The present invention relates to a process and a system for the production of liquid hydrocarbons by thermo-catalytic cracking of plastic waste. The invention relates to a technique for efficiently producing high-quality liquid fuel using designed reactor setup for the cracking of waste plastic. The invention also relates to a thermo-catalytic cracking method, which occurs in the presence of zeolite-based catalysts, more preferably the zeolite catalysts impregnated with transition metals which remain catalytically active up to 8-10 sets of reactions with higher selectivity of petroleum range hydrocarbons. The present invention also relates to a two-step approach system for the production of liquid hydrocarbons.

The present invention relates to a process and a system for the production of liquid hydrocarbons by thermo-catalytic cracking of plastic waste. The invention relates to a technique for efficiently producing high-quality liquid fuel using designed reactor setup for the cracking of waste plastic. The invention also relates to a thermo-catalytic cracking method, which occurs in the presence of zeolite-based catalysts, more preferably the zeolite catalysts impregnated with transition metals which remain catalytically active up to 8-10 sets of reactions with higher selectivity of petroleum range hydrocarbons. The present invention also relates to a two-step approach system for the production of liquid hydrocarbons.

Embodiments disclosed herein relate to systems and processes for producing olefins and/or dienes. The processes may include: thermally cracking a hydrocarbon containing feed to produce a cracked hydrocarbon effluent containing a mixture of olefins and paraffins; and catalytically cracking the cracked hydrocarbon effluent to produce a catalytically cracked effluent containing additional olefins and/or dienes. The systems may include a reaction zone for thermally cracking a hydrocarbon containing feed to produce a cracked hydrocarbon effluent containing a mixture of olefins and paraffins; and, a catalytic cracking reaction zone for catalytically cracking the cracked hydrocarbon effluent to produce a catalytically cracked hydrocarbon effluent containing additional olefins and/or dienes.

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.

Provided in one embodiment is a continuous process for converting waste plastic comprising polyethylene and/or polypropylene into recycle for polyethylene polymerization. The process comprises selecting waste plastics containing polyethylene, polypropylene, or a mixture thereof, and passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is separated into offgas, a pyrolysis oil comprising a naphtha, diesel and heavy fractions, and char. The pyrolysis oil, or at least a fraction, is passed to a filtration/metal oxide treatment, with the treated product passed to a refinery FCC unit. A liquid petroleum gas C.sub.3 olefin/paraffin mixture fraction is recovered from the FCC unit, as well as a C.sub.4 olefin/paraffin mixture fraction. The liquid petroleum gas C.sub.3 olefin/paraffin mixture fraction is passed to a steam cracker for ethylene production.

Systems and methods for processing full range naphtha to produce light olefins are disclosed. The systems and methods include separating the full range naphtha into a light naphtha stream and a heavy naphtha stream and integrating a catalytic cracking with a naphtha reforming to process the light naphtha and heavy naphtha streams.

Systems and methods for processing full range naphtha to produce light olefins are disclosed. The systems and methods include separating the full range naphtha into a light naphtha stream and a heavy naphtha stream and integrating a catalytic cracking with a naphtha reforming to process the light naphtha and heavy naphtha streams.

A process that catalytically converts olefinic (Alkenes, typically liquid at standard temperature and pressure) material in thermally cracked streams to meet olefin content specifications for crude oil transport pipelines. A thermally cracked stream or portion of a thermally cracked stream is selectively reacted to reduce the olefin content within a reactor operating at specific, controlled conditions in the presence of a catalyst and the absence of supplemental hydrogen. The process catalyst is comprised of a blend of select catalyzing metals supported on an alumina, silica or shape selective zeolite substrate together with appropriate pore acidic components.

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.

Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include a conventional riser reactor in combination with a mixed flow (e.g., including both counter-current and co-current catalyst flows) fluidized bed reactor designed for maximizing light olefins production. The effluents from the riser reactor and mixed flow reactor are processed in a catalyst disengagement vessel, and the catalysts used in each reactor may be regenerated in a common catalyst regeneration vessel. Further, integration of the two-reactor scheme with a catalyst cooler provides a refinery the flexibility of switching the operation between the two-reactor flow scheme, a catalyst cooler only flow scheme, or using both simultaneously.