Systems and methods for upgrading a hydrocarbon stream to a lower boiling point hydrocarbon feed material are disclosed. The system includes a feeding device to transport a hydrocarbon stream that includes an alternative feedstock. The hydrocarbon stream is partially cracked in a first cracking unit producing a lower boiling point hydrocarbon feed material, a catalyst rich heavy hydrocarbon stream, and coke. A slurry settler receives the catalyst rich heavy hydrocarbon stream and coke and separates the catalyst from the catalyst rich heavy hydrocarbon stream thereby defining a catalyst rich stream and a heavy hydrocarbon stream. A coking vessel receives the heavy hydrocarbon stream and coke and separates the heavy hydrocarbons from the coke thereby defining a heavy hydrocarbon stream. Finally, a second cracking unit that receives the lower boiling point feed material from the first cracking unit and produces olefins and aromatics.

This disclosure relates to the production of chemicals and plastics using pyrolysis oil from the pyrolysis of plastic waste as a co-feedstock along with a petroleum-based, fossil fuel-based, or bio-based feedstock. In an aspect, the polymers and chemicals produced according to this disclosure can be certified under International Sustainability and Carbon Certification (ISCC) provisions as circular polymers and chemicals at any point along complex chemical reaction pathways. The use of a mass balance approach which attributes the pounds of pyrolyzed plastic products derived from pyrolysis oil to any output stream of a given unit has been developed, which permits ISCC certification agency approval.

Recycle content pyoil is cracked in a cracker furnace to make olefins and the coil outlet temperature of the r-pyoil fed coils can be lowered by adding r-pyoil to the cracker feedstock, or alternatively, the coil outlet temperature of the r-pyoil fed tubes can rise if the mass flow rates of the combined cracker stream containing r-pyoil are kept the same or lowered. Further, increasing the hydrocarbon mass flow rate by addition of r-pyoil can be achieved to also increase the output of ethylene and propylene in the cracker effluent. The cracker furnace can accept ethane and/or propane feedstocks in vapor form along with a liquid and/or vapor feed of r-pyoil.

An integrated process comprising to convert crude oil, comprising: converting crude oil (10) in a feed preparation facility (800) by separating the crude oil to a gas fraction (101), liquid fraction (102), and first residuum fraction in an atmospheric distillation unit (100); separating the 1.sup.st residuum to a vacuum gas oil fraction (202) and a second residuum (201) in a vacuum distillation unit (200); converting the vacuum gas oil fraction to a CU gas fraction (301,401), a CU liquid fraction (302), and an CU higher boiling fraction (303,402) in a cracking unit (300,400); and processing the second residuum fraction to DCU gas oil/lighter fraction (501) in a coking unit (500); and steam cracking at least one of the gas fraction (101), liquid fraction (102), CU gas fraction (301,401), and DCU gas oil/lighter fraction (501) to the hydrocarbon products (920).

A sequential cracking process for the thermal cracking of a hydrocarbon feedstock in a cascade of cracking units wherein said hydrocarbon feedstock is heated in a furnace to a predetermined maximum temperature and thermally cracked in the cascade of cracking, such that the formation of coke is reduced.

Provided is a method for preparing fuel of cracking furnace that includes: preparing a first methane off-gas stream derived from a liquid cracking furnace and a second methane off-gas stream derived from a gaseous cracking furnace, diverging a portion of the first methane off-gas stream into a methane off-gas export stream and obtaining a first fuel gas stream from the rest of the stream, obtaining a second fuel gas stream from the second methane off-gas stream, mixing the first and second fuel gas streams to prepare a mixed fuel gas stream, and mixing a hydrogen gas stream with the mixed fuel gas stream.

The presently disclosed concepts relate to systems and methods for effluent stream abatement via pyrolytic emission looping. In use, the systems and methods include a feed gas stream, and at least one dissociating reactor that receives the feed gas stream. The at least one dissociating reactor outputs, at least in part, a carbon allotrope material and a discharge pyrolytic emissions stream. Additionally, a gas separating system is used to separate the discharge pyrolytic emissions stream into at least one species component, where the at least one species component is added to at least the feed gas stream.

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.

One or more reactants are flowed into thermal contact with a heating element in a reactor for a first time period. During a first part of a heating cycle, the one or more reactants are provided with a first temperature by heating with the heating element, such that one or more thermochemical reactions is initiated. The one or more thermochemical reactions includes pyrolysis, thermolysis, synthesis, hydrogenation, dehydrogenation, hydrogenolysis, or any combination thereof. The first heating element operates by Joule heating and has a porous construction that allows gas to flow therethrough. During a second part of the heating cycle, the one or more reactants are provided with a second temperature less than the first temperature, for example, by de-energizing the heating element. A duration of the first time period is equal to or greater than a duration of the heating cycle, which is less than five seconds.

Processes and facilities for producing a recycled content organic chemical compound directly or indirectly from waste plastic. Processing schemes are described herein for converting waste plastic (or hydrocarbon having recycled content derived from waste plastic) into useful intermediate chemicals and final products. In some aspects, recycled content aromatics (r-aromatics) can be processed to provide recycled content paraxylene (r-paraxylene), which can then be used to provide recycled content terephthalic acid (r-TPA) and/or recycled content polyethylene terephthalate (r-PET).