A method for operating an acetylene hydrogenation unit in an integrated steam cracking-fluidized catalytic dehydrogenation (FCDh) system may include separating a cracked gas from a steam cracking system and an FCDh effluent from an FCDh system into a hydrogenation feed and an acetylene-depleted stream, the hydrogenation feed comprising at least hydrogen, CO, and acetylene. During normal operating conditions, at least 20% of the CO in the hydrogenation feed is from the cracked gas. The method may include contacting the hydrogenation feed with an acetylene hydrogenation catalyst to hydrogenate at least a portion of the acetylene in the hydrogenation feed to produce a hydrogenated effluent. The steam cracking is operated under conditions that increase CO production such that a concentration of CO in the cracked gas is great enough that when a flowrate of the FCDh effluent is zero, a CO concentration in the hydrogenation feed is at least 100 ppmv.

Processes and systems for producing raw materials and for producing truly circular polymers. The systems and processes may include processing a waste-derived hydrocarbon stream, such as a waste plastic pyrolysis oil, in a first reactor system with a catalyst mixture, and processing a fossil-based feedstock in a second reactor system with the catalyst mixture. The catalyst mixture may be supplied to each of the first and second reactor systems from a common catalyst regenerator. An effluent comprising fossil-based hydrocarbon products may be recovered from the second reactor system, and an effluent comprising waste-derived hydrocarbon products may be recovered from the first reactor system. Following separations, spent catalyst from each of the first and second reactor systems may be returned to the common catalyst regenerator.

Processes and systems for producing raw materials and for producing truly circular polymers. The systems and processes may include processing a waste-derived hydrocarbon stream, such as a waste plastic pyrolysis oil, in a first reactor system with a catalyst mixture, and processing a fossil-based feedstock in a second reactor system with the catalyst mixture. The catalyst mixture may be supplied to each of the first and second reactor systems from a common catalyst regenerator. An effluent comprising fossil-based hydrocarbon products may be recovered from the second reactor system, and an effluent comprising waste-derived hydrocarbon products may be recovered from the first reactor system. Following separations, spent catalyst from each of the first and second reactor systems may be returned to the common catalyst regenerator.

An integrated process for conversion of a hydrocarbon stream comprising light naphtha to enhanced value products. The process includes passing the hydrocarbon stream through a first reactor, the first reactor being a catalytic bed reactor with a dual-function catalyst to simultaneously reform light naphtha to BTEX and crack light naphtha to ethane, propane, and butanes. Further, the process includes passing an effluent of the first reactor to a gas-liquid separating unit to generate a liquid stream and a gas stream, and passing the gas stream to a gas separator unit to remove hydrogen gas and methane and generate an enhanced gas stream. The process further includes passing the enhanced gas stream through a second reactor, the second reactor being a pyrolysis unit operated at steam cracking conditions to convert ethane, propane, and butanes in the enhanced gas stream to light. An associated system for performing the process is also provided wherein the integrated process does not include passage of a process stream to a separate and independent hydrocracking unit to crack light alkanes in the hydrocarbon stream to smaller alkanes.

Processes and systems for making recycle content hydrocarbons, including olefins, are provided that integrate a cracker unit with one or more other processing units. For example, in some cases, a fluidized catalytic cracking unit may be used to crack recycle content pyrolysis oil and the effluent from the FCC may be further processed in a conventional cracker unit, including its downstream separation zone, to provide recycle content hydrocarbon product stream. In other cases, a pyrolysis unit and cracking unit may be co-located and may share at least one utility, service group, boundary, conduit, energy exchange zone, and/or geographical area.

The invention relates to a catalytic process for upgrading a renewable crude oil produced from biomass and/or waste comprising providing a renewable crude oil and pressurizing it to a pressure in the range in the range 60 to 150 bar, contacting the pressurized renewable crude oil with hydrogen and at least one heterogeneous catalyst contained in a first reaction zone at a weight based hourly space velocity (WHSV) in the range 0.1 to 2.0 h.sub.−1 and at a temperature in the range of 150° C. to 360° C., hereby providing a partially upgraded renewable crude oil, separating the partially upgraded renewable crude oil from the first reaction zone to a partially upgraded heavy renewable oil fraction, a partially upgraded light renewable oil fraction, a water stream and a process gas stream, introducing the separated and partially upgraded heavy renewable oil fraction and separated process gas to a second reaction zone comprising at least two reactors arranged in parallel and being adapted to operate in a first and a second mode of operation, the reactors comprising dual functioning heterogeneous catalyst(-s) capable of performing a catalytic steam cracking reaction in a first mode of operation or a steam reforming reaction in a second mode of operation, where the partially upgraded heavy renewable oil fraction from the first reaction zone is contacted with the dual functioning heterogeneous catalyst and steam at a pressure of 10 to 150 bar and a temperature of 350° C. to 430° C. whereby a catalytic steam cracking of the partially upgraded heavy renewable oil is performed in the reactors in the first mode of operation, hereby providing a further upgraded heavy renewable oil fraction, while separated process gas from the first and/or second reaction zone is contacted with the dual functioning catalyst and steam at a pressure of 0.1 to 10 bar and a temperature of 350 to 600° C. in the reactors in the second mode of operation and contacted with the dual functioning catalyst, thereby producing a hydrogen enriched gas, separating the further upgraded heavy renewable oil fraction from the catalytically steam cracking reactor to at least one light renewable oil fraction, a heavy renewable oil fraction, a hydrogen rich process gas and a water phase, separating hydrogen from the hydrogen enriched gas from the catalytic steam cracking zone and/or from the catalytic steam reforming and recycling it to the first reaction zone, alternating the reactors between the first mode of operation and the second mode of operation at predetermined time intervals thereby allowing for regeneration of the heterogeneous catalyst for the catalytic steam cracking in the first mode of op

