A method is described for treating a hydrocarbon oil feedstream to a delayed coking unit to maximize the ratio of the yield of liquids-to-gases, and to minimize the formation of coke which includes: a. mixing an oil-soluble catalyst with the hydrocarbon oil feedstream to produce a uniform mixture; b. contacting the catalyst-containing hydrocarbon oil feedstream with an excess of hydrogen under predetermined conditions that are favorable to maximizing the solubility of the hydrogen in the feedstream in a hydrogen distribution zone that is upstream of the coking unit; c. introducing the feedstream containing the solubilized catalyst and dissolved hydrogen, and the excess hydrogen gas into a flashing zone; d. recovering from the flashing zone a hydrogen gas stream and a single-phase hydrocarbon oil feedstream containing dissolved hydrogen and catalyst; e. maintaining the hydrocarbon oil feedstream containing dissolved hydrogen and catalyst under single-phase conditions to promote the reaction of the dissolved hydrogen with free radicals formed in the feedstream and to promote the catalyzed hydrodesulfurization of any sulfur-containing compounds present in the feedstream; f. introducing the catalyst-containing feedstream into a coking furnace upstream of the coking unit to heat the feedstream to a predetermined coking temperature; g. introducing the hot feedstream into the coking unit; and h. recovering a coking unit product stream that is free of catalyst and forming a coke product that contains the catalyst.

A reaction process includes introducing hydrocarbon reactants into a vessel, reacting the hydrocarbon reactants in contact with the gas phase catalyst in the vessel to produce reaction products comprising solid carbon and a gas phase product, separating the solid carbon from the gas phase products and the gas phase catalyst to produce a solid carbon product, condensing the gas phase catalyst to produce a condensed catalyst, and returning the condensed catalyst to the liquid catalyst reservoir. The vessel comprises a gas phase catalyst and a liquid catalyst reservoir containing a liquid catalyst.

A reaction process includes introducing hydrocarbon reactants into a vessel, reacting the hydrocarbon reactants in contact with the gas phase catalyst in the vessel to produce reaction products comprising solid carbon and a gas phase product, separating the solid carbon from the gas phase products and the gas phase catalyst to produce a solid carbon product, condensing the gas phase catalyst to produce a condensed catalyst, and returning the condensed catalyst to the liquid catalyst reservoir. The vessel comprises a gas phase catalyst and a liquid catalyst reservoir containing a liquid catalyst.

This invention provides processes and systems for converting biomass into high carbon biogenic reagents that are suitable for a variety of commercial applications. Some embodiments employ pyrolysis in the presence of an inert gas to generate hot pyrolyzed solids, condensable vapors, and non-condensable gases, followed by separation of vapors and gases, and cooling of the hot pyrolyzed solids in the presence of the inert gas. Additives may be introduced during processing or combined with the reagent, or both. The biogenic reagent may include at least 70 wt %, 80 wt %, 90 wt %, 95 wt %, or more total carbon on a dry basis. The biogenic reagent may have an energy content of at least 12,000 Btu/lb, 13,000 Btu/lb, 14,000 Btu/lb, or 14,500 Btu/lb on a dry basis. The biogenic reagent may be formed into fine powders, or structural objects. The structural objects may have a structure and/or strength that derive from the feedstock, heat rate, and additives.

This invention provides processes and systems for converting biomass into high carbon biogenic reagents that are suitable for a variety of commercial applications. Some embodiments employ pyrolysis in the presence of an inert gas to generate hot pyrolyzed solids, condensable vapors, and non-condensable gases, followed by separation of vapors and gases, and cooling of the hot pyrolyzed solids in the presence of the inert gas. Additives may be introduced during processing or combined with the reagent, or both. The biogenic reagent may include at least 70 wt %, 80 wt %, 90 wt %, 95 wt %, or more total carbon on a dry basis. The biogenic reagent may have an energy content of at least 12,000 Btu/lb, 13,000 Btu/lb, 14,000 Btu/lb, or 14,500 Btu/lb on a dry basis. The biogenic reagent may be formed into fine powders, or structural objects. The structural objects may have a structure and/or strength that derive from the feedstock, heat rate, and additives.

A hydrocarbon cracker stream is combined with recycle content pyrolysis oil to form a combined cracker stream and the combined cracker stream is cracked in a cracker furnace to provide an olefin-containing effluent. The r-pyoil can be fed to the cracker feed. Alternatively, the r-pyoil with a predominantly c8+ fraction can be fed to the cracker feed. The furnace can be a gas fed furnace, or split cracker furnace.

The present disclosure an improved apparatus for fast pyrolysis and methods associated with the apparatus. For instance, the present disclosure provides methods for analyzing intermediate products formed via a fast pyrolysis reaction utilizing one or more pulses of pyrolysis vapor through a valve in the apparatus. The described methods provide improved identification of products formed in the fast pyrolysis reaction by using millisecond time resolution for qualitative and/or quantitative analysis.

A process for pyrolysis of a mixed plastic stream that contains polyvinyl chloride (PVC) is provided in which the chloride from PVC is removed from an initial melting reactor that heats the mixed plastic stream to a sufficient temperature to produce HCl but at a low enough temperature to avoid production of organochlorides. Chloride is primarily removed in a vapor stream from the initial melting reactor, while additional chloride removal may be removed downstream from the melting reactor by the use of sorbent addition to the pyrolysis reactor and by subsequent adsorbent beds.

This invention provides processes and systems for converting biomass into high-carbon biogenic reagents that are suitable for a variety of commercial applications. Some embodiments employ pyrolysis in the presence of an inert gas to generate hot pyrolyzed solids, condensable vapors, and non-condensable gases, followed by separation of vapors and gases, and cooling of the hot pyrolyzed solids in the presence of the inert gas. Additives may be introduced during processing or combined with the reagent, or both. The biogenic reagent may include at least 70 wt %, 80 wt %, 90 wt %, 95 wt %, or more total carbon on a dry basis. The biogenic reagent may have an energy content of at least 12,000 Btu/lb, 13,000 Btu/lb, 14,000 Btu/lb, or 14,500 Btu/lb on a dry basis. The biogenic reagent may be formed into fine powders, or structural objects. The structural objects may have a structure and/or strength that derive from the feedstock, heat rate, and additives.

This invention provides processes and systems for converting biomass into high-carbon biogenic reagents that are suitable for a variety of commercial applications. Some embodiments employ pyrolysis in the presence of an inert gas to generate hot pyrolyzed solids, condensable vapors, and non-condensable gases, followed by separation of vapors and gases, and cooling of the hot pyrolyzed solids in the presence of the inert gas. Additives may be introduced during processing or combined with the reagent, or both. The biogenic reagent may include at least 70 wt %, 80 wt %, 90 wt %, 95 wt %, or more total carbon on a dry basis. The biogenic reagent may have an energy content of at least 12,000 Btu/lb, 13,000 Btu/lb, 14,000 Btu/lb, or 14,500 Btu/lb on a dry basis. The biogenic reagent may be formed into fine powders, or structural objects. The structural objects may have a structure and/or strength that derive from the feedstock, heat rate, and additives.