Chemical recycling of plastic derived streams to a cracker separation zone

Abstract

Methods and systems for converting waste plastics into various useful downstream recycle content products are provided. More particularly, the present systems and methods involve integrating a pyrolysis facility with a cracker facility by introducing at least one r-pyrolysis gas stream into the cracker facility. In the cracker facility, the r-pyrolysis gas can be separated to form one or more recycle content products, and operation of the facility can be improved.

Description

[0001] This application is a divisional application of the invention patent application with priority date of February 10, 2020, filing date of February 10, 2021, application number 202180013753.4, and invention title "Chemical recovery of plastic derivative stream to cracker separation zone". Background Technology

[0002] Waste, especially non-biodegradable waste, has a negative impact on the environment when disposed of in landfills after a single use. Therefore, from an environmental perspective, it is desirable to recycle as much waste as possible. However, from an economic perspective, waste recycling can be challenging.

[0003] While some waste materials are relatively easy and inexpensive to recycle, others require extensive and costly processing for reuse. Furthermore, different types of waste typically require different types of recycling processes. In many cases, costly physical sorting of waste is necessary to reduce it to a relatively clean, homogeneous volume.

[0004] To maximize recycling efficiency, it is desirable for large-scale production facilities to process feedstocks containing recycled components from a variety of wastes. Commercial facilities involved in the production of non-biodegradable products can greatly benefit from using recycled feedstocks, as the positive environmental impact of using recycled feedstocks can offset the negative environmental impact of manufacturing non-biodegradable products. Summary of the Invention

[0005] In one aspect, the technology relates to a method for forming syngas containing recycled components, the method comprising: (a) introducing a pyrolysis feed into a pyrolysis unit, wherein the pyrolysis feed comprises at least one recycled waste plastic; (b) pyrolyzing at least a portion of the pyrolysis feed to form a pyrolysis effluent containing pyrolysis gas; and (c) feeding at least a portion of the pyrolysis gas into a partial oxidizer.

[0006] In one aspect, the present technology relates to a method for forming syngas of recycled components, the method comprising: (a) pyrolyzing at least a portion of a pyrolysis feed comprising at least one recycled waste plastic in a pyrolysis unit to form a pyrolysis effluent comprising pyrolysis gas; (b) compressing at least a portion of the pyrolysis gas in a compression unit to form compressed pyrolysis gas; and (c) feeding at least a portion of the compressed pyrolysis gas to a partial oxidizing gasifier.

[0007] In one aspect, the technology relates to a method for forming syngas containing recycled components, the method comprising: (a) pyrolyzing at least a portion of a pyrolysis feed comprising at least one recycled waste plastic in a pyrolysis unit to form a pyrolysis effluent containing pyrolysis gas; (b) removing at least a portion of halogens from the pyrolysis gas in a dehalogenation unit to form dehalogenated pyrolysis gas; and (c) feeding at least a portion of the dehalogenated pyrolysis gas to a partial oxidizer gasifier.

[0008] In one aspect, the technology relates to a method for forming syngas containing recycled components, the method comprising: (a) providing a pyrolysis feed comprising at least one recycled waste plastic; (b) removing at least a portion of halogen from the pyrolysis feed to form a halogen waste stream and a dehalogenated feed; (c) pyrolyzing at least a portion of the dehalogenated feed in a pyrolysis unit to form a pyrolysis effluent comprising pyrolysis gas; and (d) feeding at least a portion of the pyrolysis gas to a partial oxidizing gasifier.

[0009] In one aspect, the present technology relates to a method for forming a syngas of recycled components, the method comprising: (a) introducing a pyrolysis feed into a pyrolysis unit, wherein the pyrolysis feed comprises at least one recycled waste plastic; (b) pyrolyzing at least a portion of the pyrolysis feed to form a pyrolysis effluent comprising pyrolysis gas and a pyrolysis residue stream, wherein the pyrolysis residue stream comprises at least 1 wt% (wt%, weight percent) of carbonaceous solids and / or at least 20 wt% of C20+ hydrocarbons; and (c) feeding at least a portion of the pyrolysis residue into a partial oxidizer gasifier.

[0010] In one aspect, the technology relates to a method for forming syngas of recycled components, the method comprising: (a) pyrolyzing a pyrolysis feed in a pyrolysis unit, wherein the pyrolysis feed comprises at least one recycled waste plastic; (b) removing a pyrolysis underflow from a first position in the pyrolysis unit and removing a pyrolysis gaseous flow from a second position in the pyrolysis unit, wherein the first position is below the second position; and (c) feeding at least a portion of the pyrolysis underflow to a partial oxidizer.

[0011] In one aspect, the technology relates to a method for preparing olefin products, the method comprising separating a feed stream containing pyrolysis gas (r-pyrolysis gas) containing recovered components in at least one fractionation column downstream of a cracker furnace.

[0012] In one aspect, the present technology relates to a method for preparing an olefin product, the method comprising: (a) introducing a column feed stream containing alkanes and olefins into a dealkylation column, wherein the column feed stream contains a recovered component pyrolysis gas (r-pyrolysis gas); and (b) separating the column feed stream into a column overhead stream rich in target alkanes and a column bottom stream leaning in target alkanes, wherein at least one of the column overhead stream and the column bottom stream contains at least 5 wt% olefins – based on the total weight of the stream.

[0013] In one aspect, the present technology relates to a method for preparing olefin products, the method comprising: (a) introducing a column feed stream containing alkanes and olefins into an olefin-alkane fractionation column, wherein the column feed stream contains a recovered component pyrolysis gas (r-pyrolysis gas); and (b) separating the column feed stream in the olefin-alkane fractionation column into an olefin enrichment column overhead stream and an alkane enrichment column bottom stream.

[0014] In one aspect, the present technology relates to a method for preparing an olefin product, the method comprising: (a) pyrolyzing a feed stream containing recycled waste in a pyrolysis facility to provide a stream of recycled component pyrolysis gas (r-pyrolysis gas); and (b) separating a column feed stream in at least one fractionating column in a fractionating section downstream of a cracker furnace in a cracking facility to provide an olefin product, wherein the column feed stream contains at least a portion of r-pyrolysis gas, wherein prior to at least a portion of the pyrolysis in step (a), the cracker furnace is operated to form an olefin-containing effluent stream, the effluent stream being separated in the fractionating section of the cracking facility.

[0015] In one aspect, the technology relates to a method for preparing olefin products, the method comprising: (a) pyrolyzing a feed stream containing recycled waste in a pyrolysis facility to provide a stream of recycled component pyrolysis gas (r-pyrolysis gas); and (b) exchanging energy between at least a portion of the r-pyrolysis gas stream and one or more heat transfer streams in an energy exchange zone; and (c) introducing at least a portion of the r-pyrolysis gas from the energy exchange zone into a cracker facility.

[0016] In one aspect, the technology relates to recovering component pyrolysis gas (r-pyrolysis gas), wherein the r-pyrolysis gas comprises: at least 20 wt% and / or no more than 75 wt% ethylene and / or propylene, at least 5 wt% and / or no more than 50 wt% ethane and / or propane, at least 5 wt% and / or no more than 60 wt% methane, the weight ratio of ethylene to ethane or the weight ratio of propylene to propane being at least 1:1 and / or no more than 3:1, and at least one of the following characteristics (i) to (ix): (i) no more than 20 wt% of C4 hydrocarbons; (ii) no more than 10 wt% of hydrogen; (iii) no more than 10 wt% of C3+ dienes; (iv) not more than 10 wt% of C4+ olefins; (v) not more than 5 wt% of C4 alkanes; (vi) not more than 1 ppm of halogens; (v) not more than 100 ppm of carbonyl compounds; (vi) not more than 100 ppm of carbon dioxide; (vii) not more than 2500 ppm of carbon monoxide; (viii) not more than 15 ppb of arsine and / or phosphine; and (ix) not more than 100 ppm of sulfur-containing compounds, wherein each of the above amounts is by weight based on the total weight of the composition, and wherein the r-pyrolysis gas is formed by the pyrolysis of recycled waste plastics or materials derived therefrom.

[0017] In one aspect, the technology relates to a method for separating an olefin-containing stream to form one or more product streams, wherein the method includes introducing a stream containing recovered component pyrolysis gas (r-pyrolysis gas) into a cracker facility at a location downstream of the cracker furnace outlet.

[0018] In one aspect, the technology relates to a method for separating an olefin-containing stream to form one or more product streams, wherein the method comprises (a) pyrolyzing a pyrolysis feed stream containing recycled waste to form recycled component pyrolysis gas (r-pyrolysis gas); and (b) introducing at least a portion of the r-pyrolysis gas into a cracker facility at at least one location downstream of the cracker furnace outlet.

[0019] In one aspect, the present technology relates to a method for separating an olefin-containing stream to form one or more product streams, wherein the method comprises: (a) introducing a column feed stream into an olefin fractionation column, wherein the column feed stream contains a recovered component pyrolysis gas (r-pyrolysis gas); (b) separating the column feed stream in the olefin fractionation column into a column overhead stream rich in at least one olefin and a column bottom stream leaning in at least one olefin, wherein at least one of the following conditions (i) to (vi) is satisfied: (i) the molar ratio of at least one olefin in the column feed stream to its corresponding alkane is at least 0.1% higher than that if the column feed stream does not contain r-pyrolysis gas but has the same mass flow rate; (ii) the mass flow rate of the corresponding alkane in the column overhead stream is at least 0.1% higher than that if the column feed stream does not contain r-pyrolysis gas but has the same mass flow rate; (iii) The reflux ratio used in the separation process is at least 0.1% lower than that used if the column feed stream does not include r-pyrolysis gas but has the same mass flow rate; (iv) The pressure drop across the column is at least 0.1% lower than that if the column feed stream does not include r-pyrolysis gas but has the same mass flow rate; (v) The mass flow rate of the liquid in the column is at least 0.1 wt% lower than that if the column feed stream does not include r-pyrolysis gas but has the same mass flow rate; and (vi) The energy input into the column is at least 0.1% lower than that if the column feed stream does not include r-pyrolysis gas but has the same mass flow rate. Attached Figure Description

[0020] Figure 1 An exemplary pyrolysis facility is described, which can at least partially convert one or more waste plastics into a variety of pyrolysis derivatives; Figure 2 Another exemplary system is described, which can at least partially convert one or more waste plastics into a variety of useful pyrolysis derivatives; Figure 3Another exemplary system is described, which can at least partially convert one or more waste plastics into a variety of useful pyrolysis derivatives; Figure 4 An exemplary system for processing waste plastics is described, which includes a pyrolysis facility, a partial oxidation (POX) gasification facility, and a cracker facility; Figure 5 An exemplary system for processing waste plastics is depicted, comprising a pyrolysis facility and a cracker facility, with particular illustration of an embodiment of an integrated strategy; Figure 6 Another exemplary system for processing waste plastics is depicted, which includes a pyrolysis facility and a cracker facility, with other embodiments of the integrated strategy shown in particular; Figure 7 Another exemplary system for processing waste plastics is described, which includes a pyrolysis facility and a cracker facility, with a further embodiment of an integrated strategy shown in particular; Figure 8 Another exemplary system for processing waste plastics is described, which includes a pyrolysis facility and a cracker facility, with a further embodiment of an integrated strategy shown in particular; Figure 9 Another exemplary system for processing waste plastics is depicted, which includes a pyrolysis facility and a cracker facility, with other embodiments of the integrated strategy shown in particular; Figure 10 A schematic diagram of the cracker furnace is provided. Figure 11a depicts an exemplary system for pretreating a stream of furnace effluent from a cracking facility prior to separation; Figure 11b depicts an exemplary system applicable to the quenching zone shown in Figure 11a; Figure 12 An exemplary location of a cracker facility for introducing pyrolysis gas downstream of a cracker is depicted. Figure 13 An exemplary configuration of the separation zone in a cracker facility is depicted; Figure 14 Another exemplary configuration of the separation zone in a cracker facility is depicted; Figure 15 Another exemplary configuration of the separation zone in a cracker facility is depicted; and Figure 16 An exemplary system for thermal integration between pyrolysis facilities and cracker facilities is described. Detailed Implementation

[0021] When indicating a sequence of numbers, it should be understood that each number is modified in the same way as the first or last number and is in an "or" relationship, meaning that each number is "at least", "at most", or "no more than" depending on the context. For example, "at least 10wt%, 20, 30, 40, 50, 75..." means the same as "at least 10wt%, or at least 20wt%, or at least 30wt%, or at least 40wt%, or at least 50wt%, or at least 75wt%", etc.

[0022] Unless otherwise stated, all concentrations or amounts are by weight.

[0023] As used herein, “PET” includes: homopolymers of polyethylene terephthalate, or polyethylene terephthalate modified with modifiers or containing residues or portions other than ethylene glycol and terephthalic acid, such as isophthalic acid, diethylene glycol, TMCD (2,2,4,4-tetramethyl-1,3-cyclobutanediol), CHDM (cyclohexanediol), propylene glycol, isosorbide, 1,4-butanediol, 1,3-propanediol, and / or NP. G (neopentyl glycol), or polyesters having repeating terephthalate units (and whether or not they contain repeating ethylene glycol units) and one or more of the following residues or moieties: TMCD (2,2,4,4-tetramethyl-1,3-cyclobutanediol), CHDM (cyclohexanediol), propylene glycol, or NPG (neopentyl glycol), isosorbide, isophthalic acid, 1,4-butanediol, 1,3-propanediol and / or diethylene glycol, or combinations thereof.

[0024] According to one embodiment or a combination of any of the mentioned embodiments, a chemical recycling facility is provided, comprising a pyrolysis facility and a cracking facility configured to produce at least one recycled component product. As used herein, “chemical recycling” refers to a waste plastic recycling process that includes steps of chemically converting waste plastic polymers into lower molecular weight polymers, oligomers, monomers, and / or non-polymer molecules (e.g., hydrogen and carbon monoxide), which are useful in themselves and / or can be used as feedstocks for one or more other chemical production processes. The chemical recycling facility described herein can be used to convert mixed plastic waste into recycled component products or chemical intermediates for the formation of various end-use materials.

[0025] Chemical recycling facilities are not physical recycling facilities. As used herein, the term "physical recycling" (also known as "mechanical recycling") refers to a recycling process that includes steps of melting waste plastics and forming the molten plastics into new intermediate products (e.g., pellets or sheets) and / or new final products (e.g., bottles). Typically, physical recycling does not alter the chemical structure of the recycled plastics. In one embodiment or in combination with any of the embodiments mentioned herein, the chemical recycling facility described herein can be configured to receive and process streams of waste from physical recycling facilities and / or waste streams that are typically not handled by physical recycling facilities.

