Processes herein may be used to thermally crack various hydrocarbon feeds, and may eliminate the refinery altogether while making the crude to chemicals process very flexible in terms of crude. In embodiments herein, crude is progressively separated into light and heavy fractions utilizing convection heat from heaters used in steam cracking. Depending on the quality of the light and heavy fractions, these are routed to one of three upgrading operations, including a fixed bed hydroconversion unit, a fluidized catalytic conversion unit, or a residue hydrocracking unit that may utilize either an ebullated bed reactor with extrudate catalysts or a slurry hydrocracking reactor using a homogeneous catalyst system, such as a molybdenum based catalysts which may optionally be promoted with nickel. Products from the upgrading operations can be finished olefins and/or aromatics, or, for heavier products from the upgrading operations, may be used as feed to the steam cracker.

Processes herein may be used to thermally crack various hydrocarbon feeds, and may eliminate the refinery altogether while making the crude to chemicals process very flexible in terms of crude. In embodiments herein, crude is progressively separated into light and heavy fractions utilizing convection heat from heaters used in steam cracking. Depending on the quality of the light and heavy fractions, these are routed to one of three upgrading operations, including a fixed bed hydroconversion unit, a fluidized catalytic conversion unit, or a residue hydrocracking unit that may utilize either an ebullated bed reactor with extrudate catalysts or a slurry hydrocracking reactor using a homogeneous catalyst system, such as a molybdenum based catalysts which may optionally be promoted with nickel. Products from the upgrading operations can be finished olefins and/or aromatics, or, for heavier products from the upgrading operations, may be used as feed to the steam cracker.

Processes for producing olefins include integration of steam cracking with a dual catalyst metathesis process. The processes include steam cracking a hydrocarbon feed to form a cracking reaction effluent containing butenes, separating the cracking reaction effluent to produce a cracking C4 effluent including normal butenes, isobutene, and 1,3-butadiene, subjecting the cracking C4 effluent to selective hydrogenation to convert 1,3-butadiene in the cracking C4 effluent to normal butenes, removing isobutene from a hydrogenation effluent to produce a metathesis feed containing normal butenes, and contacting the metathesis feed with a metathesis catalyst and a cracking catalyst directly downstream of the metathesis catalyst to produce a metathesis reaction effluent. Contacting with the metathesis catalyst causes metathesis of normal butenes to produce ethylene, propene, and C5+ olefins, and contacting with the cracking catalyst causes C5+ olefins produced through metathesis to undergo cracking reactions to produce additional propene, ethylene, or both.

Processes for producing olefins include integration of steam cracking with a dual catalyst metathesis process. The processes include steam cracking a hydrocarbon feed to form a cracking reaction effluent containing butenes, separating the cracking reaction effluent to produce a cracking C4 effluent including normal butenes, isobutene, and 1,3-butadiene, subjecting the cracking C4 effluent to selective hydrogenation to convert 1,3-butadiene in the cracking C4 effluent to normal butenes, removing isobutene from a hydrogenation effluent to produce a metathesis feed containing normal butenes, and contacting the metathesis feed with a metathesis catalyst and a cracking catalyst directly downstream of the metathesis catalyst to produce a metathesis reaction effluent. Contacting with the metathesis catalyst causes metathesis of normal butenes to produce ethylene, propene, and C5+ olefins, and contacting with the cracking catalyst causes C5+ olefins produced through metathesis to undergo cracking reactions to produce additional propene, ethylene, or both.

A process for converting pyrolysis effluent stream into hydrocarbon products. Waste plastics are pyrolyzed at high temperature in a pyrolysis reactor to obtain a plastic pyrolysis effluent stream. The plastic pyrolysis effluent stream is further sent to a steam cracking unit for the separation of plastic pyrolysis effluent stream into a C5+ hydrocarbon stream and a C4 hydrocarbon stream. The pyrolysis reactor is operated at a to obtain hydrocarbon products of high value.

