Provided is a continuous process for converting waste plastic into recycle for polyethylene polymerization. In one embodiment, the process comprises selecting waste plastics containing polyethylene and/or polypropylene 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 naphtha/diesel fraction, a heavy fraction, and char. The naphtha/diesel fraction is passed to a crude unit distillation column in a refinery where a straight run naphtha (C.sub.5-C.sub.8) fraction or a propane/butane (C.sub.3-C.sub.4) fraction is recovered. The straight run naphtha fraction (C.sub.5-C.sub.8) or the propane/butane (C.sub.3-C.sub.4) fraction is passed to a steam cracker for ethylene production. The heavy fraction from the pyrolysis unit can also be passed to an isomerization dewaxing unit to produce a base oil.

Provided is a continuous process for converting waste plastic into recycle for polyethylene polymerization. In one embodiment, the process comprises selecting waste plastics containing polyethylene and/or polypropylene 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 naphtha/diesel fraction, a heavy fraction, and char. The naphtha/diesel fraction is passed to a crude unit distillation column in a refinery where a straight run naphtha (C.sub.5-C.sub.8) fraction or a propane/butane (C.sub.3-C.sub.4) fraction is recovered. The straight run naphtha fraction (C.sub.5-C.sub.8) or the propane/butane (C.sub.3-C.sub.4) fraction is passed to a steam cracker for ethylene production. The heavy fraction from the pyrolysis unit can also be passed to an isomerization dewaxing unit to produce a base oil.

A process for extracting fuel products from waste rubber, comprising the steps of subjecting the waste rubber to pyrolysis to produce a pyrolysis vapour, subjecting the pyrolysis vapour to a condensation step to produce a pyrolytic oil having a boiling point range of 45-400° C. and a flash point below 25° C., and then subjecting the pyrolytic oil to a vacuum steam stripping step so as to recover a fraction having a flash point of at least 40° C. but no higher than 55° C., a boiling point range starting at 100° C. or higher, a density at 15° C. of less than 990 kg/m.sup.3, a total acid number TAN of up to 12, a styrene content of less than 7000 ppm, and an organic halogen (as Cl) content of less than 50 ppm.

A process for extracting fuel products from waste rubber, comprising the steps of subjecting the waste rubber to pyrolysis to produce a pyrolysis vapour, subjecting the pyrolysis vapour to a condensation step to produce a pyrolytic oil having a boiling point range of 45-400° C. and a flash point below 25° C., and then subjecting the pyrolytic oil to a vacuum steam stripping step so as to recover a fraction having a flash point of at least 40° C. but no higher than 55° C., a boiling point range starting at 100° C. or higher, a density at 15° C. of less than 990 kg/m.sup.3, a total acid number TAN of up to 12, a styrene content of less than 7000 ppm, and an organic halogen (as Cl) content of less than 50 ppm.

Provided are an apparatus and a method for refining pyrolysis oil in which a dechlorination reaction is performed at a first temperature under a first hydrotreating catalyst, denitrification reaction is performed at a second temperature higher than the first temperature under a second hydrotreating catalyst, and chlorine adsorption by an adsorbent is performed after the dechlorination reaction, thereby preventing production of an ammonium salt (NH.sub.4Cl), and providing refined oil which is excellent in prevention of corrosion of a reactor, improvement of durability, occurrence of differential pressure, and process efficiency, has very low contents of impurities such as chlorine, nitrogen, and metal and olefin, and has excellent quality.

Provided are an apparatus and a method for refining pyrolysis oil in which a dechlorination reaction is performed at a first temperature under a first hydrotreating catalyst, denitrification reaction is performed at a second temperature higher than the first temperature under a second hydrotreating catalyst, and chlorine adsorption by an adsorbent is performed after the dechlorination reaction, thereby preventing production of an ammonium salt (NH.sub.4Cl), and providing refined oil which is excellent in prevention of corrosion of a reactor, improvement of durability, occurrence of differential pressure, and process efficiency, has very low contents of impurities such as chlorine, nitrogen, and metal and olefin, and has excellent quality.

The present invention discloses a process and an apparatus for conversion of waste plastic pyrolysis oil into value added products, wherein, the pyrolysis oil is produced from waste plastics by utilizing HCGO as a preheating stream. The process and apparatus as disclosed improves the conventional DCU process in terms of liquid, gaseous yields and reduction in coke yields and without disturbing the hardware of the conventional process along with energy efficient production of pyrolysis oil. The present process and apparatus include a delayed coking process and a system for the delayed coking process which involves the integration of delayed coking system with pyrolysis section and utilization of produced pyrolysis oil by co-processing it with residual heavy hydrocarbon feedstock.

The present invention discloses a process and an apparatus for conversion of waste plastic pyrolysis oil into value added products, wherein, the pyrolysis oil is produced from waste plastics by utilizing HCGO as a preheating stream. The process and apparatus as disclosed improves the conventional DCU process in terms of liquid, gaseous yields and reduction in coke yields and without disturbing the hardware of the conventional process along with energy efficient production of pyrolysis oil. The present process and apparatus include a delayed coking process and a system for the delayed coking process which involves the integration of delayed coking system with pyrolysis section and utilization of produced pyrolysis oil by co-processing it with residual heavy hydrocarbon feedstock.

Methods and systems for producing aromatics and light olefins from a mixed plastics stream are described. The method may include feeding a plastic feedstock to a dechlorination operation to melt the plastic feedstock to release HCl and generate a liquid plastic stream; feeding the liquid plastic stream to a pyrolysis reactor, the pyrolysis reactor to generate hydrocarbon vapors; feeding the hydrocarbon vapors to an acid gas removal reactor with a solid inorganic alkali salt disposed within the reaction vessel to remove residual HCl and sulfur-containing compounds from the hydrocarbon vapors to generate a plastic derived oil; and feeding the plastic derived oil to a steam enhanced catalytic cracking reactor to generate a product stream comprising light olefins having a carbon number of C.sub.2-C.sub.4 and aromatics. The associated system for processing mixed plastics into aromatics and light olefins is also described.

Methods and systems for producing aromatics and light olefins from a mixed plastics stream are described. The method may include feeding a plastic feedstock to a dechlorination operation to melt the plastic feedstock to release HCl and generate a liquid plastic stream; feeding the liquid plastic stream to a pyrolysis reactor, the pyrolysis reactor to generate hydrocarbon vapors; feeding the hydrocarbon vapors to an acid gas removal reactor with a solid inorganic alkali salt disposed within the reaction vessel to remove residual HCl and sulfur-containing compounds from the hydrocarbon vapors to generate a plastic derived oil; and feeding the plastic derived oil to a steam enhanced catalytic cracking reactor to generate a product stream comprising light olefins having a carbon number of C.sub.2-C.sub.4 and aromatics. The associated system for processing mixed plastics into aromatics and light olefins is also described.