Processes for using pyrolysis gas as a feedstock or a co-feedstock for making a variety of chemicals, for example, circular ethylene, circular ethylene polymers and copolymers, and other circular products. In these processes, pyrolysis reactor conditions can be selected to increase or optimized the production of pyrolysis gas over pyrolysis oil, and the pyrolysis gas which is usually used as fuel or flared can be fed downstream of the steam cracker furnace for economic use to form circular chemicals. Operating parameters of the pyrolysis unit may be adjusted to increase or decrease the proportion of pyrolysis gas relative to pyrolysis liquid as a function of their relative economic values.

Processes for using pyrolysis gas as a feedstock or a co-feedstock for making a variety of chemicals, for example, circular ethylene, circular ethylene polymers and copolymers, and other circular products. In these processes, pyrolysis reactor conditions can be selected to increase or optimized the production of pyrolysis gas over pyrolysis oil, and the pyrolysis gas which is usually used as fuel or flared can be fed downstream of the steam cracker furnace for economic use to form circular chemicals. Operating parameters of the pyrolysis unit may be adjusted to increase or decrease the proportion of pyrolysis gas relative to pyrolysis liquid as a function of their relative economic values.

In some variations, the invention provides a biocarbon composition comprising a low fixed carbon material with a fixed carbon concentration from 20 wt % to 55 wt %; a high fixed carbon material with a fixed carbon concentration from 50 wt % to 100 wt % (and higher than the fixed carbon concentration of the low fixed carbon material; from 0 to 30 wt % moisture; from 0 to 15 wt % ash; and from 0 to 20 wt % of one or more additives (such as a binder). Some variations provide a process for producing a biocarbon composition, the process comprising: pyrolyzing a first biomass-containing feedstock to generate a low fixed carbon material; separately pyrolyzing a second biomass-containing feedstock to generate a high fixed carbon material; blending the low fixed carbon material with the high fixed carbon material, thereby generating an intermediate material; optionally, blending one or more additives into the intermediate material; optionally, drying the intermediate material; and recovering a biocarbon composition containing the intermediate material or a thermally treated form thereof.

In some variations, the invention provides a biocarbon composition comprising a low fixed carbon material with a fixed carbon concentration from 20 wt % to 55 wt %; a high fixed carbon material with a fixed carbon concentration from 50 wt % to 100 wt % (and higher than the fixed carbon concentration of the low fixed carbon material; from 0 to 30 wt % moisture; from 0 to 15 wt % ash; and from 0 to 20 wt % of one or more additives (such as a binder). Some variations provide a process for producing a biocarbon composition, the process comprising: pyrolyzing a first biomass-containing feedstock to generate a low fixed carbon material; separately pyrolyzing a second biomass-containing feedstock to generate a high fixed carbon material; blending the low fixed carbon material with the high fixed carbon material, thereby generating an intermediate material; optionally, blending one or more additives into the intermediate material; optionally, drying the intermediate material; and recovering a biocarbon composition containing the intermediate material or a thermally treated form thereof.

A plastic catalytic pyrolysis process that can produce high yields of ethylene, propylene and other light olefins from waste plastics is disclosed. The catalytic product stream is quenched to below catalytic pyrolysis temperature quickly after exiting the reactor or bulk separation from the catalyst. Quench preserves selectivity of light olefinic monomers. The catalytic pyrolysis process can be operated in a single stage or a two-stage process.

An improved process is provided for catalytic pyrolysis of biomass, comprising pneumatically injecting a biomass feed via a pneumatic injection line into a fluidized heat medium, for example, hot catalyst, with a carrier gas at a velocity of from 5 to 40 m/s in at least one mixing zone in communication with a pyrolysis reactor in which catalytic pyrolysis occurs, and maintaining a catalyst/biomass mixture flowrate ratio (C/B) of from 4 to 40 downstream from the point of catalyst injection via a catalyst injection line in the at least one mixing zone.

An improved process is provided for catalytic pyrolysis of biomass, comprising pneumatically injecting a biomass feed via a pneumatic injection line into a fluidized heat medium, for example, hot catalyst, with a carrier gas at a velocity of from 5 to 40 m/s in at least one mixing zone in communication with a pyrolysis reactor in which catalytic pyrolysis occurs, and maintaining a catalyst/biomass mixture flowrate ratio (C/B) of from 4 to 40 downstream from the point of catalyst injection via a catalyst injection line in the at least one mixing zone.

Systems and methods are provided for co-processing of biomass oil with mineral coker feeds in a coking environment. The coking can correspond to any convenient type of coking, such as delayed coking or fluidized coking. The biomass oil can correspond to biomass oil with a molar ratio of oxygen to carbon of 0.24 or less on a dry basis. Such types of biomass oil can be formed from pyrolysis methods such as hydrothermal pyrolysis, and are in contrast to biomass oils formed from pyrolysis methods such as fast pyrolysis. By using a biomass oil with a molar ratio of oxygen to carbon of 0.24 or less, improved yields of light coker gas oil can be achieved in conjunction with a reduction in the yield of heavy coker gas oil.

The present invention provides an improved catalytic fast pyrolysis process for increased yield of useful and desirable products. In particular, the process comprises an improved catalytic fast pyrolysis process for producing aromatic compounds, such as, for example, benzene, toluene and xylenes, from biomass feedstock containing impurities, such as, for example alkali and alkaline earth metal, sulfur and nitrogen components.

The present invention provides an improved catalytic fast pyrolysis process for increased yield of useful and desirable products. In particular, the process comprises an improved catalytic fast pyrolysis process for producing aromatic compounds, such as, for example, benzene, toluene and xylenes, from biomass feedstock containing impurities, such as, for example alkali and alkaline earth metal, sulfur and nitrogen components.