[0026] pyrolysis facilities Figure 1 An exemplary pyrolysis facility 10 is depicted, which can be used to at least partially convert one or more recycled wastes—particularly recycled waste plastics—into a variety of useful pyrolysis derivatives, such as pyrolysis residues, pyrolysis oils, and pyrolysis gases. As used herein, "pyrolysis facility" means a facility that includes all the equipment, piping, and control devices required to perform the pyrolysis of waste plastics. It should be understood that... Figure 1 The pyrolysis facility shown is merely one example of a system in which this disclosure can be implemented. This disclosure can be applied to a variety of other systems in which it is desirable to efficiently and effectively pyrolyze waste plastics into various desired end products. These will now be described in more detail. Figure 1 The exemplary pyrolysis facility shown is illustrated.

[0027] like Figure 1 As shown, the pyrolysis facility 10 may include a waste plastic source 12 for supplying mixed plastic waste (“MPW”) and / or one or more waste plastics to the system 10. As used herein, “mixed plastic waste” or MPW refers to post-industrial (or pre-consumer) plastics, post-consumer plastics, or mixtures thereof. Examples of plastic materials include, but are not limited to, polyesters, one or more polyolefins (PO), and polyvinyl chloride (PVC). Furthermore, as used herein, “waste plastic” refers to any post-industrial (or pre-consumer) and post-consumer plastics, such as, but not limited to, polyesters, polyolefins (PO), and / or polyvinyl chloride (PVC). In one or more embodiments, the waste plastics may also include minor plastic components (other than PET and polyolefins) that total less than 50, no more than 40, no more than 30, no more than 20, no more than 15, or no more than 10 wt% of the waste plastic content, and optionally may individually represent less than 30, no more than 20, no more than 15, no more than 10, or no more than 1 wt% of the waste plastic content.

[0028] In one embodiment or in combination with any of the embodiments mentioned, the MPW and / or waste plastic supplied by plastic source 12 may be derived from or supplied as a municipal solid waste stream (“MSW”).

[0029] The plastic source 12 may include a hopper, storage bin, railcar, long-haul trailer, or any other device capable of containing or storing waste plastics. In one embodiment or in combination with any of the mentioned embodiments, the plastic source 12 may include a municipal recycling facility, an industrial facility, a recycling facility, a commercial facility, a manufacturing facility, or a combination thereof.

[0030] In one embodiment or in combination with any of the embodiments mentioned, the MPW and / or waste plastic supplied by plastic source 12 may be in the form of solid particles, such as fragments, flakes, or powder. The MPW supplied by plastic source 12 may include MPW pellets. As used herein, “MPW pellets” refers to MPW with an average particle size of less than one inch. MPW pellets may include, for example, shredded plastic pellets, minced plastic pellets, or plastic granules.

[0031] In one embodiment or in combination with any of the embodiments mentioned, the MPW and / or waste plastic provided by plastic source 12 may contain at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 95, or at least 99 wt% of any one or a combination of the following: polyolefins (e.g., low-density polyethylene, high-density polyethylene, low-density polypropylene, high-density polypropylene, cross-linked polyethylene, amorphous polyolefins, and copolymers of any of the above polyolefins), polystyrene, polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), polyesters, including those having repeating aromatic or cyclic units, such as those containing repeating terephthalate or naphthalene ester units, such as PET and PEN, or those containing repeating furanoate repeating units, and although within the definition of PET, it is also worth mentioning polyesters having repeating terephthalate units and one or more residues or portions of the following compounds: TMC D (2,2,4,4-tetramethyl-1,3-cyclobutanediol), CHDM (cyclohexanediol), propylene glycol, or NPG (neopentyl glycol), isosorbide, isophthalic acid, 1,4-butanediol, 1,3-propanediol and / or diethylene glycol or combinations thereof, and aliphatic polyesters such as PLA, polyglycolic acid, polycaprolactone and polyethylene adipate, polyamides, poly(methyl methacrylate), polytetrafluoroethylene, acrylonitrile butadiene styrene (ABS), polyurethanes, cellulose articles and their derivatives (e.g., cellulose acetate, cellulose diacetate, cellulose triacetate, cellulose acetate propionate, cellulose acetate butyrate, and regenerated cellulose such as viscose), epoxides, polyamides, phenolic resins, polyacetals, polycarbonates, polyurethanes, polyphenylene alloys, polystyrene, styrene compounds, vinyl compounds, poly(methyl methacrylate), styrene acrylonitrile, thermoplastic elastomers, polyvinyl alcohol acetals (e.g., PVB), urea polymers, melamine-containing polymers, or combinations thereof.

[0032] The waste plastic supplied from waste plastic source 12 can be any organic synthetic polymer that is solid at 25°C and 1 atm. In one embodiment or in combination with any of the mentioned embodiments, the waste plastic may include thermosetting plastics, thermoplastic plastics, and / or elastomeric plastics. The number average molecular weight of the polymer may be at least 300, or at least 500, or at least 1000, or at least 5,000, or at least 10,000, or at least 20,000, or at least 30,000, or at least 50,000, or at least 70,000, or at least 90,000, or at least 100,000, or at least 130,000. The weight-average molecular weight of the polymer may be at least 300, or at least 500, or at least 1000, or at least 5,000, or at least 10,000, or at least 20,000, or at least 30,000, or at least 50,000, or at least 70,000, or at least 90,000, or at least 100,000, or at least 130,000, or at least 150,000, or at least 300,000.

[0033] In one embodiment or in combination with any of the mentioned embodiments, the MPW and / or waste plastic supplied by plastic source 12 may contain at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 95, or at least 99 wt% of any polyolefin (e.g., high-density polyethylene, low-density polyethylene, polypropylene, other polyolefins), polyethylene terephthalate (PET), polystyrene, polyamide, poly(methyl methacrylate), polytetrafluoroethylene, or combinations thereof. Furthermore, in some embodiments, the MPW and / or waste plastic supplied by plastic source 12 may include high-density polyethylene, low-density polyethylene, polypropylene, other polyolefins, or combinations thereof.

[0034] In one embodiment or in combination with any of the mentioned embodiments, the MPW and / or waste plastic supplied by plastic source 12 may contain at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 95, or at least 99 wt% of any polyolefin (e.g., high-density polyethylene, low-density polyethylene, polypropylene, other polyolefins) and polyethylene terephthalate (PET).

[0035] In one embodiment or in combination with any of the mentioned embodiments, the MPW and / or waste plastic supplied by plastic source 12 may contain at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 95, or at least 99 wt% of any of the following plastics having resin ID codes numbered 1-7 within the chasing arrow triangle established by SPI. In one embodiment or in combination with any of the mentioned embodiments, the MPW and / or waste plastic supplied by plastic source 12 may include no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 5, no more than 3, no more than 2, no more than 1, or no more than 0.5 wt% of any plastic having resin ID codes numbered 1-7.

[0036] In one embodiment or in combination with any of the mentioned embodiments, the MPW and / or waste plastic supplied by the plastic source may comprise plastics having resin ID codes #1-7 and plastics not having resin ID codes #1-7. In one embodiment or in combination with any of the mentioned embodiments, the MPW and / or waste plastic supplied by the plastic source 12 may comprise at least 10, at least 20, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 95, or at least 99 wt% of any of the following plastics having a resin ID code numbered 3-7 or 4-7 within the chasing arrow triangle established by the SPI, or a resin ID code corresponding to that resin ID code.

[0037] In one embodiment or in combination with any other embodiment, the MPW includes, but is not limited to: plastic components, such as polyesters, including those having repeating aromatic or cyclic units, such as those containing repeating terephthalate or naphthalene ester units, such as PET and PEN, or those containing repeating furanoate repeating units, and although within the definition of PET, it is also worth mentioning polyesters having repeating terephthalate units and one or more residues or portions of the following compounds: TMCD (2,2,4,4-tetramethyl-1,3-cyclobutanediol), CHDM (cyclohexanediol), propylene glycol, or NPG (neopentyl glycol), isosorbide, isophthalic acid, 1,4-butanediol, 1,3-propanediol and / or diethylene glycol or combinations thereof, and aliphatic polyesters such as PL A. Polyglycolic acid, polycaprolactone, and polyethylene adipate; polyolefins (e.g., low-density polyethylene, high-density polyethylene, low-density polypropylene, high-density polypropylene, cross-linked polyethylene, amorphous polyolefins, and copolymers of any of the above polyolefins), polyvinyl chloride (PVC), polystyrene, polytetrafluoroethylene, acrylonitrile butadiene styrene (ABS), cellulose products such as cellulose acetate, cellulose diacetate, cellulose triacetate, cellulose acetate propionate, cellulose acetate butyrate, and regenerated cellulose such as viscose; epoxides, polyamides, phenolic resins, polyacetals, polycarbonates, polyphenylene alloys, poly(methyl methacrylate), styrene-containing polymers, polyurethanes, vinyl polymers, styrene-acrylonitrile, thermoplastic elastomers other than tires, and urea-containing polymers and melamine.

[0038] In one embodiment or in combination with any of the mentioned embodiments, the MPW contains a thermosetting polymer. Examples of the amount of thermosetting polymer present in the MPW, based on its weight, may be at least 1 wt%, or at least 2 wt%, or at least 5 wt%, or at least 10 wt%, or at least 15 wt%, or at least 20 wt%, or at least 25 wt%, or at least 30 wt%, or at least 40 wt%.

[0039] In one embodiment or in combination with any of the mentioned embodiments, the MPW contains a plastic at least in part derived from cellulose, such as cellulose derivatives with an acyl substitution degree of less than 3 or 1.8 to 2.8, such as cellulose acetate, cellulose diacetate, cellulose triacetate, cellulose acetate propionate, and cellulose acetate butyrate.

[0040] In one embodiment or in combination with any of the mentioned embodiments, the MPW contains a plastic, at least a portion of which is derived from a polymer having repeating terephthalate units, such as polyethylene terephthalate, polyethylene terephthalate, polyethylene terephthalate, and copolyesters thereof.

[0041] In one embodiment or in combination with any of the mentioned embodiments, the MPW contains a plastic, at least a portion of which is obtained from a copolyester having a plurality of dicyclohexanediethanol moieties, 2,2,4,4-tetramethyl-1,3-cyclobutanediol moieties or combinations thereof.

[0042] In one embodiment or in combination with any of the mentioned embodiments, the MPW contains a plastic, at least a portion of which is derived from low-density polyethylene, high-density polyethylene, linear low-density polyethylene, polypropylene, polymethylpentene, polybutene-1, and copolymers thereof.

[0043] In one embodiment or in combination with any of the mentioned embodiments, the MPW contains a plastic, at least a portion of which is derived from eyeglass frames or cross-linked polyethylene.

[0044] In one embodiment or in combination with any of the mentioned embodiments, the MPW contains a plastic, at least a portion of which is derived from a plastic bottle.

[0045] In one embodiment or in combination with any of the mentioned embodiments, the MPW contains a plastic, at least a portion of which is derived from diapers.

[0046] In one embodiment or in combination with any of the mentioned embodiments, the MPW contains a plastic, at least a portion of which is derived from polystyrene foam or expanded polystyrene.

[0047] In one embodiment or in combination with any of the mentioned embodiments, the MPW contains a plastic, at least a portion of which is derived from flash-spun high-density polyethylene.

[0048] In one embodiment or in combination with any of the mentioned embodiments, the MPW contains plastics having or derived from resin ID codes 1-7 (within the chasing arrow triangle established by the SPI). In one embodiment or in combination with any of the mentioned embodiments, at least a portion of the MPW contains one or more plastics that are not typically mechanically recyclable. These include plastics having codes 3 (polyvinyl chloride), 5 (polypropylene), 6 (polystyrene), and 7 (others). In one embodiment or in combination with any of the mentioned embodiments, based on the weight of the plastics in the MPW, the MPW contains at least 0.1 wt%, or at least 0.5 wt%, or at least 1 wt%, or at least 2 wt%, or at least 3 wt%, or at least 5 wt%, or at least 7 wt%, or at least 10 wt%, or at least 12 wt%, or at least 15 wt%, or at least 20 wt%, or at least 25 wt%, or at least 30 wt%, or at least 40 wt%, or at least or greater than 50 wt%, or at least 65 wt%, or at least 85 wt%, or at least 90 wt% of plastics having or corresponding to codes 3, 5, 6, 7, or combinations thereof.

[0049] In one embodiment or in combination with any of the embodiments mentioned, the MPW comprises plastic having or obtained from at least one, two, three or four different kinds of resin ID codes having the following contents: at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95 or at least 99 wt%.

[0050] In one embodiment or in combination with any of the mentioned embodiments, the MPW and / or waste plastic supplied by plastic source 12 may contain at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 95, or at least 99 wt% of at least one post-consumer plastic and / or at least one post-industrial (pre-consumer) plastic. As used herein, “post-consumer plastic” is plastic that has been used at least once for its intended application for any duration, regardless of wear and tear, has been sold to an end-user consumer, or has been discarded into a recycling bin by any individual or entity other than the manufacturer or enterprise engaged in the manufacture or sale of the material.

[0051] Furthermore, "post-industrial plastics" (or "pre-consumer plastics") include all manufactured recyclable organic plastics that are not post-consumer plastics, such as materials that have been manufactured or processed by a manufacturer but have not yet been used for their intended application, have not yet been sold to end-user consumers, or have been discarded or transferred by the manufacturer or any other entity involved in the sale or disposal of the materials. Examples of post-industrial (pre-consumer) plastics include reprocessed, re-grinded, scrapped, trimmed, non-conforming materials, and finished materials that have been transferred from the manufacturer to any downstream consumer (e.g., manufacturer to wholesaler to distributor) but have not yet been used or sold to end-user consumers.

[0052] The MPW and / or waste plastics provided by plastic source 12 are not limited in form and may include articles, products, materials or portions thereof in any form. A portion of an article may take the form of sheets, extruded profiles, molded articles, films, carpets, laminates, foam sheets, fragments, flakes, granules, agglomerates, lumps, powders, scraps, strips, or sheets of random shapes of various forms, or any other form besides the original form of the article that is suitable for feeding into the pyrolysis unit.

[0053] In one embodiment or in combination with any of the mentioned embodiments, the MPW and / or waste plastic supplied by plastic source 12 may contain at least 50, 55, 60, 65, 70, 75, 80, 85, 95, or 99 wt% of recycled textiles and / or recycled carpets, such as synthetic fibers, rovings, yarns, nonwoven webs, fabrics, textiles, and products made from or containing any of the aforementioned plastics. Textiles may include woven, knitted, knotted, stitched, tufted, felted, embroidered, lace, crocheted, braided, or nonwoven webs and materials. Textiles may include fabrics, fibers separated from textiles or other fiber-containing products, waste or non-standard fibers or yarns or fabrics, or any other source of loose fibers and yarns. In addition, textiles may include staple fibers, continuous fibers, yarns, yarn bundles, twisted and / or spun yarns, greige fabrics made from yarns, finished fabrics made from wet-processed greige fabrics, garments made from finished fabrics, or any other fabrics.

