A system and process for refining crude oil to produce higher-purity, cleaner-burning designer fuels with reduced emissions. The crude oil may be treated with viscosity-reductant additives, which reduces viscosity by up to 50% and increases API gravity by more than 2 points. The method of spray-cracking and vacuum-flashing of crude oil separates light end chains and heavy end chains inside the reactor. The vapor is condensed into designer fuels like bunker, diesel, jet/kerosene fuel, naphtha and gasoline fuel using multi-stage horizontal reverse condensate-condenser. The GVF centrifuges are configured to separate targeted fuels of desired density value as per their ideal fuel densities, which carry out centrifugal polishing to generate targeted fuel products of desired density and hydrocarbon molecules of desired purity values. These designer fuels are further treated with desulfurization additive.

A system and process for refining crude oil to produce higher-purity, cleaner-burning designer fuels with reduced emissions. The crude oil may be treated with viscosity-reductant additives, which reduces viscosity by up to 50% and increases API gravity by more than 2 points. The method of spray-cracking and vacuum-flashing of crude oil separates light end chains and heavy end chains inside the reactor. The vapor is condensed into designer fuels like bunker, diesel, jet/kerosene fuel, naphtha and gasoline fuel using multi-stage horizontal reverse condensate-condenser. The GVF centrifuges are configured to separate targeted fuels of desired density value as per their ideal fuel densities, which carry out centrifugal polishing to generate targeted fuel products of desired density and hydrocarbon molecules of desired purity values. These designer fuels are further treated with desulfurization additive.

According to embodiments described herein, a method of processing a whole crude oil feed stream may include passing a whole crude oil feed stream into a fluid catalytic cracking unit and contacting the whole crude oil feed stream with an adsorbent material and a cracking catalyst. The adsorbent material may adsorb at least a portion of the sulfur of the whole crude oil feed stream and at least a portion of the whole crude oil feed stream may be catalytically cracked to produce coke disposed on the cracking catalyst. The method may further include passing the adsorbent material and the cracking catalyst to a regenerator, wherein the adsorbent material and the cracking catalyst contact an oxygen-containing gas at a temperature sufficient to remove at least a portion of the sulfur on the adsorbent material and combust at least a portion of the coke on the catalyst.

According to embodiments described herein, a method of processing a whole crude oil feed stream may include passing a whole crude oil feed stream into a fluid catalytic cracking unit and contacting the whole crude oil feed stream with an adsorbent material and a cracking catalyst. The adsorbent material may adsorb at least a portion of the sulfur of the whole crude oil feed stream and at least a portion of the whole crude oil feed stream may be catalytically cracked to produce coke disposed on the cracking catalyst. The method may further include passing the adsorbent material and the cracking catalyst to a regenerator, wherein the adsorbent material and the cracking catalyst contact an oxygen-containing gas at a temperature sufficient to remove at least a portion of the sulfur on the adsorbent material and combust at least a portion of the coke on the catalyst.

A process for continuously upgrading heavy oil to produce light hydrocarbon gases which are recycled in the process as a carrier gas used in spark-discharge hydrocarbon cracking within the process. The process also produces light hydrocarbon liquids which are used to upgrade the heavy oil. An apparatus for continuously upgrading heavy oil to produce light hydrocarbon gases which are recycled in the as a carrier gas used in spark-discharge hydrocarbon cracking within the apparatus. The apparatus also produces light hydrocarbon liquids which are used to upgrade the heavy oil.

A process for continuously upgrading heavy oil to produce light hydrocarbon gases which are recycled in the process as a carrier gas used in spark-discharge hydrocarbon cracking within the process. The process also produces light hydrocarbon liquids which are used to upgrade the heavy oil. An apparatus for continuously upgrading heavy oil to produce light hydrocarbon gases which are recycled in the as a carrier gas used in spark-discharge hydrocarbon cracking within the apparatus. The apparatus also produces light hydrocarbon liquids which are used to upgrade the heavy oil.

Systems and processes for upgrading natural gas liquids (NGL). A natural gas, preferably a shale gas, comprising methane and one or more natural gas liquids can be converted to one or more liquid hydrocarbons. Methane can be separated from the one or more liquid hydrocarbons using a liquid absorbent to provide a first separated stream comprising the methane from the converted stream and a second separated stream comprising the one or more liquid hydrocarbons from the converted stream. At least a portion of the one or more liquid hydrocarbons can be recycled as the liquid absorbent.

A distillation device including: a first distillation column having first top, bottom and upper outlets and first upper and lower inlets; a second distillation column equipped with a top condenser and a bottom reboiler, and having second top, bottom and upper outlets and second upper and lower inlets; a vapor recompressor; a heat exchanger; a first supply line supplying a feedstock to the first lower inlet; a first connection line transferring a first bottom flow to the second lower inlet via the heat exchanger; and a second connection line transferring a second top flow to the top condenser via the heat exchanger after passing through the vapor recompressor. The first bottom flow flowing through the first connection line and the second top flow flowing through the second connection line are heat-exchanged in the heat exchanger. A distillation method of a feedstock using the distillation device.

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.

A process for continuously upgrading heavy oil to produce light hydrocarbon gases which are recycled in the process as a carrier gas used in spark-discharge hydrocarbon cracking within the process. The process also produces light hydrocarbon liquids which are used to upgrade the heavy oil. An apparatus for continuously upgrading heavy oil to produce light hydrocarbon gases which are recycled in the as a carrier gas used in spark-discharge hydrocarbon cracking within the apparatus. The apparatus also produces light hydrocarbon liquids which are used to upgrade the heavy oil.