The present invention relates to a method and system for recovering and processing a hydrocarbon mixture from a subterranean formation. The method comprises: (i) mobilizing said hydrocarbon mixture; (ii) recovering said mobilized hydrocarbon mixture; (iii) deasphalting said recovered hydrocarbon mixture to produce deasphalted hydrocarbon and asphaltenes; (iv) gasifying said asphaltenes in a gasifier to generate hydrogen, steam and/or energy and CO.sub.2; (v) upgrading said deasphalted hydrocarbon by hydrogen addition to produce upgraded hydrocarbon; and (vi) adding a diluent to said upgraded hydrocarbon, wherein said method is at least partially self-sufficient in terms of hydrogen and diluent.

The disclosed technology is a fundamental improvement to existing art for producing valuable products from kerogen ore (oil shale). The disclosure teaches the techniques and benefits of integrating a pyrolysis process with a fluidized catalytic cracking (FCC) unit. Preferred embodiments are based on the use of pyrolysis products from a pyrolysis reactor as feedstock to an FCC unit; within the FCC unit a mixture of high-purity oxygen and carbon dioxide replaces air for coke combustion. To continuously regenerate the FCC catalyst, a coke-oxidation gas contains from 9 mol % to 35 mol % oxygen and from 50 mol % to 90 mol % carbon dioxide. In various embodiments, carbon dioxide is used in place of nitrogen, or used in place of steam, or both of these replacements. Several process configurations are shown, utilizing different recycle schemes and different distillation strategies, among other options. Many valuable co-products are described, including fuels and chemicals.

A process and system for recovering a recycle content carbon dioxide is provided that can lower the carbon footprint and global warming potential of a chemical recycling facility. More particularly, a pyrolysis flue gas and/or a pyrolysis gas from waste plastic pyrolysis may be treated in an absorber system to thereby form a recovered CO.sub.2 stream comprising recycle content carbon dioxide. Thus, the global warming potential of the chemical recycling facility may be optimized and lowered due to the carbon dioxide recovery process and system herein.

Systems and methods are provided for expanding the operating envelope for an FCC reaction system while also reducing or minimizing the net environmental CO.sub.2 emissions associated with the FCC reaction system and/or the resulting FCC products. In some aspects, reducing or minimizing net environmental CO.sub.2 emissions can be achieved during processing of unconventional feeds, such as feeds that are traditionally viewed as having insufficient tendency to coke in order to maintain heat balance within an FCC reaction system. In other aspects, this can correspond to expanding the production of diesel within an FCC reaction system by modifying the reaction conditions in a manner that can cause a reaction system to fall out of heat balance (relative to the heat needed to maintain a target operating temperature) even when using conventional feeds.

This invention is an improvement to refinery Fluid Catalytic Cracking Unit (FCCU) additives. The improved is obtained through the adjustment of the particle size distributions of the additives. Narrowing the range of particle size distributions for the additives results in improved performance in a wide range of additive compounds. In addition it allows for removal of the additives when combined with cracking catalysts.

Systems and methods are provided for incorporating molten carbonate fuel cells into a heat recovery steam generation system (HRSG) for production of electrical power while also reducing or minimizing the amount of CO.sub.2 present in the flue gas exiting the HRSG. An optionally multi-layer screen or wall of molten carbonate fuel cells can be inserted into the HRSG so that the screen of molten carbonate fuel cells substantially fills the cross-sectional area. By using the walls of the HRSG and the screen of molten carbonate fuel cells to form a cathode input manifold, the overall amount of duct or flow passages associated with the MCFCs can be reduced.

Processes and facilities for producing recycled chemical products from waste plastic are described herein. The processes include treating process streams, such as a pyrolysis gas stream and/or at least a portion of a cracker furnace effluent stream, in a caustic scrubber process to remove certain components, such as carbon dioxide. The spent caustic solution from the caustic scrubber process is then recycled and reused in other caustic processes within the facility, which can include a halogen neutralization process from removing halogens from a liquification process off-gas.

Systems and methods are provided for expanding the operating envelope for an FCC reaction system while also reducing or minimizing the net environmental CO.sub.2 emissions associated with the FCC reaction system and/or the resulting FCC products. In some aspects, reducing or minimizing net environmental CO.sub.2 emissions can be achieved during processing of unconventional feeds, such as feeds that are traditionally viewed as having insufficient tendency to coke in order to maintain heat balance within an FCC reaction system. In other aspects, this can correspond to expanding the production of diesel within an FCC reaction system by modifying the reaction conditions in a manner that can cause a reaction system to fall out of heat balance (relative to the heat needed to maintain a target operating temperature) even when using conventional feeds.

A cracking furnace system for converting a hydrocarbon feedstock into cracked gas includes a convection section, a radiant section and a cooling section. The convection section includes a plurality of convection banks configured to receive only a hydrocarbon feedstock and a diluent. The radiant section includes a firebox comprising at least oxygen or oxygen enriched air burners and several radiant coils configured to heat up the feedstock to a temperature allowing a pyrolysis reaction. The cooling section includes at least two transfer line exchangers (TLE), a primary transfer line exchanger (PTLE) and a secondary transfer line exchanger (STLE). The system includes a mixing device for mixing the preheated hydrocarbon feedstock and the preheated diluent. The system is configured such that the hydrocarbon feedstock and diluent mixture is preheated in the secondary transfer line exchanger before entry into the radiant section. The primary transfer line exchanger is configured to generate saturated steam. The system includes a steam drum which is connected to the primary transfer line exchanger.

A process for capturing carbon dioxide includes the steps of mixing a hydrogen stream and a feedstock stream to produce a mixed stream, wherein the feedstock stream includes hydrocarbons, reacting the hydrocarbons and the hydrogen in the primary reactor of the hydroprocessing unit to produce a hydroprocessing product stream and a carbon dioxide stream, wherein the hydroprocessing product stream includes light products, wherein the hydroprocessing unit is further configured to produce ammonium bisulfide, collecting the ammonium bisulfide in the water to produce a sour water, processing the sour water in the waste water unit to produce an ammonia stream, a hydrogen sulfide stream, and a stripped water stream, introducing the ammonia stream to a carbon dioxide recovery system, and separating carbon dioxide from the carbon dioxide stream using the ammonia in the ammonia stream to produce a carbon dioxide product.