[0054] Examples of recycled textiles that can be used in the apparel industry include: sports jackets, suits, trousers and casual or work pants, shirts, socks, sportswear, dresses, close-fitting garments, outerwear such as raincoats, low-temperature jackets and coats, sweaters, protective clothing, uniforms, and accessories such as scarves, hats, and gloves. Examples of textiles that can be used in the interior decorating category include: furniture upholstery and sofa covers, rugs and rugs, curtains, bedding such as sheets, pillowcases, comforters, quilts, mattress covers, linens, tablecloths, towels, washcloths, and blankets. Examples of industrial textiles that can be used include: transport seats, floor mats, trunk liners and roof liners, outdoor furniture and mats, tents, backpacks, luggage, ropes, conveyor belts, calendering roller felt, polishing cloths, rags, soil-eroded fabrics and geotextiles, agricultural mats and screens, personal protective equipment, bulletproof vests, medical bandages, stitching, tape, etc.

[0055] MPW may contain recycled (post-consumer or post-industrial (or pre-consumer) textiles. Textiles may contain natural and / or synthetic fibers, rovings, yarns, nonwoven webs, fabrics, textiles, and products made from or containing any of the foregoing items. Textiles may be woven, knitted, knotted, sewn, tufted, or made by pressing fibers together—for example, in felting operations, embroidered, lace, crocheted, braided, or nonwoven webs and materials. As used herein, textiles include: textiles, and sources of fibers, waste or non-standard fibers or yarns or textiles separated from textiles or other products containing fibers, or any other loose fibers and yarns. Textiles also include staple fibers, continuous fibers, threads, tows, twisted and / or spun yarns, greige fabrics made from yarns, finished fabrics made from wet-processed greige fabrics, and garments made from finished fabrics or any other fabrics. Textiles include clothing, interior decoration, and industrial textiles. Textiles also include post-industrial textiles or post-consumer textiles or both.

[0056] Examples of textiles in the Clothing category (things worn by humans or made for the body) include: sports jackets, suits, trousers and casual or work pants, shirts, socks, sportswear, dresses, close-fitting garments, outerwear such as raincoats, low-temperature jackets and coats, sweaters, protective clothing, uniforms, and accessories such as scarves, hats, and gloves. Examples of textiles in the Interior Decoration category include: furniture upholstery and sofa covers, rugs and rugs, curtains, bedding such as sheets, pillowcases, comforters, quilts, mattress covers; linen products, tablecloths, towels, washcloths, and blankets. Examples of industrial textiles include: transportation (cars, airplanes, trains, buses) seats, floor mats, trunk liners, and roof liners; outdoor furniture and mats, tents, backpacks, luggage, ropes, conveyor belts, calendered felt, polishing cloths, rags, soil erosion fabrics and geotextiles, agricultural mats and screens, personal protective equipment, bulletproof vests, medical bandages, stitching, tape, etc.

[0057] The category of nonwoven webs classified as textiles does not include wet-laid nonwoven webs and articles made therefrom. While various articles having the same function can be made by either dry-laid or wet-laid methods, articles made from dry-laid nonwoven webs are classified as textiles. Examples of suitable articles that can be formed from the dry-laid nonwoven webs described herein may include those for personal, consumer, industrial, food service, medical, and other types of end-use. Specific examples may include, but are not limited to: baby wipes, rinseable wipes, disposable diapers, training pants, feminine hygiene products such as sanitary napkins and tampons, adult incontinence pads, underwear, and pet training mats.

[0058] Other examples include various types of dry or wet wipes, including those for consumer (e.g., personal care or home) and industrial (e.g., food service, healthcare, or professional) use. Nonwoven webs can also be used as filling for pillows, mattresses, and upholstery, as well as for quilts and comforters. In the medical and industrial fields, the nonwoven webs of this invention can be used in medical and industrial face shields, protective clothing, caps and shoe covers, disposable sheets, surgical gowns, curtains, bandages, and medical dressings.

[0059] In addition, the nonwoven webs described herein can be used in environmental fabrics such as geotextiles and tarpaulins, oil-absorbing mats and chemical-absorbing mats, as well as building materials such as sound or heat insulation, tents, timber and soil coverings, and sheets. Nonwoven webs can also be used for other consumer end-uses, such as for carpet backing, packaging of consumer, industrial, and agricultural products, heat or sound insulation, and various types of clothing. Dry-laid nonwoven webs as described herein can also be used in a variety of filtration applications, including transportation (e.g., automotive or aerospace), commercial, residential, industrial, or other professional applications. Examples may include filter elements for consumer or industrial air or liquid filters (e.g., gasoline, oil, water), including nanofiber webs for microfiltration, and end-uses such as tea bags, coffee filters, and drying paper. Furthermore, nonwoven webs as described herein can be used to form various components for automobiles, including but not limited to brake pads, trunk liners, carpet tufting, and underlayment.

[0060] Textiles may include one or more types of natural fibers and / or one or more types of synthetic fibers. Examples of textile fiber combinations include: all-natural, all-synthetic, two or more types of natural fibers, two or more types of synthetic fibers, one type of natural fiber and one type of synthetic fiber, one type of natural fiber and two or more types of synthetic fibers, two or more types of natural fibers and one type of synthetic fiber, and two or more types of natural fibers and two or more types of synthetic fibers.

[0061] Natural fibers include those of plant or animal origin. Natural fibers can be cellulose, hemicellulose, and lignin. Examples of plant-derived natural fibers include: hardwood pulp, softwood pulp, and wood flour; and other plant fibers, including those found in wheat straw, rice straw, Manila hemp, coconut fiber, cotton, flax, hemp, jute, bagasse, kapok, papyrus, ramie, rattan, grapevine, kenaf, Manila hemp, hena lamina, sisal, soybean, cereal straw, bamboo, reeds, fine-stemmed needlegrass, bagasse, Indian grass, milkweed fiber, pineapple leaf fiber, switchgrass, and lignin-containing plants. Examples of animal-derived fibers include wool, silk, mohair, cashmere, goat hair, horsehair, poultry fiber, camel hair, Angora wool, and alpaca wool.

[0062] Synthetic fibers are those fibers that are synthesized or derived, or regenerated, at least in part, through chemical reactions, including but not limited to: rayon, viscose, mercerized fiber, or other types of regenerated cellulose (natural cellulose is converted into soluble cellulose derivatives and subsequently regenerated), such as lyocell (also known as Tencel), cupro (CuPro), Modal, acetates such as polyvinyl acetate, polyamides including nylon, polyesters such as PET, olefin polymers such as polypropylene and polyethylene, polycarbonate, polysulfone, polyethers such as polyether-urea called spandex or elastic fiber, polyacrylates, acrylonitrile copolymers, polyvinyl chloride (PVC), polylactic acid, polyglycolic acid, sulfonated polyester fibers, and combinations thereof.

[0063] Textiles can be in any of the forms mentioned above, such as by reducing their size through chopping, tearing, raking, grinding, pulverizing, or cutting textile raw materials to produce smaller textiles. Textiles can also be densified. Examples of densification methods include those that soften or melt part or all of the textile by applying heat generated by friction, or by extruding particles, or by other external heat to the textile, thereby causing the textile to clump together.

[0064] In one embodiment or in combination with any of the mentioned embodiments, based on the weight of the MPW, the amount of textiles (including textile fibers) in the MPW is at least 0.1 wt%, or at least 0.5 wt%, or at least 1 wt%, or at least 2 wt%, or at least 5 wt%, or at least 8 wt%, or at least 10 wt%, or at least 15 wt%, or at least 20 wt% of material derived from textiles or textile fibers. In one embodiment or in combination with any of the mentioned embodiments, based on the weight of the MPW, the amount of textiles (including textile fibers) in the MPW is no more than 50, no more than 40, no more than 30, no more than 20, no more than 15, no more than 10, no more than 8, no more than 5, no more than 2, no more than 1, no more than 0.5, no more than 0.1, no more than 0.05, no more than 0.01, or no more than 0.001 wt%.

[0065] Back Figure 1 MPW and / or waste plastic supplied by plastic source 12 can be introduced into raw material pretreatment system 14. In one embodiment or in combination with any of the mentioned embodiments, the MPW and / or waste plastic introduced into raw material pretreatment system 14 may contain at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% solids content.

[0066] In the raw material pretreatment system 14, the introduced MPW and / or waste plastics may undergo one or more pretreatments to facilitate subsequent pyrolysis reactions and / or enrich the resulting pyrolysis products. In one embodiment or in combination with any of the mentioned embodiments, the introduced MPW and / or waste plastics may be pretreated in the pretreatment system 14. As used herein, “pretreatment” means preparing waste plastics for chemical modification using one or more of the following steps: (i) crushing, (ii) granulation, (iii) washing, (iv) drying, and / or (v) separation. Furthermore, in one embodiment or in combination with any of the mentioned embodiments, the raw material pretreatment system 14 may include a pretreatment facility. As used herein, “pretreatment facility” means a facility that includes all the equipment, piping, and control devices required to perform waste plastic pretreatment.

[0067] Exemplary pretreatment may include, for example, crushing, granulation, washing, drying, mechanical agitation, flotation, size reduction, separation, dehalogenation, or any combination thereof. In one embodiment or in combination with any of the mentioned embodiments, the introduced MPW and / or waste plastics may be subjected to crushing, mechanical agitation, and / or granulation to reduce the particle size of the waste plastics.

[0068] For example, this can be done by chopping, shredding, rake-crushing, grinding, pulverizing, cutting, molding, compressing, or dissolving in a solvent. Pulverizing, mechanical agitation, and / or granulation can be performed using any mixing, shearing, or grinding apparatus known in the art, and can reduce the average particle size of the introduced plastic by at least 10%, at least 25%, at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or at least 95%. For example, after pulverizing, mechanical agitation, and / or granulation, the average particle size of the milled MPW and / or waste plastic can be at least 0.1, at least 0.2, at least 0.3, or at least 0.4 and / or no more than 0.9, no more than 0.8, no more than 0.7, no more than 0.6, or no more than 0.5 inches.

[0069] In one embodiment or in combination with any of the mentioned embodiments, the raw material pretreatment system 14 may include at least one separator unit, optionally in fluid communication with the aforementioned mixing, shearing, or grinding apparatus, configured to further purify MPW and / or waste plastics by removing unwanted components and plastics. The separator unit may include a filter, hydrocyclone separator, fractionation column, centrifuge, flotation cell, or a combination thereof. In one embodiment or in combination with any of the mentioned embodiments, the pretreatment system 14 may include at least one grinding unit and at least one separator unit, the order of which may vary depending on the plastic raw material introduced into the raw material pretreatment system 14. Typically, in one embodiment or in combination with any of the mentioned embodiments, the separator may be placed downstream of the grinding unit.

[0070] Via the separator, the raw material pretreatment system 14 can remove at least a portion of undesirable plastics, such as polyvinyl chloride (PVC) and polyethylene terephthalate (PET), from the MPW and / or waste plastics introduced into the pretreatment system 14. In one embodiment or in combination with any of the mentioned embodiments, the raw material pretreatment system 14 can remove at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 99% of the polyvinyl chloride (PVC) and polyethylene terephthalate (PET) initially present in the MPW and / or waste plastics supplied from the waste plastic source 12.

[0071] In one embodiment or in combination with any of the mentioned embodiments, the raw material pretreatment system 14 may include flotation cells and / or hydrocyclones capable of separating unwanted plastics from desired plastics in MPW and / or waste plastics based on the density of the plastics in a liquid medium (e.g., water). In other words, these flotation cells and hydrocyclones can use density separation processes to separate unwanted plastics from MPW and / or waste plastics from waste plastic source 12. As used herein, a “density separation process” refers to a process that separates materials based at least in part on their respective densities.

[0072] In a flotation cell, MPW and / or waste plastics from waste plastic source 12 can be introduced into a liquid medium, such as brine, to separate desired plastics from undesired plastics through float-sink density separation based on a target separation density. As used herein, “float-sink density separation” refers to a density separation process in which the separation of materials is primarily caused by floating or sinking in a selected liquid medium. As used herein, “target separation density” refers to a density above which the material undergoing the density separation process preferentially separates into a higher density output, and below which the material separates into a lower density output. In such an embodiment, undesired plastics (e.g., PET and / or PVC) can be removed from MPW and / or waste plastics.

[0073] In one embodiment or in combination with any of the mentioned embodiments, the liquid medium comprises water. Salts, sugars, and / or other additives may be added to the liquid medium, for example, to increase the density of the liquid medium and adjust the target separation density for the flotation-sinking separation stage. In one embodiment or in combination with any of the mentioned embodiments, the liquid medium comprises a concentrated salt solution.

[0074] In one or more such embodiments, the salt is sodium chloride. However, in one or more other embodiments, the salt is a non-halogenated salt, such as an acetate, carbonate, citrate, nitrate, nitrite, phosphate, and / or sulfate. The liquid medium may include a concentrated salt solution comprising: sodium bromide, sodium dihydrogen phosphate, sodium hydroxide, sodium iodide, sodium nitrate, sodium thiosulfate, potassium acetate, potassium bromide, potassium carbonate, potassium hydroxide, potassium iodide, calcium chloride, cesium chloride, ferric chloride, strontium chloride, zinc chloride, manganese sulfate, zinc sulfate, and / or silver nitrate. The liquid medium may include sugars, such as sucrose. The liquid medium may include carbon tetrachloride, chloroform, dichlorobenzene, dimethyl sulfate, and / or trichloroethylene. The specific components and concentrations of the liquid medium may be selected based on the desired target separation density for the separation stage.

[0075] In a hydrocyclone, MPW and / or waste plastics from waste plastic source 12 can be introduced into a liquid medium (e.g., brine) to separate desired plastics from undesired plastics based on centrifugal density separation. As used herein, “centrifugal density separation” refers to a density separation process in which the separation of particles is primarily caused by centrifugal force. In such an embodiment, undesired plastics (e.g., PET and / or PVC) can be removed from MPW and / or waste plastics.

[0076] In one embodiment or in combination with any of the mentioned embodiments, the feedstock pretreatment system 14 may include one or more systems or components capable of at least partially dehalogenating the MPW and / or waste plastics introduced into the feedstock pretreatment system 14. More specifically, the pretreatment system 14 may remove at least a portion of halogen-containing (e.g., chlorine-containing) compounds from the MPW and / or waste plastics introduced into the pretreatment system 14, thereby forming a dehalogenated feedstock. The dehalogenated waste containing the removed halogen-containing compounds (e.g., chlorinated plastics and compounds such as HCl) may be discarded from the pyrolysis facility 10.

