Systems and methods are provided for conversion of polymers (such as plastic waste) to olefins. The systems and methods can include an initial pyrolysis stage where a plastic feedstock is delivered to the initial pyrolysis stage by one or more melt extruders. The one or more melt extruders can be heated to maintain the plastic feedstock in a liquid state during delivery of the plastic feedstock to the initial pyrolysis stage. This can allow for delivery of the plastic feedstock into the pyrolysis process with a controlled distribution of plastic into the pyrolysis reactor.

The present invention describes a processes, systems, and catalysts for the conversion of carbon dioxide and water and electricity into low carbon or zero carbon high quality fuels and chemicals. In one aspect, the present invention provides an integrated process for the conversion of a feed stream comprising carbon dioxide to a product stream comprising hydrocarbons between 5 and 24 carbon atoms in length.

Chemical recycling facilities for processing mixed plastic waste are provided herein. Such facilities have the capability of processing mixed plastic waste streams and utilize a variety of recycling facilities, such as, for example, solvolysis facility, a pyrolysis facility, a cracker facility, a partial oxidation gasification facility, an energy generation/energy production facility, and a solidification facility. Streams from one or more of these individual facilities may be used as feed to one or more of the other facilities, thereby maximizing recovery of valuable chemical components and minimizing unusable waste streams.

The invention is directed to a process to prepare propylene from a mixture of hydrocarbons having an olefin content of between 5 and 50 wt. % and boiling for more than 90 vol. % between 35 and 280° C. or from a hydrocarbon feed comprising paraffins, naphthenics, aromatics and optionally up to 10 wt. % of olefins, by first contacting the feed with a low acidic density cracking catalyst in a fixed bed reactor, separating propylene and subsequently contacting the residue with a high acidic density cracking catalyst in a fixed bed reactor at a more elevated temperature, separating propylene and recycling the residue to first and second cracking reactors. Aromatics may be added to first and second cracking step to improve cycle length.

A process for producing light olefins comprising thermal cracking. Hydrocracked streams are thermally cracked to produce light olefins. A pyrolysis gas stream is separated into a light pyrolysis gas stream and a heavy pyrolysis gas stream. A light pyrolysis gas stream is separated into a normal paraffins stream and a non-normal paraffins stream. A normal paraffins stream is thermally cracked. The integrated process may be employed to obtain olefin products of high value from a crude stream.

A process for the catalytic cracking of hydrocarbon oils includes the step of contacting a hydrocarbon oil feedstock with a catalytic cracking catalyst in a reactor having one or more fast fluidized reaction zones for reaction. At least one of the fast fluidized reaction zones of the reactor is a full dense-phase reaction zone, and the axial solid fraction ε of the catalyst is controlled within a range of about 0.1 to about 0.2 throughout the full dense-phase reaction zone. When used for catalytic cracking of hydrocarbon oils, particularly heavy feedstock oils, the process, reactor and system show a high contact efficiency between oil and catalyst, a selectivity of the catalytic reaction, an effectively reduced yield of dry gas and coke, and an improved yield of high value-added products such as ethylene and propylene.

The present disclosure relates to an FCC catalyst composition and a process for preparing the same. In a first aspect, there is provided an FCC catalyst composition comprising 25 to 45 wt % Y-type zeolite, 20 to 40 wt % silicon oxide, 5 to 25 wt % alumina, 5 to 35 wt % of at least one clay and 0.5 to 3 wt % of at least one rare earth oxide. The weight % of each of the component is with respect to the total weight of the composition. The FCC catalyst composition has an average particle size in the range of 45-120μ. In a second aspect, there is provided a process for preparing the FCC catalyst composition, which uses ball milled pseudoboehmite having an average particle size in the range of 1 to 8 micron and the whole process is carried out at a pH value in the range of 6 to 7.

A system and a method for steam cracking hydrocarbons are disclosed. The system includes a steam cracking furnace that includes ceramic radiant coils. The system is configured to heat the radiant coils by oxy-fuel combustion in the firebox. The system further includes an oxygen production unit configured to produce pure oxygen used for the oxy-fuel combustion. The effluent from the steam cracking furnace can be further separated into various product streams or fed into a polymerization unit.

Processes and systems for pyrolysing a hydrocarbon feed for a predetermined period of time, e.g., by steam cracking. The process can include determining a first amount of silicon material present in the hydrocarbon feed that is to be steam cracked to produce a steam cracker effluent. The process can also include determining a second amount of silicon material that will be present in a steam cracker naphtha that is to be separated from the steam cracker effluent.

A method for producing green olefins and green gasoline from renewable sources, the method including: providing CO.sub.2 and hydrogen as feed to produce methanol in a methanol reactor, to produce an MTO reaction effluent, reacting the MTO reaction effluent in a plurality of separation columns to separate hydrocarbons, wherein the plurality of separation columns includes a Deethanizer column, a Depropanizer column, and a Debutanizer column, hydrogenating a fraction of separated hydrocarbons in the Debutanizer column with the hydrogen in a hydrogenation reactor, wherein the fraction of separated hydrocarbons from the Debutanizer column includes C.sub.5+ hydrocarbons; producing the green gasoline and Liquefied Petroleum Gas (LPG) by stabilizing the hydrogenated hydrocarbons in a gasoline stabilizer column; and producing the olefins by separating ethylene from C.sub.2 hydrocarbons using a C.sub.2 splitter column and by separating propylene from C.sub.3 hydrocarbons using a C.sub.3 splitter column.