The present invention relates to a coke reducing additive composition capable of simultaneously (a) reducing coke formation and (b) increasing distillate yield during pyrolysis of a feedstock in the presence of a plastic material, wherein the feedstock is a vacuum residue (VR), plastic material is a waste plastic material or an olefin polymer (OP) material, or a mixture thereof, and the coke reducing additive composition comprises a naphthenate, preferably a calcium naphthenate, or sodium naphthenate, or a mixture thereof, and to a method of employing the coke reducing additive composition, and to a method of use of the coke reducing additive composition of the present invention. Particularly, in another embodiment, the present invention relates to a coke reducing additive composition capable of simultaneously (a) reducing formation of coke deposits on walls of the processing unit; and (b) reducing fouling caused due to deposits of coke products on walls of the processing unit during pyrolysis of a feedstock in the presence of a plastic material, wherein the feedstock is a vacuum residue (VR), plastic material is a waste plastic material or an olefin polymer (OP) material, or a mixture thereof, and the coke reducing additive composition comprises a naphthenate, preferably a calcium naphthenate, or sodium naphthenate, or a mixture thereof, and to a method of employing the coke reducing additive composition, and to a method of use of the coke reducing additive composition of the present invention. Particularly, in yet another embodiment, the present invention relates to a method to convert a waste plastic into useful chemical commodity.

Some variations provide a process for producing biocarbon pellets, comprising: pyrolyzing a biomass-containing feedstock in a first pyrolysis reactor to generate a first biogenic reagent and a pyrolysis vapor; introducing the pyrolysis vapor to a separation unit, to generate a pyrolysis precipitate in liquid or solid form; contacting the first biogenic reagent with the pyrolysis precipitate, thereby generating an intermediate material; pelletizing the intermediate material, to generate intermediate pellets; optionally, drying the intermediate pellets; separately pyrolyzing the intermediate pellets in a second pyrolysis reactor to generate a second biogenic reagent and a pyrolysis off-gas; and recovering the second biogenic reagent as biocarbon pellets. Some variations provide a similar process that utilizes a carbon-containing condensed-matter material, which is not necessarily a pyrolysis precipitate. The disclosure provides improved processes for producing biocarbon compositions, especially with respect to carbon yield and biocarbon properties, such as reactivity.

The present invention relates to crude oil processing, particularly related to conversion of crude oil containing high amount of naphthenic acid compounds to lighter hydrocarbon materials with minimum capital expenditure. The invented process utilizes a novel scheme for high TAN crude oils by employing thermal cracking process to maximize the residue conversion to valuable products, which require minimum modifications in unit metallurgies and corrosion inhibitor injection schemes in refineries.

Methods are disclosed to make coke, graphite, graphene and other materials from biomass derived bio-oil.

Methods and systems for producing anode grade coke are disclosed, which allow anode grade coke to be produced from crude oil having a high sulfur content. A fraction of the resid is hydrotreated while another fraction of the resid is treated in a solvent deasphalting unit. A synthetic stream is provided by blending hydrotreated resid with one or more streams from the deasphalting unit. The synthetic stream is fed to an anodic coker unit.

Embodiments of a process for producing high grade coke from crude oil residue include at least partially separating, in a solvent extraction unit, the crude oil residue into a deasphalted oil (DAO)-containing stream and an asphaltene containing-stream, producing a pressurized, heated DAO-containing stream, where the pressurized, heated DAO-containing stream, mixing a supercritical water stream with the pressurized, heated DAO-containing stream to create a combined feed stream, introducing the combined feed stream to an upgrading reactor system operating at supercritical temperature and pressure to yield one or more upgrading reactor output streams comprising upgraded product and a slurry mixture, where the slurry mixture comprises sulfur and one or more additional metals. The process also may include calcining the slurry mixture at a temperature of from 700 C. to 1900 C. to produce a product stream comprising the high grade coke.

Systems and methods are provided for reducing or minimizing the chloride content of products generated during co-processing of a plastic feedstock (such as plastic waste) in a refinery process. The reduction in chloride is achieved by mixing the plastic feedstock with one or more additional feedstocks for co-processing in a mixing and/or holding vessel that is maintained at a dechlorination temperature that allows for decomposition of chlorine from the plastic feedstock to form HCl, while reducing or minimizing other conversion of the plastic feedstock and/or the additional feedstock. A purge gas can be passed through the mixing/holding vessel to remove the evolved HCl from the vessel. Because the dechlorination temperature is selected to reduce or minimize conversion of the feedstocks in the mixture, the amount of carbon-containing products that are removed with the purge gas can be reduced or minimized. The dechlorinated mixture of plastic feedstock and additional feedstock(s) can then be processed in a convenient refinery process, such as a thermal cracking process (e.g., coking, visbreaking, other types of pyrolysis) or a catalytic conversion process (e.g., fluid catalytic cracking).

The present disclosure provides a process for preparing a needle coke or a crystalline coke from aromatic rich hydrocarbon streams. The process includes preparing a needle coke or a crystalline coke from Pyrolytic Fuel Oil (PFO) and Clarified Oil (CLO) stream along with Purified fraction of CLO after solvent separation of refractory asphaltene compounds while the low boiling fractions separated from PFO and light gasoil (LGO) from the thermal cracking section are selectively hydro cracked to produce high value aromatic chemicals.

Process embodiments for producing high grade coke and fuel grade coke from residual oil comprises: introducing the residual oil and a first paraffinic solvent having a carbon number C.sub.n to a first solvent deasphalting unit to produce a high quality deasphalted oil (HQDAO) fraction and a first asphalt fraction; passing the HQDAO fraction to a delayed coker to produce green coke; passing at least a portion of the first asphalt fraction and a second paraffinic solvent carbon number of C.sub.n+1 to a second solvent deasphalting unit to produce a low quality deasphalted oil (LQDAO) fraction and a second asphalt fraction; and passing the LQDAO fraction to the delayed coker to produce the fuel grade coke.

A method of producing low CTE graphite electrodes from needle coke formed from a coal tar distillate material having a relatively high initial boiling point.