[0077] In one embodiment or in combination with any of the mentioned embodiments, the dehalogenation process within the pretreatment system 14 may include one or more of the following steps: (i) physically separating solid halogenated waste plastics from at least one other type of waste plastic (e.g., by using at least one flotation cell and / or at least one hydrocyclone); (ii) melting at least a portion of the MPW and / or waste plastics from waste plastic source 12, and physically separating the melted halogenated waste plastics from at least one other type of melted waste plastic; or (iii) heating the halogenated waste plastics from the MPW and / or waste plastics from waste plastic source 12 to a temperature sufficient to crack at least a portion of the halogenated waste plastics to release halogenated gas (e.g., gaseous hydrogen chloride), and then venting the halogenated gas. The melting in step (ii) and / or the heating in step (iii) may occur at temperatures of at least 150°C, at least 175°C, at least 200°C, at least 225°C, at least 250°C, at least 275°C, or at least 300°C and / or not exceeding 400°C, not exceeding 375°C, or not exceeding 350°C.

[0078] More specifically, the melting in step (ii) and / or the heating in step (iii) can be carried out at temperatures of 150°C to 400°C, 175°C to 375°C, or 250°C to 375°C. Exhausting can be performed using a tower equipped with an exhaust system, piping system, polycondensation reactor, scraped film reactor, stirred reactor, vacuum, or separator capable of removing at least a portion of the gaseous halogen-containing byproducts, such as gaseous HCl.

[0079] Furthermore, in one embodiment or in combination with any of the embodiments mentioned, the gaseous halogen-containing byproducts generated during the melting in step (ii) and / or the heating in step (iii) may subsequently be contacted with a halogen scavenger in the absorption bed to remove them from the system. The halogen scavenger may include metal oxides, metal hydroxides, carbon complexes, or combinations thereof. For example, the halogen scavenger may include porous alumina, modified porous alumina, quicklime, calcium carbonate, or combinations thereof.

[0080] In one embodiment or in combination with any of the mentioned embodiments, the pretreatment system 14 can remove at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 99% of the halogens originally present in the MPW and / or waste plastics derived from the waste plastic source 12.

[0081] In one embodiment or in combination with any of the mentioned embodiments, the resulting dehalogenated feedstock leaving the pretreatment system 14 may contain no more than 1,000, 500, 400, 300, 250, 200, 150, 100, 90, 80, 70, 60, 50, 40, 30, 20, 10, or 5 ppm of halogen content, such as chlorine content.

[0082] Back Figure 1 The pretreated plastic material leaving the pretreatment system 14 can be introduced into the plastic feeding system 16. The plastic feeding system 16 can be configured to introduce the plastic feed into the pyrolysis reactor 18. The plastic feeding system 16 can include any system known in the art capable of feeding solid plastic material into the pyrolysis reactor 18. In one embodiment or in combination with any of the embodiments mentioned herein, the plastic feeding system 16 can include one or more of a screw feeder, hopper, paddle feeder, impeller airlock, pneumatic conveying system, mechanical metal wheel system or chain, or a combination thereof.

[0083] In one embodiment or in combination with any of the embodiments mentioned, the plastic-containing feedstock leaving the pretreatment system 14 and being introduced into the pyrolysis reactor 18 may comprise at least 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 99 wt% of at least one, two, three, four, five, or six different types of recycled waste plastics. The reference to "type" may be determined by resin ID codes 1-7 or a specific type of waste plastic (e.g., high-density polyethylene).

[0084] In one embodiment or in combination with any of the mentioned embodiments, the plastic-containing raw material leaving the pretreatment system 14 and being introduced into the pyrolysis reactor 18 may contain at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% of any polyolefin, such as high-density polyethylene, low-density polyethylene, polypropylene, other polyolefins, or combinations thereof.

[0085] In one embodiment or in combination with any of the embodiments mentioned, the plastic raw material leaving the pretreatment system 14 and entering the pyrolysis reactor 18 may contain no more than 90, 80, 70, 60, 50, 40, 30, 20, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 wt% of polyethylene terephthalate (PET) and / or polyvinyl chloride (PVC).

[0086] In pyrolysis reactor 18, at least a portion of the plastic feedstock undergoes a pyrolysis reaction that produces a pyrolysis effluent comprising pyrolysis oil, pyrolysis gas, and pyrolysis residues. As used herein, “pyrolysis” refers to the thermal decomposition of one or more organic materials at elevated temperatures in an inert (i.e., substantially oxygen-free) atmosphere. While not wishing to be bound by any particular theory, the pyrolysis of waste plastics can be used as a form of chemical recycling.

[0087] Typically, pyrolysis is a process involving the chemical and thermal decomposition of an introduced feedstock. Although all pyrolysis processes are generally characterized by a substantially oxygen-free reaction environment, the pyrolysis process can be further defined by factors such as the pyrolysis reaction temperature within the reactor, the residence time in the pyrolysis reactor, the type of reactor, the pressure within the pyrolysis reactor, and the presence or absence of a pyrolysis catalyst.

[0088] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis reactor may be, for example, a screw extruder, a tubular reactor, a tank, a stirred tank reactor, a riser reactor, a fixed bed reactor, a fluidized bed reactor, a rotary kiln, a vacuum reactor, a microwave reactor, or an autoclave.

[0089] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis reaction may involve heating and converting the plastic raw material in a substantially oxygen-free atmosphere or in an atmosphere containing less oxygen than ambient air. For example, based on the internal volume of reactor 18, the atmosphere within pyrolysis reactor 18 may contain no more than 5, 4, 3, 2, 1, or 0.5% oxygen.

[0090] In one embodiment or in combination with any of the mentioned embodiments, the riser gas and / or feed gas can be used to introduce the plastic raw material into the pyrolysis reactor 18 and / or to promote various reactions within the pyrolysis reactor 18. For example, the riser gas and / or feed gas may include nitrogen, carbon dioxide, and / or steam, and may consist substantially of nitrogen, carbon dioxide, and / or steam, or may consist of nitrogen, carbon dioxide, and / or steam. The riser gas and / or feed gas may be added with the plastic waste before being introduced into the pyrolysis reactor 18 and / or may be added directly to the pyrolysis reactor.

[0091] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis process can be carried out in the presence of a riser gas and / or a feed gas containing steam, consisting substantially of steam, or consisting of steam. For example, the pyrolysis process can be carried out in the presence of a feed gas and / or a riser gas containing at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% steam.

[0092] Additionally or alternatively, in one embodiment or in combination with any of the mentioned embodiments, the pyrolysis process is carried out in the presence of a feed gas and / or a booster gas containing no more than 99, 90, 80, 70, 60, 50, 40, 30, or 20 wt% steam. While not wishing to be bound by theory, it is believed that the presence of steam in the pyrolysis reactor 18 can promote the water-gas shift reaction, which can facilitate the removal of any halogen compounds that may be generated during the pyrolysis reaction. The steam may be added with the plastic waste prior to introduction into the pyrolysis reactor 18 and / or may be added directly to the pyrolysis reactor.

[0093] Additionally or alternatively, in one embodiment or in combination with any of the mentioned embodiments, the pyrolysis process may be carried out in the presence of a riser gas and / or a feed gas containing, substantially consisting of, or composed of, a reducing gas such as hydrogen, carbon monoxide, or a combination thereof. The reducing gas can act as both a feed gas and / or a riser gas and can facilitate the introduction of the plastic feed into the pyrolysis reactor 18. The reducing gas may be added with the plastic waste prior to its introduction into the pyrolysis reactor 18 and / or may be added directly to the pyrolysis reactor.

[0094] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis process may be carried out in the presence of a feed gas and / or a riser gas comprising at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 99 wt% of at least one reducing gas. Additionally or alternatively, the pyrolysis process may be carried out in the presence of a feed gas and / or a riser gas comprising at least 99, 90, 80, 70, 60, 50, 40, 30, or 20 wt% of at least one reducing gas.

[0095] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis process may be carried out in the presence of a feed gas and / or a riser gas 115 containing at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 99 wt% hydrogen. Additionally or alternatively, the pyrolysis process may be carried out in the presence of a feed gas and / or a riser gas containing no more than 99, 90, 80, 70, 60, 50, 40, 30, or 20 wt% hydrogen.

[0096] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis process may be carried out in the presence of a feed gas and / or a riser gas containing at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 99 wt% carbon monoxide. Additionally or alternatively, the pyrolysis process may be carried out in the presence of a feed gas and / or a riser gas containing no more than 99, 90, 80, 70, 60, 50, 40, 30, or 20 wt% carbon monoxide.

[0097] Furthermore, the temperature in the pyrolysis reactor 18 can be adjusted to promote the production of certain final products. In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis temperature in the pyrolysis reactor 18 can be at least 325°C, at least 350°C, at least 375°C, at least 400°C, at least 425°C, at least 450°C, at least 475°C, at least 500°C, at least 525°C, at least 550°C, at least 575°C, at least 600°C, at least 625°C, at least 650°C, at least 675°C, at least 700°C, at least 725°C, at least 750°C, at least 775°C, or at least 800°C.

[0098] Additionally, or alternatively, the pyrolysis temperature in the pyrolysis reactor 18 may be no more than 1,100°C, no more than 1,050°C, no more than 1,000°C, no more than 950°C, no more than 900°C, no more than 850°C, no more than 800°C, no more than 750°C, no more than 700°C, no more than 650°C, no more than 600°C, no more than 550°C, no more than 525°C, no more than 500°C, no more than 475°C, no more than 450°C, no more than 425°C, or no more than 400°C. More specifically, the pyrolysis temperature in the pyrolysis reactor 18 can be in the range of 325 to 1,100°C, 350 to 900°C, 350 to 700°C, 350 to 550°C, 350 to 475°C, 425 to 1,100°C, 425 to 800°C, 500 to 1,100°C, 500 to 800°C, 600 to 1,100°C, 600 to 800°C, 650 to 1,000°C, or 650 to 800°C.

[0099] In one embodiment or in combination with any of the mentioned embodiments, the residence time of the plastic raw material in the pyrolysis reactor 18 may be at least 0.1, at least 0.2, at least 0.3, at least 0.5, at least 1, at least 1.2, at least 1.3, at least 2, at least 3, or at least 4 seconds. Alternatively, the residence time of the plastic raw material in the pyrolysis reactor 18 may be at least 1, at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 20, at least 30, at least 45, at least 60, at least 75, or at least 90 minutes. Additionally or alternatively, the residence time of the plastic raw material in the pyrolysis reactor 18 may be no more than 6, no more than 5, no more than 4, no more than 3, no more than 2, no more than 1, or no more than 0.5 hours.

[0100] Furthermore, the residence time of the plastic raw material in the pyrolysis reactor 18 can be no more than 100, 90, 80, 70, 60, 50, 40, 30, 20, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 second. More specifically, in one embodiment or in combination with any of the mentioned embodiments, the residence time of the plastic raw material in the pyrolysis reactor 18 can be in the range of 0.1 to 10 seconds, 0.5 to 10 seconds, 30 minutes to 4 hours, 30 minutes to 3 hours, 1 hour to 3 hours, or 1 hour to 2 hours.

[0101] In one embodiment or in combination with any of the embodiments mentioned herein, the pressure within the pyrolysis reactor 18 may be maintained at at least 0.1, at least 0.2, or at least 0.3 bar and / or no more than 60, no more than 50, no more than 40, no more than 30, no more than 20, no more than 10, no more than 8, no more than 5, no more than 2, no more than 1.5, or no more than 1.1 bar. In one embodiment or in combination with any of the embodiments mentioned herein, the pressure within the pyrolysis reactor 18 may be maintained at approximately atmospheric pressure or within the range of 0.1 to 100 bar, or 0.1 to 60 bar, or 0.1 to 30 bar, or 0.1 to 10 bar, or 1.5 bar, 0.2 to 1.5 bar, or 0.3 to 1.1 bar.

[0102] In one embodiment or in combination with any of the embodiments mentioned, the pyrolysis catalyst may be introduced into the plastic raw material prior to the introduction into the pyrolysis reactor 18 and / or directly into the pyrolysis reactor 18. In addition, catalysts may include: (i) solid acids, such as zeolites (e.g., ZSM-5, mordenite, β-zeolite, magnesium alkali zeolite and / or zeolite-Y); (ii) superacids, such as sulfonated, phosphorylated or fluorinated forms of zirconium oxide, titanium dioxide, alumina, silica-alumina, and / or clay; (iii) solid bases, such as metal oxides, mixed metal oxides, metal hydroxides and / or metal carbonates, especially those of alkali metals, alkaline earth metals, transition metals and / or rare earth metals; (iv) hydrotalcites and other clays; (v) metal hydrides, especially those of alkali metals, alkaline earth metals, transition metals and / or rare earth metals; (vi) alumina and / or silica-alumina; (vii) homogeneous catalysts, such as Lewis acids, metal tetrachloroaluminates or organic ionic liquids; (viii) activated carbon; or (ix) combinations thereof.

[0103] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis catalyst may include a homogeneous catalyst or a heterogeneous catalyst.

[0104] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis catalyst may include a mesoporous catalyst, such as MCM-41, FSM-16, Al-SBA-15, or a combination thereof.

[0105] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis catalyst may include silicon-aluminum oxide, alumina, mordenite, zeolite, microporous catalyst, macroporous catalyst, or a combination thereof.

[0106] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis reaction in the pyrolysis reactor 18 occurs in the absence of a catalyst. In such embodiments, non-catalyst-containing, heat-retaining, inert additives (e.g., sand) may still be introduced into the pyrolysis reactor 18 to facilitate heat transfer within the reactor 18. This catalyst-free pyrolysis process may be referred to as "thermal pyrolysis." In one embodiment or in combination with any of the embodiments mentioned, the pyrolysis reaction in the pyrolysis reactor 18 can occur in the absence of a pyrolysis catalyst, at a temperature in the range of 350 to 550°C, at a pressure in the range of 0.1 to 60 bar, and at a residence time of 0.2 seconds to 4 hours or 0.5 hours to 3 hours.

[0107] Refer again Figure 1The pyrolysis effluent 20 leaving the pyrolysis reactor 18 typically includes pyrolysis gas, pyrolysis oil, and pyrolysis residues. Upon leaving the pyrolysis reactor 18, the pyrolysis oil may be in the form of vapor due to the heat generated by the reactor.

[0108] As used herein, “pyrolysis oil” (or “pyoil”) refers to a composition obtained by pyrolysis that is liquid at 25°C and 1 atm.

[0109] As used in this article, "pyrolysis gas" refers to a composition obtained by pyrolysis that is gaseous at 25°C.

