A highly active and selective solid catalyst comprising stable single-atom iridium (Ir) anchored in a zeolite, e.g., ZSM-5, for upcycling of plastics, such as high-density polyethylene, to yield valuable lower molecular weight hydrocarbon products is disclosed.

A nonlimiting example method for producing a diesel boiling range composition comprises: oligomerizing an ethylene stream to a C4+ olefin stream in a first olefin oligomerization unit, wherein the C4+ olefin stream contains no greater than 10 wt% of methane, ethylene, and ethane combined in a first oligomerization; and wherein the ethylene stream contains at least 50 wt% ethylene, at least 2000 wppm ethane, no greater than 1000 wppm of methane, and no greater than 20 wppm each of carbon monoxide and hydrogen; oligomerizing the C4+ olefin stream and a propylene/C4+ olefin stream in a second oligomerization unit to produce an isoolefinic stream; wherein at least a portion of the isoolefinic stream is used to create the diesel boiling range composition.

A method for producing a blended jet boiling range composition stream may include: oligomerizing an ethylene stream to a C4+ olefin stream in a first olefin oligomerization unit, wherein the C4+ olefin stream contains no greater than 10 wt % of methane, ethylene, and ethane combined; wherein the ethylene stream contains at least 50 wt % ethylene, at least 2000 wppm ethane, no greater than 1000 wppm of methane, and no greater than 20 wppm each of carbon monoxide and hydrogen; oligomerizing the C4+ olefin stream and a propylene/C4+ olefin stream in a second oligomerization unit to produce an isoolefinic stream; subjecting at least a portion of the isoolefinic stream to a hydroprocessing process with hydrogen as treat gas to produce an isoparaffinic stream having no greater than 10 wt % olefin content; and using least a portion of the isoparaffinic stream to create the blended jet boiling range.

Processes and systems for making recycle content hydrocarbons, including olefins, from recycled waste material. Recycle waste material may be pyrolyzed to form recycle content pyrolysis oil composition (r-pyoil), at least a portion of which may then be cracked to form a recycle content olefin composition (r-olefin). The r- olefin may then be further separated into product streams in a separation zone downstream of the cracker furnace. In some cases, presence of recycle content hydrocarbons may facilitate more efficient operation of one or more distillation columns in the separation zone, including the demethanizer.

Processes and systems for making recycle content hydrocarbons, including olefins, from recycled waste material. Recycle waste material may be pyrolyzed to form recycle content pyrolysis oil composition (r-pyoil), at least a portion of which may then be cracked to form a recycle content olefin composition (r-olefin). In some cases, a heavy fraction from the cracker effluent may be used to form a recycle content pyrolysis gasoline composition (r-pyrolysis gasoline).

Provided is a continuous process for converting waste plastic into recycle for polypropylene polymerization. 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. Pyrolysis oil and wax, comprising naphtha/diesel and heavy fractions, is passed to a refinery FCC unit. A liquid petroleum gas C.sub.3 olefin/paraffin mixture is recovered from the FCC unit. The C.sub.3 paraffins and C.sub.3 olefins are separated into different fractions with the C.sub.3 olefin fraction passed to a propylene polymerization reactor, and the C.sub.3 paraffin fraction passed optionally to a dehydrogenation unit to produce additional propylene.

A process for commencing a continuous reaction in a reactor system includes introducing a catalyst to a catalyst processing portion of the reactor system, the catalyst initially having a first temperature of 500 C or less, and contacting the catalyst at the first temperature with a commencement fuel gas stream, which includes at least 80 mol % commencement fuel gas, in the catalyst processing portion. Contacting of the catalyst with the commencement fuel gas stream causes combustion of the commencement fuel gas. The process includes maintaining the contacting of the catalyst with the commencement fuel gas stream until the temperature of the catalyst increases from the first temperature to a second temperature at which combustion of a regenerator fuel source maintains an operating temperature range in the catalyst processing portion.

A process and apparatus for two stage hydrocracking saturates aromatics from the first stage hydrocracking unit to prevent production of HPNA's. The saturated HPNA's can be hydrocracked in the second stage to minimize or eliminate purged unconverted oil to approach or obtain maximum conversion. In an aspect, the second stage hydrocracking reactor and hydrotreating reactor may be located in the same vessel.

Improved alkylation catalysts, alkylation methods, and methods of making alkylation catalysts are described. The alkylation method comprises reaction over a solid acid, zeolite-based catalyst and can be conducted for relatively long periods at steady state conditions. The alkylation catalyst comprises a crystalline zeolite structure, a Si/Al molar ratio of 20 or less, less than 0.5 weight percent alkali metals, and further having a characteristic catalyst life property. Some catalysts may contain rare earth elements in the range of 10 to 35 wt %. One method of making a catalyst includes a calcination step following exchange of the rare earth element(s) conducted at a temperature of at least 575° C. to stabilize the resulting structure followed by an deammoniation treatment. An improved method of deammoniation uses low temperature oxidation.

A highly efficient method for the conversion of a natural product into the high density fuel RJ-4 with concomitant evolution of isobutylene for conversion to fuels and polymers, more specifically, embodiments of the invention relate to efficient methods for the conversion of the renewable, linear terpene alcohol, linalool into a drop-in, high density fuel suitable for ramjet or missile propulsion.