Provided is a continuous process for converting waste plastic into recycle for polypropylene polymerization. The process comprises selecting waste plastics containing polyethylene and/or polypropylene and preparing a stable blend of petroleum and the selected plastic. The amount of plastic in the blend comprises no more than 20 wt. % of the blend. The blend is passed to a refinery hydrocracking unit. A liquid petroleum gas C.sub.3 olefin/paraffin mixture is recovered from the hydrocracking unit. The C.sub.3 paraffins and C.sub.3 olefins are separated into different fractions with the C.sub.3 olefin fraction passed to a propylene polymerization reactor, and the C.sub.3 paraffin fraction passed optionally to a dehydrogenation unit to produce additional propylene. A heavy fraction can also be recovered from the hydrocracking unit and passed to an isomerization dewaxing unit to prepare base oil.

Provided is a continuous process for converting waste plastic into recycle for polypropylene polymerization. The process comprises selecting waste plastics containing polyethylene and/or polypropylene and preparing a stable blend of petroleum and the selected plastic. The amount of plastic in the blend comprises no more than 20 wt. % of the blend. The blend is passed to a refinery hydrocracking unit. A liquid petroleum gas C.sub.3 olefin/paraffin mixture is recovered from the hydrocracking unit. The C.sub.3 paraffins and C.sub.3 olefins are separated into different fractions with the C.sub.3 olefin fraction passed to a propylene polymerization reactor, and the C.sub.3 paraffin fraction passed optionally to a dehydrogenation unit to produce additional propylene. A heavy fraction can also be recovered from the hydrocracking unit and passed to an isomerization dewaxing unit to prepare base oil.

The present disclosure refers to systems and methods for efficiently converting a C.sub.1-C.sub.3 alkane such as natural gas to a liquid C.sub.2-C.sub.10 product and hydrogen. Generally, the process comprises flowing the C.sub.1-C.sub.3 alkane through a plurality of tubes within a vessel wherein the tubes house a catalyst for converting the C.sub.1-C.sub.3 alkane to the liquid C.sub.2-C.sub.10 product and hydrogen. The C.sub.1-C.sub.3 alkane is heated under suitable conditions to produce the liquid C.sub.2-C.sub.10 product and hydrogen. Advantageously, the C.sub.1-C.sub.3 alkane is heated by burning a fuel outside the tubes in fuel burning nozzles configured to transfer heat from the burning through the tubes.

The present disclosure refers to systems and methods for efficiently converting a C.sub.1-C.sub.3 alkane such as natural gas to a liquid C.sub.2-C.sub.10 product and hydrogen. Generally, the process comprises flowing the C.sub.1-C.sub.3 alkane through a plurality of tubes within a vessel wherein the tubes house a catalyst for converting the C.sub.1-C.sub.3 alkane to the liquid C.sub.2-C.sub.10 product and hydrogen. The C.sub.1-C.sub.3 alkane is heated under suitable conditions to produce the liquid C.sub.2-C.sub.10 product and hydrogen. Advantageously, the C.sub.1-C.sub.3 alkane is heated by burning a fuel outside the tubes in fuel burning nozzles configured to transfer heat from the burning through the tubes.

A catalyst structure includes a porous support structure, where the support structure includes an aluminosilicate material and any two or more metals loaded in the porous support structure selected from Ga, Ag, Mo, Zn, Co and Ce. The catalyst structure is used in a hydrocarbon upgrading process that is conducted in the presence of methane, nitrogen or hydrogen.

The present disclosure generally relates to upgrading difficult to process heavy-oil. In particular, the disclosure relates to upgrading heavy oil and other high carbon content materials by using an integrated thermal-process (ITP) that utilizes anti-coking management and toluene insoluble organic residues (TIOR) management to directly incorporate lighter hydrocarbons into high molecular weight, low hydrogen content hydrocarbons such as thermally processed heavy oil products. This process can be integrated with other thermal processing schemes, such as cokers and visbreakers, to improve the conversion and yields from these integrated processes.

The present disclosure generally relates to upgrading difficult to process heavy-oil. In particular, the disclosure relates to upgrading heavy oil and other high carbon content materials by using an integrated thermal-process (ITP) that utilizes anti-coking management and toluene insoluble organic residues (TIOR) management to directly incorporate lighter hydrocarbons into high molecular weight, low hydrogen content hydrocarbons such as thermally processed heavy oil products. This process can be integrated with other thermal processing schemes, such as cokers and visbreakers, to improve the conversion and yields from these integrated processes.

A catalyst structure includes a porous support structure, where the support structure includes an aluminosilicate material. Any two or more metals are loaded in the porous support structure, the two or more metals selected from the group consisting of Ga, Ag, Mo, Zn, Co and Ce, where each metal loaded in the porous support structure is present in an amount from about 0.1 wt % to about 20 wt %. In example embodiments, the catalyst structure includes three or more of the metals loaded in the porous support structure. The catalyst structure is used in a hydrocarbon upgrading process that is conducted in the presence of methane, nitrogen or hydrogen.

A process for hydrotreating a sulfur-containing hydrocarbon feedstock may include producing a hydrotreated effluent by hydrotreating the feedstock in a three-phase trickle reactor to remove a first portion of the sulfur from the feedstock, separating the first hydrotreated effluent to give a hydrogen-containing gaseous fraction and a separated hydrotreated effluent, stripping the separated hydrotreated effluent to give a hydrogen sulfide-containing gaseous fraction and a stripped hydrotreated effluent, saturating the stripped hydrotreated effluent with hydrogen, and hydrotreating the hydrogen-saturated effluent in a two-phase reactor to remove a remaining second portion of the sulfur and produce a second hydrotreated effluent.

A process for hydrotreating a sulfur-containing hydrocarbon feedstock may include producing a hydrotreated effluent by hydrotreating the feedstock in a three-phase trickle reactor to remove a first portion of the sulfur from the feedstock, separating the first hydrotreated effluent to give a hydrogen-containing gaseous fraction and a separated hydrotreated effluent, stripping the separated hydrotreated effluent to give a hydrogen sulfide-containing gaseous fraction and a stripped hydrotreated effluent, saturating the stripped hydrotreated effluent with hydrogen, and hydrotreating the hydrogen-saturated effluent in a two-phase reactor to remove a remaining second portion of the sulfur and produce a second hydrotreated effluent.