[0110] As used herein, “pyrolysis residue” refers to a composition obtained from pyrolysis that is not pyrolysis gas or pyrolysis oil and primarily comprises pyrolysis char and pyrolysis heavy wax. Typically, pyrolysis residue may include char, ash, heavy wax, unconverted plastic solids, and / or particles of spent catalyst (if a catalyst was used). As used herein, “pyrolysis char” refers to a carbon-containing composition obtained from pyrolysis that is solid at 200°C and 1 atm. As used herein, “pyrolysis heavy wax” refers to C20+ hydrocarbons obtained from pyrolysis that are not pyrolysis char, pyrolysis gas, or pyrolysis oil.

[0111] For example, such as Figure 1 As shown, the pyrolysis oil fraction may be contained in: the pyrolysis effluent 20 exiting the pyrolysis reactor 18, in line 36 exiting the fractionation tower 34, in line 40 exiting the quenching system, or in line 42 exiting the hydrotreating unit. In one embodiment or in combination with any of the mentioned embodiments, the solids in the pyrolysis effluent 20 may include particles of char, ash, unconverted plastic solids, and / or spent catalyst (if a catalyst is used).

[0112] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis effluent 20 may contain at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, or at least 75 wt% of pyrolysis oil, which may be in the form of vapor in the pyrolysis effluent 20 when leaving the heated reactor 18; however, these vapors may subsequently condense into the resulting pyrolysis oil. Additionally, or alternatively, the pyrolysis effluent 20 may contain no more than 99, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, or 25 wt% of pyrolysis oil, which may be in vapor form in the pyrolysis effluent 20 upon exiting the heating reactor 18. In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis effluent 20 may contain pyrolysis oil in the range of 20 wt%-99 wt%, 25 wt%-80 wt%, 30 wt%-85 wt%, 30 wt%-80 wt%, 30 wt%-75 wt%, 30 wt%-70 wt%, or 30 wt%-65 wt%.

[0113] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis effluent 20 may contain at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, or at least 80 wt% of pyrolysis gas. Additionally or alternatively, the pyrolysis effluent 20 may contain no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, or no more than 45 wt% of pyrolysis gas. The pyrolysis effluent 20 may contain 1 wt%-90 wt%, 10 wt%-85 wt%, 15 wt%-85 wt%, 20 wt%-80 wt%, 25 wt%-80 wt%, 30 wt%-75 wt%, or 35 wt%-75 wt% of pyrolysis gas.

[0114] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis effluent 20 may contain at least 0.5, at least 1, at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, or at least 10 wt% of pyrolysis residue. Additionally or alternatively, the pyrolysis effluent 20 may contain no more than 60, no more than 50, no more than 40, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 9, no more than 8, no more than 7, no more than 6, or no more than 5 wt% of pyrolysis residue. The pyrolysis effluent 20 may contain pyrolysis residue in the range of 0.1 wt%-25 wt%, 1 wt%-15 wt%, 1 wt%-8 wt%, or 1 wt%-5 wt%.

[0115] In one embodiment or in combination with any of the embodiments mentioned, the pyrolysis effluent 20 may contain no more than 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, or 0.5 wt% free water. As used herein, “free water” means water previously added to the pyrolysis unit and water generated in the pyrolysis unit.

[0116] like Figure 1 As shown, the conversion effluent 20 from the pyrolysis reactor 18 can be introduced into a solids separator 22. The solids separator 22 can be any conventional device capable of separating solids and heavier waxes from gases and vapors, such as a cyclone separator, multistage separator, effluent separator, or gas filter. In one embodiment or in combination with any of the mentioned embodiments, the solids separator 22 removes most of the solids and heavier waxes from the conversion effluent 20.

[0117] Back Figure 1 The residual gas and vapor conversion products 24 from the solids separator 22 can be introduced into the gas separation unit 26. In the gas separation unit 26, at least a portion of the pyrolysis oil vapors can be separated from the pyrolysis gas, thereby forming a pyrolysis gas stream and a pyrolysis oil stream. Suitable systems for the gas separation unit 26 may include, for example, distillation columns, membrane separation units, filters, quenching towers, condensers, or any other known separation units in the art. If desired, after removal from the gas separation unit 26, the pyrolysis oil stream can be further quenched in a condenser to quench the pyrolysis vapors into their liquid form (i.e., pyrolysis oil). The resulting pyrolysis oil stream and pyrolysis gas stream can be removed from facility 10 and used in other downstream applications described herein.

[0118] In one embodiment or in combination with any of the mentioned embodiments, the waste plastic source 12, the raw material pretreatment system 14, the pyrolysis feed system 16, the pyrolysis reactor 18, the solids separator 22, and the gas separation unit 26 may be in fluid communication with all or some of the units. For example, the pyrolysis reactor 18 may be in fluid communication with the raw material pretreatment system 14, the pyrolysis feed system 16, the solids separator 22, and the gas separation unit 26. Fluid communication may include jacketed pipes, heated pipes, and / or insulated pipes.

[0119] In one embodiment or in combination with any of the embodiments mentioned, the pyrolysis reactor 18 is not in fluid communication with the waste plastic source 12.

[0120] Despite Figure 1 Not shown in the image, but Figure 1 The pyrolysis facility 10 shown herein may be part of a chemical recycling facility. As used herein, a “chemical recycling facility” means a facility that produces recycled component products by chemically recycling waste plastics. A chemical recycling facility may employ one or more of the following steps: (i) pretreatment, (ii) solvent decomposition, (iii) pyrolysis, (iv) cracking, and / or (v) POX vaporization.

[0121] The pyrolysis system described herein can produce pyrolysis oil, pyrolysis gas, and pyrolysis residues, which can be directly used in various downstream applications based on their formulations. Various characteristics and properties of the pyrolysis oil, pyrolysis gas, and pyrolysis residues are described below. It should be noted that while all of the following characteristics and properties can be listed individually, it is conceivable that each of the following characteristics and / or properties of the pyrolysis gas, pyrolysis oil, and / or pyrolysis residues is not mutually exclusive and can be combined and exist in any combination.

[0122] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis oil may primarily comprise hydrocarbons (e.g., C4-C30 hydrocarbons) having 4 to 30 carbon atoms per molecule. As used herein, the term “Cx” or “Cx hydrocarbon” refers to a hydrocarbon compound comprising a total of “x” carbon atoms per molecule and encompasses all alkenes, alkanes, aromatics, heterocycles, and isomers having that number of carbon atoms. For example, each of n-butane, isobutane, and tert-butane, as well as butene and butadiene molecules, falls into the general description of “C4”.

[0123] In one embodiment or in combination with any of the embodiments mentioned, the C4-C30 hydrocarbon content of the pyrolysis oil may be at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt%, based on the total weight of the pyrolysis oil.

[0124] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis oil may primarily comprise C5-C25 hydrocarbons, C5-C22 hydrocarbons, or C5-C20 hydrocarbons. For example, based on the total weight of the pyrolysis oil, the pyrolysis oil may contain at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% of C5-C25 hydrocarbons, C5-C22 hydrocarbons, or C5-C20 hydrocarbons.

[0125] In one embodiment or in combination with any of the mentioned embodiments, the C5-C12 hydrocarbon content of the pyrolysis oil, based on the total weight of the pyrolysis oil, may be at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, or at least 55 wt%. Additionally, or alternatively, the C5-C12 hydrocarbon content of the pyrolysis oil may be no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, or no more than 50 wt%. The C5-C12 hydrocarbon content of the pyrolysis oil may be in the range of 10 wt%-95 wt%, 20 wt%-80 wt%, or 35 wt%-80 wt%.

[0126] In one embodiment or in combination with any of the mentioned embodiments, the C13-C23 hydrocarbon content of the pyrolysis oil may be at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, or at least 30 wt%, based on the total weight of the pyrolysis oil. Additionally, or alternatively, the C13-C23 hydrocarbon content of the pyrolysis oil may be no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, or no more than 40 wt%. The C13-C23 hydrocarbon content of the pyrolysis oil may be in the range of 1 wt%-80 wt%, 5 wt%-65 wt%, or 10 wt%-60 wt%.

[0127] In one embodiment or in combination with any of the mentioned embodiments, the C24+ hydrocarbon content of the pyrolysis oil, based on its weight, can be at least 1, at least 2, at least 3, at least 4, or at least 5 and / or no more than 15, no more than 10, no more than 9, no more than 8, no more than 7, or no more than 6 wt%. The C24+ hydrocarbon content of the pyrolysis oil can be in the range of 1 wt%-15 wt%, 3 wt%-15 wt%, or 5 wt%-10 wt%.

[0128] In one embodiment or in combination with any of the mentioned embodiments, the two aliphatic hydrocarbons (branched or unbranched alkanes and alkenes, and alicyclic hydrocarbons) having the highest concentrations in the pyrolysis oil are in the range of C5-C18, C5-C16, C5-C14, C5-C10, or C5-C8, including the end values.

[0129] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis oil may further comprise various amounts of olefins and aromatic hydrocarbons. Based on the total weight of the pyrolysis oil, the pyrolysis oil contains at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, or at least 40 wt% of olefins and / or aromatic hydrocarbons. Additionally or alternatively, the pyrolysis oil may comprise no more than 90, no more than 80, no more than 70, no more than 60, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 5, or no more than 1 wt% of olefins and / or aromatic hydrocarbons.

[0130] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis oil may also comprise various amounts of olefins. Based on the total weight of the pyrolysis oil, the pyrolysis oil may contain at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, or at least 65 wt% of olefins. Additionally or alternatively, the pyrolysis oil may include no more than 90, no more than 80, no more than 70, no more than 60, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 5, or no more than 1 wt% of olefins.

[0131] In one embodiment or in combination with any of the mentioned embodiments, the aromatic hydrocarbon content of the pyrolysis oil may be no more than 25, 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 wt%, based on the total weight of the pyrolysis oil. The term "aromatic hydrocarbon" as used herein refers to the total amount (by weight) of any compound containing an aromatic moiety, such as benzene, toluene, xylene, and styrene.

[0132] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the pyrolysis oil, the cycloalkane (e.g., cyclic aliphatic hydrocarbon) content of the pyrolysis oil can be at least 1, at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 11, at least 12, at least 13, at least 14 or at least 15 and / or no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25 or no more than 20 wt%.

[0133] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the pyrolysis oil, the alkane (e.g., straight-chain or branched alkanes) content of the pyrolysis oil can be at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, or at least 65 wt%. Additionally or alternatively, the alkane content of the pyrolysis oil can be no more than 99, no more than 97, no more than 95, no more than 93, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, or no more than 30 wt%. The alkane content of the pyrolysis oil can be in the range of 25 wt%-90 wt%, 35 wt%-90 wt%, or 50 wt%-80 wt%.

[0134] In one embodiment or in combination with any of the mentioned embodiments, the weight ratio of alkanes to cycloalkanes, based on the total weight of the pyrolysis oil, can be at least 1:1, at least 1.5:1, at least 2:1, at least 2.2:1, at least 2.5:1, at least 2.7:1, at least 3:1, at least 3.3:1, at least 3.5:1, at least 3.75:1, at least 4:1, at least 4.25:1, at least 4.5:1, at least 4.75:1, at least 5:1, at least 6:1, at least 7:1, at least 8:1, at least 9:1, at least 10:1, at least 13:1, at least 15:1, or at least 17:1.

[0135] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the pyrolysis oil, the weight ratio of the combination of alkanes and cycloalkanes to aromatics can be at least 1:1, at least 1.5:1, at least 2:1, at least 2.5:1, at least 2.7:1, at least 3:1, at least 3.3:1, at least 3.5:1, at least 3.75:1, at least 4:1, at least 4.5:1, at least 5:1, at least 7:1, at least 10:1, at least 15:1, at least 20:1, at least 25:1, at least 30:1, at least 35:1, or at least 40:1.

[0136] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the pyrolysis oil, the total alkane and olefin content of the pyrolysis oil can be at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, or at least 45 and / or not more than 99, not more than 90, not more than 85, not more than 80, not more than 75, or not more than 70 wt%. The total alkane and olefin content of the pyrolysis oil can be in the range of 25 wt%-90 wt%, 35 wt%-90 wt%, or 50 wt%-80 wt%.

[0137] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the pyrolysis oil, the pyrolysis oil may include an amount of at least 0.01, at least 0.1, at least 1, at least 2, or at least 5 and / or no more than 20, no more than 15, no more than 14, no more than 13, no more than 12, no more than 11, no more than 10, no more than 9, no more than 8, no more than 7, or no more than 6 wt% of an oxygen-containing compound or polymer. The oxygen-containing compound and polymer are those containing oxygen atoms.

[0138] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the pyrolysis oil, the pyrolysis oil may include an amount of no more than 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1, 0.5, or 0.1 wt% of heteroatom compounds or polymers. Heteroatom compounds or polymers include any compounds or polymers containing nitrogen, sulfur, or phosphorus. For determining the amount of heteroatoms, heterocompounds, or heteropolymers present in the pyrolysis oil, any other atoms are not considered heteroatoms.

[0139] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis oil contains no more than 5, 4, 3, 2, 1, or 0.5 wt% water based on the total weight of the pyrolysis oil.

[0140] In one embodiment or in combination with any of the embodiments mentioned, the pyrolysis oil contains less than 5, no more than 4, no more than 3, no more than 2, no more than 1, no more than 0.5, no more than 0.4, no more than 0.3, no more than 0.2, or no more than 0.1 wt% of solids based on the total weight of the pyrolysis oil.

[0141] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis oil contains at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80 or at least 85 and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 65 or no more than 60 wt% of atomic carbon, based on the total weight of the pyrolysis oil.

[0142] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis oil contains at least 5, at least 6, at least 7, at least 8, at least 9 or at least 10 and / or no more than 30, no more than 25, no more than 20, no more than 15, no more than 14, no more than 13, no more than 12 or no more than 11 wt% atomic hydrogen based on the total weight of the pyrolysis oil.

[0143] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis oil contains no more than 10, 9, 8, 7, 6, 5, 4, 3, 2, 1 or 0.5 wt% atomic oxygen based on the total weight of the pyrolysis oil.

[0144] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis oil contains less than 1,000, no more than 500, no more than 400, no more than 300, no more than 200, no more than 100, or no more than 50 ppm of atomic sulfur based on the total weight of the pyrolysis oil.

[0145] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis oil contains less than 1,000, no more than 500, no more than 400, no more than 300, no more than 200, no more than 100, or no more than 50 ppm of metal, based on the total weight of the pyrolysis oil.

[0146] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis oil contains less than 1,000, no more than 500, no more than 400, no more than 300, no more than 200, no more than 100, or no more than 50 ppm of metal, based on the total weight of the pyrolysis oil.

[0147] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis oil contains less than 1,000, no more than 500, no more than 400, no more than 300, no more than 200, no more than 100, or no more than 50 ppm of alkali metals and / or alkaline earth metals, based on the total weight of the pyrolysis oil.

[0148] It should be noted that all publicly available hydrocarbon weight percentages can be determined using gas chromatography-mass spectrometry (GC-MS).

