consumed through oxidation in an oxidation zone in the first vessel. The temperature of the oxidation zone can be controlled by limiting the oxygen concentration in the cooling fuel gas. This can produce a hot oxidation product gas that heats rubblized carbon ore in a pyrolysis zone downstream of the oxidation zone. Gaseous and vapor hydrocarbons can be produced in the pyrolysis zone. The vapor hydrocarbons can be condensed in a condensing zone downstream of the pyrolysis zone and then collected. The remaining gaseous hydrocarbons and oxidation products can be recycled as the recycle gas. The oxidation zone and the pyrolysis zone can continuously move through the rubblized carbon ore in a downstream direction. Optionally, by using nitrogen free oxygen for the oxidation, a nitrogen free stream of carbon dioxide is produced suitable for carbon dioxide capture and management. This can also eliminate the production of NOx in the oxidation process.