A process for converting pyrolysis effluent stream into hydrocarbon products. Waste plastics are pyrolyzed at high temperature in a pyrolysis reactor to obtain a plastic pyrolysis effluent stream. The plastic pyrolysis effluent stream is further sent to a steam cracking unit for the separation of plastic pyrolysis effluent stream into a C5+ hydrocarbon stream and a C4 hydrocarbon stream. The pyrolysis reactor is operated at a to obtain hydrocarbon products of high value.

A process for treating plastics pyrolysis oil by a) selectively hydrogenating a feedstock in the presence hydrogen and a selective hydrogenation catalyst, at a temperature between 100 and 150° C., a hydrogen partial pressure between 1.0 and 10.0 MPa abs. and an hourly space velocity between 1.0 and 10.0 h.sup.−1, to obtain a hydrogenated effluent; b) hydrotreating the hydrogenated effluent in the presence of hydrogen and a hydrotreating catalyst, at a temperature between 250 and 370° C., a hydrogen partial pressure between 1.0 and 10.0 MPa abs. and an hourly space velocity between 0.1 and 10.0 h.sup.−1, to obtain a hydrotreating effluent; c) separating the hydrotreating effluent in the presence of an aqueous stream, at a temperature between 50 and 370° C., to obtain at least one gaseous effluent, a liquid aqueous effluent and a liquid hydrocarbon effluent; e) recycling at least one fraction of the product obtained.

A process for treating plastics pyrolysis oil by a) selectively hydrogenating a feedstock in the presence hydrogen and a selective hydrogenation catalyst, at a temperature between 100 and 150° C., a hydrogen partial pressure between 1.0 and 10.0 MPa abs. and an hourly space velocity between 1.0 and 10.0 h.sup.−1, to obtain a hydrogenated effluent; b) hydrotreating the hydrogenated effluent in the presence of hydrogen and a hydrotreating catalyst, at a temperature between 250 and 370° C., a hydrogen partial pressure between 1.0 and 10.0 MPa abs. and an hourly space velocity between 0.1 and 10.0 h.sup.−1, to obtain a hydrotreating effluent; c) separating the hydrotreating effluent in the presence of an aqueous stream, at a temperature between 50 and 370° C., to obtain at least one gaseous effluent, a liquid aqueous effluent and a liquid hydrocarbon effluent; e) recycling at least one fraction of the product obtained.

Processes herein may be used to thermally crack various hydrocarbon feeds, and may eliminate the refinery altogether while making the crude to chemicals process very flexible in terms of crude. In embodiments herein, crude is progressively separated into light and heavy fractions utilizing convection heat from heaters used in steam cracking. Depending on the quality of the light and heavy fractions, these are routed to one of three upgrading operations, including a fixed bed hydroconversion unit, a fluidized catalytic conversion unit, or a residue hydrocracking unit that may utilize either an ebullated bed reactor with extrudate catalysts or a slurry hydrocracking reactor using a homogeneous catalyst system, such as a molybdenum based catalysts which may optionally be promoted with nickel. Products from the upgrading operations can be finished olefins and/or aromatics, or, for heavier products from the upgrading operations, may be used as feed to the steam cracker.

Processes herein may be used to thermally crack various hydrocarbon feeds, and may eliminate the refinery altogether while making the crude to chemicals process very flexible in terms of crude. In embodiments herein, crude is progressively separated into light and heavy fractions utilizing convection heat from heaters used in steam cracking. Depending on the quality of the light and heavy fractions, these are routed to one of three upgrading operations, including a fixed bed hydroconversion unit, a fluidized catalytic conversion unit, or a residue hydrocracking unit that may utilize either an ebullated bed reactor with extrudate catalysts or a slurry hydrocracking reactor using a homogeneous catalyst system, such as a molybdenum based catalysts which may optionally be promoted with nickel. Products from the upgrading operations can be finished olefins and/or aromatics, or, for heavier products from the upgrading operations, may be used as feed to the steam cracker.