[0149] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis oil may exhibit a concentration of at least 0.6, at least 0.65, or at least 0.7 and / or no more than 1, no more than 0.95, no more than 0.9, or no more than 0.9 g / cm³ at 15°C. 3 The density. In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis oil exhibits a density of 0.6 to 1 g / cm³ at 15°C. 3 0.65 to 0.95 g / cm³ 3 Or 0.7 to 0.9 g / cm³ 3 The density.

[0150] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis oil may exhibit an API density of at least 28, at least 29, at least 30, at least 31, at least 32, or at least 33 and / or no more than 50, no more than 49, no more than 48, no more than 47, no more than 46, or no more than 45 at 15°C. The pyrolysis oil exhibits an API density in the range of 28-50, 29-58, or 30-44 at 15°C.

[0151] In one embodiment or in combination with any of the mentioned embodiments, the intermediate boiling point of the pyrolysis oil may be at least 75°C, at least 80°C, at least 85°C, at least 90°C, at least 95°C, at least 100°C, at least 105°C, at least 110°C, or at least 115°C and / or not exceeding 250°C, not exceeding 245°C, not exceeding 240°C, not exceeding 235°C, not exceeding 230°C, not exceeding 225°C, not exceeding 220°C, not exceeding 215°C, not exceeding 210°C, not exceeding 205°C, not exceeding 200°C, not exceeding 195°C, not exceeding 190°C, not exceeding 185°C, not exceeding 180°C, not exceeding 175°C, not exceeding 170°C, not exceeding 165°C, not exceeding 160°C, not exceeding 155°C, not exceeding 150°C, not exceeding 145°C, not exceeding 140°C, not exceeding 135°C, not exceeding 130°C, not exceeding 125°C, or not exceeding 120°C, as measured according to ASTM D5399. The intermediate boiling point of pyrolysis oil can be in the range of 75 to 250°C, 90 to 225°C, or 115 to 190°C. As used herein, "intermediate boiling point" refers to the median boiling point temperature of pyrolysis oil, wherein 50% by volume of the pyrolysis oil boils above the intermediate boiling point and 50% by volume boils below the intermediate boiling point.

[0152] In one embodiment or in combination with any of the mentioned embodiments, the boiling point range of the pyrolysis oil may be such that no more than 10% of the pyrolysis oil has a final boiling point (FBP) of at least 250°C, at least 280°C, at least 290°C, at least 300°C, or at least 310°C, as measured according to ASTM D-5399.

[0153] The methane content of the pyrolysis gas, based on its total weight, can be at least 1, at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 11, at least 12, at least 13, at least 14, or at least 15 and / or not more than 50, not more than 45, not more than 40, not more than 35, not more than 30, not more than 25, or not more than 20 wt%. The methane content of the pyrolysis gas can be in the range of 1 wt%-50 wt%, 5 wt%-50 wt%, or 15 wt%-45 wt%.

[0154] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the pyrolysis gas, the C3 hydrocarbon content of the pyrolysis gas can be at least 1, at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 15, at least 20, or at least 25 and / or not more than 50, not more than 45, not more than 40, not more than 35, or not more than 30 wt%. The C3 hydrocarbon content of the pyrolysis gas can be in the range of 1 wt%-50 wt%, 5 wt%-50 wt%, or 20 wt%-50 wt%.

[0155] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the pyrolysis gas, the C4 hydrocarbon content of the pyrolysis gas can be at least 1, at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 11, at least 12, at least 13, at least 14, at least 15, at least 16, at least 17, at least 18, at least 19, at least 20, or at least 25 and / or no more than 50, no more than 45, no more than 40, no more than 35, or no more than 30 wt%. The C4 hydrocarbon content of the pyrolysis gas can be in the range of 1 wt%-50 wt%, 5 wt%-50 wt%, or 20 wt%-50 wt%.

[0156] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the pyrolysis gases, the total C3 and C4 hydrocarbon content of the pyrolysis gases (including all hydrocarbons with a carbon chain length of C3 or C4) can be at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, or at least 60 and / or not more than 99, not more than 95, not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, or not more than 65 wt%. The total C3 / C4 hydrocarbon content of the pyrolysis gases can be in the range of 10 wt%-90 wt%, 25 wt%-90 wt%, or 25 wt%-80 wt%.

[0157] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis gas contains at least 1, at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 11, at least 12, at least 13, at least 14 or at least 15 and / or no more than 1,000, no more than 500, no more than 400, no more than 300, no more than 200 or no more than 100 ppm of sulfur.

[0158] While not wishing to be bound by theory, it is believed that higher pyrolysis temperatures (e.g., those exceeding 550°C), selection of specific catalyst types, or the absence of specific catalysts (e.g., ZSM-5) can promote the production of C3 and C4 hydrocarbons.

[0159] Turning to the pyrolysis residue, in one embodiment or in combination with any of the mentioned embodiments, the pyrolysis residue comprises at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, or at least 85 wt% of C20+ hydrocarbons, based on the total weight of the pyrolysis residue. As used herein, “C20+ hydrocarbon” means a hydrocarbon compound containing at least a total of 20 carbon atoms per molecule and encompasses all alkenes, alkanes, and isomers having that number of carbon atoms.

[0160] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the pyrolysis residue, the pyrolysis residue contains no more than 15, no more than 14, no more than 13, no more than 12, no more than 11, no more than 10, no more than 9, no more than 8, no more than 7, no more than 6, no more than 5, no more than 4, no more than 3, no more than 2, no more than 1 or no more than 0.5 wt% water.

[0161] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the pyrolysis residue, the pyrolysis residue comprises at least 1, at least 2, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% carbon-containing solids. Additionally or alternatively, the pyrolysis residue comprises no more than 99, no more than 90, no more than 80, no more than 70, no more than 60, no more than 50, no more than 40, no more than 30, no more than 20, no more than 10, no more than 9, no more than 8, no more than 7, no more than 6, no more than 5, or no more than 4 wt% carbon-containing solids. As used herein, “carbon-containing solids” refers to a carbon-containing composition derived from pyrolysis and solid at 25°C and 1 atm. Based on the total weight of the carbon-containing solids, the carbon-containing solids may contain at least 20, at least 30, at least 40, at least 50, at least 60, at least 70, at least 80, or at least 90 wt% carbon.

[0162] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis residue contains a C:H atomic ratio greater than or equal to that of alkanes, or greater than or equal to 0.25:1, 0.3:1, 0.35:1, 0.4:1 or 0.45:1.

[0163] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the pyrolysis residue, the separated pyrolysis residue contains no more than 40, no more than 30, no more than 20, no more than 10, no more than 5, no more than 4, no more than 3, no more than 2, or no more than 1 wt% of pyrolysis oil.

[0164] Figure 2 Another exemplary system 10 is described, which can be used to at least partially convert one or more waste plastics, particularly recycled plastic waste, into various useful pyrolysis derivatives. It should be understood that... Figure 2 The system shown is merely one example of a system in which this disclosure can be implemented. This disclosure can be applied to a variety of other systems in which it is desirable to efficiently and effectively convert pyrolysis products into various desired final products. Furthermore, the components or units depicted with dashed lines represent optional streams and / or components that can be found in exemplary system 10. Therefore, there are contemplated embodiments in which the components in the dashed lines may or may not be present. A more detailed description will now follow. Figure 2 The exemplary system shown.

[0165] like Figure 2 The pyrolysis facility 10 shown includes a waste plastic source 12, a raw material pretreatment system 14, a pyrolysis feed system 16, a pyrolysis reactor 18, a solid separator 22, and a gas separation unit 26, which are related to the above-mentioned Figure 1 The components described work in the same way. Figure 2 An embodiment is demonstrated in which a partial oxidation (POX) gasification facility is incorporated into the overall system. As used herein, a "partial oxidation (POX) gasification facility" or "POX facility" refers to a facility that includes all equipment, piping, and control devices required for the POX gasification of waste plastics. For example, a gasification facility may include a gasifier, a gasifier feed injector, a gasifier ball mill, a feed spray unit, and / or a curing tank. Figure 2 As shown, at least a portion of the pyrolysis gas stream from the gas separation unit 26 can be introduced into the dehalogenation unit 30, the compression system 32, and / or the partial oxidation (POX) unit 34.

[0166] In one embodiment or in combination with any of the mentioned embodiments, at least a portion of the pyrolysis gas from gas separation unit 26 may be compressed in compression system 32 to form compressed pyrolysis gas. Compression system 32 may include any compression system known in the art and may include a gas compressor having 1-10, 2-8, or 2-6 compression stages, each stage having optional interstage cooling and liquid removal. In one embodiment or in combination with any of the mentioned embodiments, the pressure of the compressed pyrolysis gas stream at the outlet of compression system 32 may be in the range of 7-50 bar gauge pressure, 8.5-40 psig, or 9.5-30 barg.

[0167] In one embodiment or in combination with any of the mentioned embodiments, the intake pressure of the compression system may be at least 0.01, at least 0.05, or at least 0.1 barg and / or no more than 1.1, no more than 0.95, no more than 0.90, or no more than 0.85 barg, while the outlet pressure of the first compression stage may be at least 1.3, at least 1.4, at least 1.5, or at least 1.6 barg and / or no more than 4, no more than 3.75, no more than 3.5, no more than 3.25, no more than 3, no more than 2.9, no more than 2.8, or no more than 2.7 barg.

[0168] The outlet of the second compression stage can be at least 3.8, at least 3.9, at least 4, at least 4.5, at least 5, or at least 5.5 barg and / or not exceeding 11, not exceeding 10.5, not exceeding 10, not exceeding 9, not exceeding 8.5, not exceeding 8, not exceeding 7, not exceeding 6.5, not exceeding 6.4, or not exceeding 6.3 barg, while the outlet of the third compression stage can be at least 8.7, at least 8.8, at least 8.9, at least 9, at least 10, at least 12, or at least 14 barg and / or not exceeding 30, not exceeding 27, not exceeding 25, not exceeding 20, not exceeding 15, not exceeding 13.5, not exceeding 13.4, or not exceeding 13.25 barg. The outlet of the fourth compression stage can be at least 14.2, at least 14.3, or at least 14.4 barg, and / or not exceeding 23.5, not exceeding 23.4, not exceeding 23.3, or not exceeding 23.2 barg. The outlet pressure of the fifth compression stage, when present, may be at least 27.5, at least 27.7, or at least 27.9 barg and / or not more than 46, not more than 45.5, or not more than 45.2 barg. When the fifth compression stage is not present, the outlet pressure of the fourth compression stage may be at least 30, at least 32, at least 35, at least 37, or at least 40 barg and / or not more than 65, not more than 60, or not more than 57 barg.

[0169] The first stage's inlet pressure can range from 0.1 to 0.8 barg, and the first stage's outlet pressure can range from 1.6 to 2.7 barg. The second stage's outlet pressure can range from 4 to 6 barg, while the third stage's outlet pressure can range from 9 to 13 barg. The fourth stage's outlet pressure can range from 14 to 23 barg, and the fifth stage (if present)'s outlet pressure can range from 28 to 45 barg. Alternatively, the first stage's inlet pressure can range from 0.1 to 1 barg, and the first stage's outlet pressure can range from 1.5 to 3.75 barg. The second stage's outlet pressure can range from 14.5 to 27 barg. The fourth stage's outlet pressure, especially when, for example, the fourth stage is the last stage, can range from 30 to 60 barg.

[0170] In one embodiment or in combination with any of the mentioned embodiments, the compression system 32 can remove at least a portion of the residual pyrolysis oil, which may exist in the pyrolysis gas in the form of condensed residual pyrolysis oil.

[0171] In one embodiment or in combination with any of the mentioned embodiments, at least a portion of the removed residual pyrolysis oil may be returned to the pyrolysis reactor and / or cracking unit, such as a naphtha cracker.

[0172] Additionally or alternatively, in one embodiment or in combination with any of the mentioned embodiments, at least a portion of the removed residual pyrolysis oil may be combined with the pyrolysis oil stream from gas separation unit 26.

[0173] Additionally or alternatively, in one embodiment or in combination with any of the mentioned embodiments, at least a portion of the pyrolysis gas from gas separation unit 26 and / or at least a portion of the compressed pyrolysis gas from compression system 32 may be introduced into dehalogenation unit 30. Simultaneously, in dehalogenation unit 30, at least a portion of the halogens in the pyrolysis gas may be removed, thereby forming dehalogenated pyrolysis gas and a halogen-containing waste stream. The halogen-containing waste stream (e.g., chlorinated compounds such as HCl) may be in gaseous form and may be discarded from the pyrolysis system. Dehalogenation unit 30 may include a distillation column, a wiped film reactor, a halogen scavenger container, or a combination thereof.

[0174] In one embodiment or in combination with any of the mentioned embodiments, the dehalogenation unit 30 may include a halogen scavenger capable of absorbing at least a portion of gaseous halogen-containing byproducts. The halogen scavenger may include metal oxides, metal hydroxides, carbon complexes, or combinations thereof. For example, the halogen scavenger may include porous alumina, modified porous alumina, quicklime, calcium carbonate, or combinations thereof.

[0175] Typically, in one embodiment or in combination with any of the embodiments mentioned, the halogens removed by the dehalogenation unit 30 include covalently bonded halogen atoms originally present in the polymer backbone of the waste plastic used as a pyrolysis feedstock to produce pyrolysis gas. The dehalogenation unit 30 can remove at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, or at least 99% of the covalently bonded halogen atoms from the pyrolysis gas.

[0176] In one embodiment or in combination with any of the mentioned embodiments, the dehalogenated pyrolysis gas may contain less than 500, not more than 400, not more than 300, not more than 250, not more than 200, not more than 150, not more than 100, not more than 90, not more than 80, not more than 70, not more than 60, not more than 50, not more than 40, not more than 30, not more than 20, not more than 10, or not more than 5 ppm of halogen.

[0177] Alternatively, in one embodiment or in combination with any of the mentioned embodiments, at least a portion of the pyrolysis gas may be introduced into the dehalogenation unit 30 first, and at least a portion of the resulting dehalogenation gas may be introduced into the compression system 32 to form compressed pyrolysis gas.

[0178] Back Figure 2 At least a portion of the pyrolysis gas from gas separator 26, at least a portion of the dehalogenated pyrolysis gas from dehalogenation unit 30, and / or at least a portion of the compressed pyrolysis gas from compression system 32 can be introduced into a gasifier, such as partial oxidation (POX) unit 34. In partial oxidation unit 34, at least a portion of the pyrolysis gas can undergo partial oxidation (POX) gasification. As used herein, “partial oxidation (POX) gasification” or “POX” refers to the high-temperature conversion of a hydrocarbon feedstock into syngas (carbon monoxide, hydrogen, and carbon dioxide), wherein this conversion is carried out with an oxygen content below the stoichiometry required to completely oxidize carbon to CO2. The feedstock for POX gasification can include solids, liquids, and / or gases.

