This disclosure relates to the production of chemicals and plastics using pyrolysis oil from the pyrolysis of plastic waste as a co-feedstock along with a petroleum-based, fossil fuel-based, or bio-based feedstock. In an aspect, the polymers and chemicals produced according to this disclosure can be certified under International Sustainability and Carbon Certification (ISCC) provisions as circular polymers and chemicals at any point along complex chemical reaction pathways. The use of a mass balance approach which attributes the pounds of pyrolyzed plastic products derived from pyrolysis oil to any output stream of a given unit has been developed, which permits ISCC certification agency approval.

Process for the conversion of plastics to olefins comprising the following steps: A) gasification of the plastics to synthesis gas by reaction of the plastics with pure oxygen; B) catalytic conversion of the synthesis gas produced in stage A) to methane in at least three successive stages, in each of which hydrogen is added; C) catalytic conversion of the methane produced in stage B) into olefins by the oxidative coupling reaction of methane; and D) separation of the olefins produced in stage C) from other compounds present in the reaction mixture of said stage C).

Process for the conversion of plastics to olefins comprising the following steps: A) gasification of the plastics to synthesis gas by reaction of the plastics with pure oxygen; B) catalytic conversion of the synthesis gas produced in stage A) to methane in at least three successive stages, in each of which hydrogen is added; C) catalytic conversion of the methane produced in stage B) into olefins by the oxidative coupling reaction of methane; and D) separation of the olefins produced in stage C) from other compounds present in the reaction mixture of said stage C).

Processes for chemically treating polyaromatic feedstock to form aromatic-containing oligomers or polymers are provided. The processes are characterized by treatment of a plurality of different polyaromatic hydrocarbon molecules and/or polyheterocyclic molecules present in polyaromatic feedstock with a first reagent so as to functionalize the molecules. Further treatment in a second step affords oligomeric or polymeric products which may be crosslinked. The products may be thermoplastic or thermoset materials and may find use in, for example, infrastructure applications, composites, fillers, fire retardants and 3-D printing materials.

Disclosed herein are processes for the production of hydrocarbon fuel products from C.sub.2-5 alkanes. Methane is converted to ethylene in a methane thermal olefination reactor operating at a temperature of at least 900° C. and a pressure of at least 150 psig, and without a dehydrogenation catalyst or steam. C.sub.2-5 alkanes are converted to olefins in a C.sub.2-5 thermal olefination reactor operating at a temperature, pressure and space velocity to convert at least 80% of the alkanes to C.sub.2-5 olefins. The ethylene and C.sub.2-5 olefins are passed through an oligomerization reactor containing a zeolite catalyst and operating at a temperature, pressure and space velocity to crack, oligomerize and cyclize the olefins. In one aspect, methane in the effluent of the oligomerization reactor is recycled through the C.sub.2-5 thermal olefination reactor. Methods for the thermal olefination of methane are also disclosed.

The present invention is directed to metallocene catalyzed oligomerization of olefin feed stock without fractionation of alkane and olefin.

A process for converting C2-5 alkanes to higher value C5-24 hydrocarbon fuels and blendstocks. The C2-5 alkanes are converted to olefins by thermal olefination, without the use of a dehydrogenation catalyst and without the use of steam. The product olefins are fed to an oligomerization reactor containing a zeolite catalyst to crack, oligomerize and cyclize the olefins to the fuel products which are then recovered. Optionally, hydrogen and methane are removed from the product olefin stream prior to oligomerization. Further optionally, C2-5 alkanes are removed from the product olefin stream prior to oligomerization.

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.

The present invention relates to a process for the production of propylene-based polymers from waste plastics feedstocks comprising the steps in this order of: (a) providing a hydrocarbon stream A obtained by hydrotreatment of a pyrolysis oil produced from a waste plastics feedstock; (b) optionally providing a hydrocarbon stream B; (c) supplying a feed C comprising a fraction of the hydrocarbon stream A and optionally a fraction of the hydrocarbon stream B to a thermal cracker furnace comprising cracking coil(s); (d) performing a thermal cracking operation in the presence of steam to obtain a cracked hydrocarbon stream D; (e) supplying the cracked hydrocarbon stream D to a separation unit; (f) performing a separation operation in the separation unit to obtain a product stream E comprising propylene; (g) supplying the product stream E to a polymerisation reactor; and (h) performing a polymerisation reaction in the polymerisation reactor to obtain an propylene-based polymer; wherein in step (d): • the coil outlet temperature is ≥800 and ≤850° C., preferably ≥805 and ≤835° C.; and • the weight ratio of steam to feed C is >0.3 and <0.8.

The present invention relates to a process for the production of polymers from waste plastics feedstocks comprising the steps in this order of: (a) providing a hydrocarbon stream A obtained by treatment of a waste plastics feedstock; (b) optionally providing a hydrocarbon stream B; (c) supplying a feed C comprising a fraction of the hydrocarbon stream A and a fraction of the hydrocarbon stream B to a thermal cracker furnace comprising cracking coil(s); (d) performing a thermal cracking operation in the presence of steam to obtain a cracked hydrocarbon stream D; (e) supplying the cracked hydrocarbon stream D to a separation unit; (f) performing a separation operation in the separation unit to obtain a product stream E comprising a monomer; (g) supplying the product stream E to a polymerisation reactor; and (h) performing a polymerisation reaction in the polymerisation reactor to obtain an polymer. The process of the present invention allows for optimisation of the quantity of waste plastic material that finds its way back into a polymer that is produced as outcome of the process.