The invention relates to a catalytic process for upgrading a renewable crude oil produced from biomass and/or waste comprising providing a renewable crude oil and pressurizing it to a pressure in the range in the range 60 to 150 bar, contacting the pressurized renewable crude oil with hydrogen and at least one heterogeneous catalyst contained in a first reaction zone at a weight based hourly space velocity (WHSV) in the range 0.1 to 2.0 h.sub.−1 and at a temperature in the range of 150° C. to 360° C., hereby providing a partially upgraded renewable crude oil, separating the partially upgraded renewable crude oil from the first reaction zone to a partially upgraded heavy renewable oil fraction, a partially upgraded light renewable oil fraction, a water stream and a process gas stream, introducing the separated and partially upgraded heavy renewable oil fraction and separated process gas to a second reaction zone comprising at least two reactors arranged in parallel and being adapted to operate in a first and a second mode of operation, the reactors comprising dual functioning heterogeneous catalyst(-s) capable of performing a catalytic steam cracking reaction in a first mode of operation or a steam reforming reaction in a second mode of operation, where the partially upgraded heavy renewable oil fraction from the first reaction zone is contacted with the dual functioning heterogeneous catalyst and steam at a pressure of 10 to 150 bar and a temperature of 350° C. to 430° C. whereby a catalytic steam cracking of the partially upgraded heavy renewable oil is performed in the reactors in the first mode of operation, hereby providing a further upgraded heavy renewable oil fraction, while separated process gas from the first and/or second reaction zone is contacted with the dual functioning catalyst and steam at a pressure of 0.1 to 10 bar and a temperature of 350 to 600° C. in the reactors in the second mode of operation and contacted with the dual functioning catalyst, thereby producing a hydrogen enriched gas, separating the further upgraded heavy renewable oil fraction from the catalytically steam cracking reactor to at least one light renewable oil fraction, a heavy renewable oil fraction, a hydrogen rich process gas and a water phase, separating hydrogen from the hydrogen enriched gas from the catalytic steam cracking zone and/or from the catalytic steam reforming and recycling it to the first reaction zone, alternating the reactors between the first mode of operation and the second mode of operation at predetermined time intervals thereby allowing for regeneration of the heterogeneous catalyst for the catalytic steam cracking in the first mode of op

A method of converting naphtha is disclosed. The method includes heating the naphtha in stages in different heating units. The naphtha is vaporized in the first heating unit. And the vaporized naphtha undergoes the largest temperature change of the process in the second heating unit. A third heating unit can be a part of the reactor. The reactor includes a catalyst which is contacted with the pre-heated naphtha to convert it to C.sub.2 to C.sub.4 olefins.

A method of converting naphtha is disclosed. The method includes heating the naphtha in stages in different heating units. The naphtha is vaporized in the first heating unit. And the vaporized naphtha undergoes the largest temperature change of the process in the second heating unit. A third heating unit can be a part of the reactor. The reactor includes a catalyst which is contacted with the pre-heated naphtha to convert it to C.sub.2 to C.sub.4 olefins.

An integrated process for conversion of a hydrocarbon stream comprising light naphtha to enhanced value products. The process includes passing the hydrocarbon stream through a first reactor, the first reactor being a catalytic bed reactor with a dual-function catalyst to simultaneously reform light naphtha to BTEX and crack light naphtha to ethane, propane, and butanes. Further, the process includes passing an effluent of the first reactor to a gas-liquid separating unit to generate a liquid stream and a gas stream, and passing the gas stream to a gas separator unit to remove hydrogen gas and methane and generate an enhanced gas stream. The process further includes passing the enhanced gas stream through a second reactor, the second reactor being a pyrolysis unit operated at steam cracking conditions to convert ethane, propane, and butanes in the enhanced gas stream to light. An associated system for performing the process is also provided wherein the integrated process does not include passage of a process stream to a separate and independent hydrocracking unit to crack light alkanes in the hydrocarbon stream to smaller alkanes.