[0179] In one embodiment or in combination with any of the mentioned embodiments, the POX vaporization unit may include a gas-feed vaporizer, a liquid-feed vaporizer, a solid-feed vaporizer, or a combination thereof. More particularly, the POX vaporization unit can perform liquid-feed POX vaporization. As used herein, "liquid-feed POX vaporization" refers to a POX vaporization process in which the feed to the process primarily comprises components that are liquid at 25°C and 1 atm. Additionally, or alternatively, the POX vaporization unit can perform gas-feed POX vaporization. As used herein, "gas-feed POX vaporization" refers to a POX vaporization process in which the feed to the process primarily comprises components that are gaseous at 25°C and 1 atm.

[0180] like Figure 2 As shown, a method for producing syngas with recovered components is provided, wherein the method includes: (a) charging an oxygenating agent and a feedstock composition containing pyrolysis gas into a gasification zone within a gasifier; (b) gasifying the feedstock composition together with the oxygenating agent in the gasification zone to produce a syngas composition; and (c) discharging at least a portion of the syngas composition from the gasifier. Figure 2As shown, fossil fuels (such as natural gas, coal, petroleum coke, biomass, and combinations thereof) can be combined with pyrolysis gas from gas separator 26, dehalogenation unit 30, and / or compression system 32 to produce gasification feedstock.

[0181] In one embodiment or in combination with any of the mentioned embodiments, the gasification feedstock comprises at least 1, at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 11, at least 12, at least 13, at least 14, at least 15, at least 16, at least 17, at least 18, at least 19, at least 20, at least 21, at least 22, at least 23, at least 24 or at least 25 and / or no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 40, no more than 35 or no more than 30 wt% of pyrolysis gas, which may be derived from gas separation 26, dehalogenation unit 30 and / or compression system 32.

[0182] More specifically, based on the total weight of the gasification feedstock, the gasification feedstock includes 1wt%-75wt%, 1wt%-50wt%, 1wt%-40wt%, or 1wt%-30wt% of pyrolysis gas, which may be derived from gas separation 26, dehalogenation unit 30, and / or compression system 32.

[0183] As described above, the gasification feedstock may also include fossil fuels such as coal, PET coke, natural gas, or liquid hydrocarbons such as heavy oil. In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the gasification feedstock, the gasification feedstock may contain at least 1, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, or at least 85 and / or no more than 99, no more than 95, or no more than 90 wt% of fossil fuels, such as natural gas. More specifically, the gasification feedstock contains 10 wt%-99 wt%, 40 wt%-99 wt%, or 75 wt%-99 wt% of fossil fuels, such as natural gas.

[0184] The gasified feedstock stream is desired to be injected, along with oxygen, into the refractory-lined combustion chamber of the syngas generator gasifier. In one embodiment or in combination with any of the mentioned embodiments, the feedstock stream and oxygen are injected via an injector into the gasification zone under significant pressure, typically at least 500, 600, 800, 1000, or 1250 psig. Typically, the velocity or flow rate of the feedstock and oxygen stream injected from the injector nozzle into the combustion chamber will exceed the flame propagation rate to avoid backflash.

[0185] In one embodiment or in combination with any of the mentioned embodiments, the oxygen agent comprises an oxidizing gas, which may include air. More specifically, the oxygen agent comprises an oxygen-enriched gas having an oxygen content greater than that found in air. In one embodiment or in combination with any of the mentioned embodiments, based on the total number of moles in the oxygen agent stream injected into the reaction (combustion) zone of the gasifier, the oxygen agent comprises at least 25, at least 35, at least 40, at least 50, at least 60, at least 70, at least 80, at least 90, at least 95, at least 97, at least 99, or at least 99.5 mol% (mol%, mole percent) of oxygen. Taking into account the amount of feed stream, the amount of feed introduced, the process conditions, and the reactor design, the specific amount of oxygen supplied to the reaction zone relative to the composition of the feed stream is expected to be sufficient to obtain the maximum or near-maximum yield of carbon monoxide and hydrogen from the gasification reaction.

[0186] In one embodiment or in combination with any of the mentioned embodiments, steam is not supplied to the vaporization zone. Alternatively, or additionally, steam may be supplied to the vaporization zone.

[0187] In addition to oxygen, other reducible oxygen-containing gases, such as carbon dioxide, nitrogen, or air alone, may be supplied to the reaction zone. In one embodiment or in combination with any of the mentioned embodiments, a gas stream rich in carbon dioxide or nitrogen (e.g., greater than the molar amount found in air, or at least 2, at least 5, at least 10, or at least 40 mol%) is not loaded into the vaporizer. These gases can be used as carrier gases to propel the feedstock into the vaporization zone. Due to the pressure within the vaporization zone, these carrier gases can be compressed to provide the power for introduction into the vaporization zone.

[0188] In one embodiment or in combination with any of the mentioned embodiments, a gas stream containing more than 0.01 mol% or 0.02 mol% carbon dioxide is not introduced into the vaporizer or vaporization zone. Additionally or alternatively, a gas stream containing more than 77, 70, 50, 30, 10, 5, or 3 mol% nitrogen is not introduced into the vaporizer or vaporization zone. Furthermore, a gaseous hydrogen stream containing more than 0.1, 0.5, 1, or 5 mol% hydrogen may not be introduced into the vaporizer or vaporization zone. Additionally, a methane gas stream containing more than 0.1, 0.5, 1, or 5 mol% methane may not be introduced into the vaporizer or vaporization zone. In some embodiments, the only gaseous stream introduced into the vaporization zone is an oxygen-enriched gas stream as described above.

[0189] The desired gasification process is a partial oxidation gasification reaction, as described above. Typically, to increase the yield of hydrogen and carbon monoxide, the oxidation process involves partial rather than complete oxidation of the gasification feedstock; therefore, the oxidation process can operate in an oxygen-deficient environment relative to the amount required to completely oxidize 100% of the carbon and hydrogen bonds. In one embodiment or in combination with any of the mentioned embodiments, the total oxygen requirement of the gasifier can exceed the theoretically required amount by at least 5%, at least 10%, at least 15%, or at least 20% of the carbon content of the gasification feedstock to carbon monoxide. Generally, satisfactory operation is obtained when the total oxygen supply exceeds the theoretical requirement by 10% to 80%. Examples of suitable oxygen amounts per pound of carbon could be in the range of 0.4 to 3.0, 0.6 to 2.5, 0.9 to 2.5, or 1.2 to 2.5 pounds of free oxygen per pound of carbon.

[0190] The mixing of the feedstock and oxidant streams can be completed entirely within the reaction zone by introducing separate feedstock and oxidant streams, allowing them to collide with each other within the reaction zone. In one embodiment, or in combination with any of the mentioned embodiments, the oxidant stream is introduced into the reaction zone of the vaporizer at a high speed to both exceed the flame propagation rate and improve mixing with the feedstock stream. The oxidant can be injected into the vaporization zone at speeds ranging from 25 to 500, 50 to 400, or 100 to 400 feet per second. These values ​​will be the velocity of the gaseous oxidant stream at the injector-vaporization zone interface, or the injector tip velocity.

[0191] In one embodiment or in combination with any of the mentioned embodiments, the gasification feedstock stream and oxygen stream may optionally be preheated to a temperature of at least 200°C, at least 300°C, or at least 400°C. However, the gasification process employed does not require preheating of the feedstock stream to effectively gasify the feedstock, and the preheating step may result in reduced energy efficiency of the process.

[0192] In one embodiment or in combination with any of the mentioned embodiments, the type of gasification technology employed is a partially oxidizing fluidized bed gasifier that produces syngas. This technology differs from fixed-bed (or moving-bed) gasifiers and fluidized-bed gasifiers. In a fixed-bed (or moving-bed) gasifier, the feed stream moves in a countercurrent direction to the oxidant gas, and the oxidant gas typically used is air. The feed stream falls into the gasification chamber, accumulates, and forms a feed bed.

[0193] Air (or oxygen) flows continuously upward from the bottom of the gasifier through the feedstock bed, while fresh feedstock falls continuously from the top due to gravity to renew the bed during combustion. Combustion temperatures are typically below the melting point of the ash, and no ash is discharged. Whether the fixed bed operates counter-currently or, in some cases, concurrently, the fixed bed reaction process generates significant amounts of tar, oil, and methane produced from the pyrolysis of the feedstock, thus contaminating the resulting syngas and the gasifier.

[0194] Contaminated syngas requires significant effort and cost to remove tar-like residues (which condense once the syngas cools), and therefore, such syngas streams are typically not used for chemical production but rather for direct heating applications. In a fluidized bed, the feed material in the gasification zone is fluidized by an oxidant flowing through the bed at a sufficiently high velocity to fluidize the particles. The homogeneous reaction temperature and low reaction temperature in the gasification zone of a fluidized bed also promote the generation of a large amount of unreacted feed material and low-carbon conversion; the operating temperature in a fluidized bed is typically between 800-1000°C. Furthermore, in a fluidized bed, it is important to operate under conditions below slag discharge to maintain the fluidization of the feed particles, which would otherwise adhere to the slag and agglomerates. By employing entrained gasification, these shortcomings of fixed-bed (or moving-bed) and fluidized-bed gasifiers, typically used for waste treatment, are overcome.

[0195] Exemplary vaporizers available are described in U.S. Patent No. 3,544,291, the entire disclosure of which is incorporated herein by reference.

[0196] In one embodiment or in combination with any of the mentioned embodiments, the gasifier is non-catalytic, meaning that the gasifier does not contain a catalyst bed, and the gasification process is non-catalytic, meaning that the catalyst is not introduced into the gasification zone as a discrete, unbound catalyst. Furthermore, the gasification process can also be a slag-discharge gasification process; that is, operating under slag-discharge conditions (far above the melting temperature of the ash), causing molten slag to form in the gasification zone and flow downwards along the refractory wall.

[0197] In one embodiment or in combination with any of the mentioned embodiments, the vaporization zone and optionally all reaction zones in the vaporizer operate at temperatures of at least 1000°C, at least 1100°C, at least 1200°C, at least 1250°C, or at least 1300°C and / or not exceeding 2500°C, not exceeding 2000°C, not exceeding 1800°C, or not exceeding 1600°C. The reaction temperature can be self-generated. Advantageously, the vaporizer operating in steady-state mode can be at a self-generated temperature and does not require the application of external energy to heat the vaporization zone.

[0198] In one embodiment or in combination with any of the mentioned embodiments, the vaporizer is a vaporizer for the main gas feed.

[0199] In one embodiment or in combination with any of the mentioned embodiments, the gasifier is a non-slag-discharge gasifier or operates under conditions that do not form slag.

[0200] In one embodiment or in combination with any of the mentioned embodiments, the vaporizer is not under negative pressure during operation, but under positive pressure during operation.

[0201] In one embodiment or in combination with any of the mentioned embodiments, the vaporizer operates at a pressure of at least 200 psig (1.38 MPa), at least 300 psig (2.06 MPa), at least 350 psig (2.41 MPa), at least 400 psig (2.76 MPa), at least 420 psig (2.89 MPa), at least 450 psig (3.10 MPa), at least 475 psig (3.27 MPa), at least 500 psig (3.44 MPa), or at least 550 psig within the vaporization zone (or combustion chamber). Operate at pressures of at least 600 psig (3.79 MPa), at least 650 psig (4.48 MPa), at least 700 psig (4.82 MPa), at least 750 psig (5.17 MPa), at least 800 psig (5.51 MPa), at least 900 psig (6.2 MPa), at least 1000 psig (6.89 MPa), at least 1100 psig (7.58 MPa), or at least 1200 psig (8.2 MPa).

[0202] Additionally, or alternatively, the vaporizer shall be operated in the vaporization zone (or combustion chamber) at pressures not exceeding 1300 psig (8.96 MPa), 1250 psig (8.61 MPa), 1200 psig (8.27 MPa), 1150 psig (7.92 MPa), 1100 psig (7.58 MPa), 1050 psig (7.23 MPa), 1000 psig (6.89 MPa), 900 psig (6.2 MPa), 800 psig (5.51 MPa), or 750 psig (5.17 MPa).

[0203] Examples of suitable pressure ranges include 400 to 1000, 425 to 900, 450 to 900, 475 to 900, 500 to 900, 550 to 900, 600 to 900, 650 to 900, 400 to 800, 425 to 800, 450 to 800, 475 to 800, 500 to 800, 550 to 800, 600 to 800, 650 to 800, 400 to 750, 425 to 750, 450 to 750, 475 to 750, 500 to 750, or 550 to 750 psig.

[0204] Typically, the average residence time of the gas in the gasifier reactor can be very short to increase throughput. Because the gasifier can operate at high temperatures and pressures, a near-complete conversion of the feedstock to gas can occur within a very short timeframe. In one embodiment or in combination with any of the mentioned embodiments, the average residence time of the gas in the gasifier can be no more than 30 seconds, no more than 25 seconds, no more than 20 seconds, no more than 15 seconds, no more than 10 seconds, or no more than 7 seconds.

[0205] To avoid scaling in downstream equipment (scrubbers, CO / H2 shift reactors, acid gas removal, chemical synthesis) and intermediate pipelines of the gasifier, the resulting syngas may have low or no tar content. In one embodiment or in combination with any of the mentioned embodiments, the syngas exiting the gasifier may contain no more than 4, 3, 2, 1, 0.5, 0.2, 0.1, or 0.01 wt% tar based on the weight of all condensable solids in the syngas stream. For measurement purposes, condensable solids are those compounds and elements that condense at 15°C and 1 atm. Examples of tar products include naphthalene, cresol, xylenol, anthracene, phenanthrene, phenol, benzene, toluene, pyridine, catechol, biphenyl, benzofuran, benzaldehyde, acenaphthene, fluorene, naphthol, benzanthracene, pyrene, phenanthrene, benzo[a]pyrene, and other high molecular weight aromatic polynuclear compounds. Tar content can be determined by GC-MSD.

[0206] Typically, the crude synthesis gas stream discharged from the gasification vessel includes gases such as hydrogen, carbon monoxide, and carbon dioxide, and may include other gases such as methane, hydrogen sulfide, and nitrogen, depending on the fuel source and reaction conditions.

[0207] In one embodiment or in combination with any of the mentioned embodiments, the crude synthesis gas stream (the stream exiting the vaporizer and prior to any further treatment by scrubbing, shifting, or acid gas removal) may have the following composition, in dry basis mole percentages, based on the number of moles of all gases (elements or compounds in gaseous state at 25°C and 1 atm) in the crude synthesis gas stream: • Hydrogen content in the range of 15mol%-60mol%, 18mol%-50mol%, 18mol%-45mol%, 18mol%-40mol%, 23mol%-40mol%, 25mol%-40mol%, 23mol%-38mol%, 29mol%-40mol%, and 31mol%-40mol%. • Carbon monoxide content of 20mol%-75mol%, 20mol%-65mol%, 30mol%-70mol%, 35mol%-68mol%, 40mol%-68mol%, 40mol%-60mol%, 35mol%-55mol% or 40mol%-52mol%; • Carbon dioxide content of 1.0 mol%-30 mol%, 2 mol%-25 mol%, 2 mol%-21 mol%, 10 mol%-25 mol%, or 10 mol%-20 mol%; • Water content of 2.0 mol%-40 mol%, 5 mol%-35 mol%, 5 mol%-30 mol%, or 10 mol%-30 mol%; • Methane content of 0.0 mol%-30 mol%, 0.01 mol%-15 mol%, 0.01 mol%-10 mol%, 0.01 mol%-8 mol%, 0.01 mol%-7 mol%, 0.01 mol%-5 mol%, 0.01 mol%-3 mol%, 0.1 mol%-1.5 mol% or 0.1 mol%-1 mol%; • H2S content of 0.01mol%-2.0mol%, 0.05mol%-1.5mol%, 0.1mol%-1mol%, or 0.1mol%-0.5mol%; • COS content of 0.05 mol%-1.0 mol%, 0.05 mol%-0.7 mol%, or 0.05 mol%-0.3 mol%; • Sulfur content of 0.015 mol%-3.0 mol%, 0.02 mol%-2 mol%, 0.05 mol%-1.5 mol%, or 0.1 mol%-1 mol%; and / or • Nitrogen content of 0.0mol%-5mol%, 0.005mol%-3mol%, 0.01mol%-2mol%, 0.005mol%-1mol%, 0.005mol%-0.5mol%, or 0.005mol%-0.3mol%.

[0208] In one embodiment or in combination with any of the mentioned embodiments, the syngas comprises a hydrogen / carbon monoxide molar ratio of at least 0.65, at least 0.68, at least 0.7, at least 0.73, at least 0.75, at least 0.78, at least 0.8, at least 0.85, at least 0.88, at least 0.9, at least 0.93, at least 0.95, at least 0.98, or at least 1.

[0209] The composition of the gas can be determined by FID-GC and TCD-GC or any other recognized method for analyzing the composition of gas streams.

[0210] Back Figure 2 At least a portion of the pyrolysis residue 28 from the solids separator 22 can be introduced into an optional regenerator 30 for regeneration, typically by combustion. After regeneration, at least a portion of the thermally regenerated solids can be directly reintroduced into the pyrolysis reactor 18. Additionally, or alternatively, at least a portion of the solid particles recovered in the solids separator 22 can be directly returned to the pyrolysis reactor 18, particularly if the solid residue contains a significant amount of unconverted plastic waste. Furthermore, residual solids can be removed from the regenerator 26 via the solids removal unit 32 and discharged from the system.

[0211] In one embodiment or in combination with any of the mentioned embodiments, the waste plastic source 12, raw material pretreatment system 14, pyrolysis feed system 16, pyrolysis reactor 18, solid separator 22, gas separation unit 26, dehalogenation unit 30, compression system 32, and POX unit 34 may be in fluid communication between all or some of the units. For example, pyrolysis reactor 18 may be in fluid communication with POX unit 34. In one embodiment or in combination with any of the mentioned embodiments, fluid communication includes jacketed pipes, heat-traced pipes, and / or insulated pipes.

[0212] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis reactor 18 is not in fluid communication with the POX unit 34.

[0213] Figure 3 Another exemplary system 10 is described, which can be used to at least partially convert one or more waste plastics, particularly recycled plastic waste, into various useful pyrolysis derivatives. It should be understood that... Figure 3 The system shown is merely one example of a system in which this disclosure can be implemented. This disclosure can be applied to a variety of other systems in which it is desirable to efficiently and effectively convert pyrolysis products into various desired final products. Furthermore, the components or units depicted with dashed lines represent optional streams and / or components that can be found in exemplary system 10. Therefore, there are contemplated embodiments in which the components in the dashed lines may or may not be present. A more detailed description will now follow. Figure 3 The exemplary system shown.

[0214] like Figure 3 The pyrolysis facility 10 shown includes a waste plastic source 12, a raw material pretreatment system 14, a pyrolysis feed system 16, a pyrolysis reactor 18, a solid separator 22, a gas separation unit 26, and a partial oxidation (POX) unit 34, which can be connected to the above-mentioned... Figure 1 and 2The same components described work in the same way. Figure 3 An embodiment is demonstrated in which at least a portion of the pyrolysis residue, in the form of bottom stream derived from pyrolysis reactor 18 and / or pyrolysis residue 44 from solids separator 22, is introduced into a partial oxidation (POX) gasification facility to produce syngas containing recovered components. Figure 2 As shown, at least a portion of the pyrolysis tower bottom stream 40 from the pyrolysis reactor 18 and / or the pyrolysis residue 44 from the solids separator 22 can be introduced into the partial oxidation (POX) unit 34. Alternatively, or additionally, at least a portion of the pyrolysis oil may also be introduced into the POX unit, such as... Figure 3 As generally shown in the figure.

[0215] like Figure 3 As shown, the pyrolysis tower underflow 40 can be discharged from the pyrolysis reactor 18. In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis tower underflow 40 mainly comprises the above-mentioned... Figure 1 The pyrolysis residues described. For example, based on the total weight of the pyrolysis tower underflow, the pyrolysis tower underflow 40 may contain at least 50, at least 60, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, at least 96, at least 97, at least 98, at least 99, or at least 99.9 wt% of pyrolysis residues. Typically, the pyrolysis tower underflow 40 can be removed from the pyrolysis reactor 18 at a height below the discharge point from which the pyrolysis effluent 20 is removed from the pyrolysis reactor 18.

[0216] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis tower bottoms 40 contains at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, or at least 85 wt% of C20+ hydrocarbons, based on the total weight of the pyrolysis tower bottoms.

[0217] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis tower underflow 40 contains no more than 15, 14, 13, 12, 11, 10, 9, 8, 7, 6, 5, 4, 3, 2, 1 or 0.5 wt% water, based on the total weight of the pyrolysis tower underflow.

[0218] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the pyrolysis tower bottoms, the pyrolysis tower bottoms 40 contains at least 1, at least 2, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 wt% of carbonaceous solids. Additionally or alternatively, in one embodiment or in combination with any of the mentioned embodiments, the pyrolysis tower bottoms contains no more than 99, no more than 90, no more than 80, no more than 70, no more than 60, no more than 50, no more than 40, no more than 30, no more than 20, no more than 10, no more than 9, no more than 8, no more than 7, no more than 6, no more than 5, or no more than 4 wt% of carbonaceous solids.

[0219] In one embodiment or in combination with any of the embodiments mentioned, the pyrolysis tower bottom stream 40 contains a C:H atomic ratio greater than or equal to that of alkanes, or greater than or equal to that of 0.25:1, 0.3:1, 0.35:1, 0.4:1 or 0.45:1.

[0220] In one embodiment or in combination with any of the embodiments mentioned, the pyrolysis tower underflow 40 contains no more than 40, 30, 20, 10, 5, 4, 3, 2 or 1 wt% pyrolysis oil based on the total weight of the pyrolysis tower underflow.

[0221] Back Figure 3 At least a portion of the pyrolysis tower underflow 40 can be introduced into an optional heavy refiner to remove at least a portion of undesirable solids (e.g., metals) from the pyrolysis tower underflow 40. In one embodiment or in combination with any of the mentioned embodiments, the heavy refiner 42 can remove at least 25%, 50%, 75%, 80%, 85%, 90%, 95%, or 99% of the metal-containing compounds present in the pyrolysis tower underflow 40. The heavy refiner 42 may include, for example, a cyclone separator, a filter, or any other separator known in the art capable of separating solids.

[0222] Back Figure 3 At least a portion of the pyrolysis tower bottom stream 40 can be combined with at least a portion of the pyrolysis residue stream 44 from the solids separator 22. It should be noted that this combined pyrolysis residue stream (i.e., the stream containing the pyrolysis tower bottom stream 40 and the pyrolysis residue stream 44) can contain and exhibit the characteristics described above regarding... Figure 1The characteristics of the pyrolysis residue. In one embodiment or in combination with any of the mentioned embodiments, the combined pyrolysis residue stream contains at least 80, at least 85, at least 90, at least 95, at least 99, or at least 99.9 wt% pyrolysis residue based on the total weight of the combined stream. In some embodiments, the pyrolysis bottom stream 40 may be combined with the pyrolysis residue stream 44 after treatment in the heavy refining mill 42.

[0223] like Figure 3 As shown, at least a portion of the pyrolysis tower bottom stream 40 and / or pyrolysis residue stream 44 can be introduced into a gasifier, such as a partial oxidation (POX) unit 34. In the partial oxidation gasifier unit 34, at least a portion of the pyrolysis tower bottom stream 40 and / or pyrolysis residue stream 44 can undergo partial oxidation (POX) gasification. Additionally, or alternatively, at least a portion of the pyrolysis oil stream from the gas separation unit 26 can also undergo partial oxidation gasification.

[0224] In one embodiment or in combination with any of the mentioned embodiments, the POX vaporization unit may include a gas feed vaporizer, a liquid feed vaporizer, a solid feed vaporizer, or a combination thereof.

[0225] like Figure 3 As shown, a method for producing syngas with recovered components is provided, wherein the method includes: (a) charging an oxygenator and a feed composition comprising pyrolysis tower bottom stream 40 and / or pyrolysis residue stream 44 into a gasification zone within a gasifier; (b) gasifying the feed composition together with the oxygenator in the gasification zone to produce a syngas composition; and (c) discharging at least a portion of the syngas composition and residue from the gasifier. Figure 3 As shown, another solid fuel (such as fossil fuels like coal, and / or solid waste plastics) may be combined with the pyrolysis tower bottom stream 40 and / or pyrolysis residue stream 44 to produce gasification feedstock 46.

[0226] In one embodiment or in combination with any of the embodiments mentioned, based on the total weight of the feedstock, the gasification feedstock 46 comprises at least 0.1, at least 0.5, at least 1, at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, at least 10, at least 11, at least 12, at least 13, at least 14, at least 15, at least 16, at least 17, at least 18, at least 19, at least 20, at least 21, at least 22, at least 23, at least 24 or at least 25 and / or no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10 or no more than 5 wt% of pyrolysis residue, which may be derived from the pyrolysis tower bottom stream 40 and / or the pyrolysis residue stream 44. More specifically, based on the total weight of the gasification feedstock, the gasification feedstock may contain 1wt%-75wt%, 1wt%-50wt%, 1wt%-40wt%, or 1wt%-30wt% of pyrolysis residue, which may be derived from the pyrolysis tower bottom stream 40 and / or pyrolysis residue stream 44.

[0227] As described above, the gasification feedstock may also comprise another carbonaceous solid fuel such as coal, and / or solid waste plastics. In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the gasification feedstock, the gasification feedstock may comprise at least 1, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80 or at least 85 and / or no more than 99, no more than 95 or no more than 90 wt% of solid fossil fuel (e.g., coal) and / or solid waste plastics. More specifically, the gasification feedstock may comprise 10 wt%-99 wt%, 40 wt%-99 wt%, or 75 wt%-99 wt% of solid fossil fuel (e.g., coal) and / or solid waste plastics.

[0228] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the gasification feedstock, or alternatively based on the weight of the solids, the gasification feedstock may comprise at least 1, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80 or at least 85 and / or no more than 99, no more than 95 or no more than 90 wt% of coal. More specifically, based on the weight of the gasification feedstock, or alternatively based on the weight of the solids, the gasification feedstock may comprise 10 wt%-99 wt%, 40 wt%-99 wt%, or 65 wt%-78 wt%, or 75 wt%-99 wt% of coal.

[0229] The quality of the coal used is not limited. Anthracite, bituminous coal, sub-bituminous coal, brown coal, and lignite coal can be sources of coal feedstock. In one embodiment or in combination with any of the mentioned embodiments, to improve the thermal efficiency of the reactor, the carbon content of the coal used exceeds 35 wt% or 42 wt% based on the weight of the coal. Therefore, bituminous coal or anthracite may be desirable due to their higher energy content.

[0230] In one embodiment or in combination with any of the embodiments mentioned, the coal may contain a moisture content of no more than 25, 20, 15, 10, or 8% based on the total weight of the coal.

[0231] In one embodiment or in combination with any of the mentioned embodiments, the calorific value of the coal is at least 11,000 BTU / lb, at least 11,500 BTU / lb, at least 12,500 BTU / lb, at least 13,000 BTU / lb, at least 13,500 BTU / lb, 14,000 BTU / lb, 14,250 BTU / lb, or at least 14,500 BTU / lb.

[0232] In one embodiment or in combination with any of the mentioned embodiments, water may be added to the gasification feedstock 46 before being injected into the gasifier 34 to produce a slurry containing water. Thus, in such an embodiment, the gasification feedstock is in the form of a slurry. The gasification feedstock 46 contains at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, at least 28, at least 30, or at least 31 and / or no more than 90, no more than 80, no more than 70, no more than 60, no more than 50, no more than 40, no more than 35, or no more than 30 wt% water.

[0233] In one embodiment or in combination with any of the mentioned embodiments, solid fuels such as coal and / or waste plastics may be ground to a size of 2 mm or less. The small size of the solid fuels may be important for ensuring uniform suspension in the slurry, allowing sufficient movement relative to the gaseous reactants, ensuring substantially complete gasification, and providing a pumpable slurry with a high solids content and minimal grinding.

[0234] Although Figure 3 Not shown, but gasification facilities may include grinding equipment, such as ball mills, rod mills, hammer mills, Raymond mills, or ultrasonic mills, to grind the solid particles of the gasification feedstock (including pyrolysis residues and other solid fuels) to a desired particle size (e.g., an average diameter of less than 2 mm). It should be noted that water may be added to the pyrolysis residues and / or other solid fuels (e.g., coal) when these components are ground in the grinding equipment.

[0235] The pyrolysis tower underflow 40 and / or pyrolysis residue stream 44 can be ground to a suitable particle size, optionally sieved, and then combined with one or more fossil fuel components of the feedstream at any location before the feedstream is introduced into the gasification zone within the gasifier. In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis tower underflow 40 and / or pyrolysis residue stream 44 can be combined with solid carbonaceous fuels (e.g., coal and / or waste plastics) in the grinding apparatus. This location may be particularly attractive for slurry-feed gasifiers, as it may be desirable to use a feedstream with potentially the highest stable solids concentration, and at higher solids concentrations, the slurry viscosity is also high. The high torque and shear forces used in fossil fuel grinding apparatuses, coupled with the shear-thinning behavior of coal slurry, allow for good mixing of the pre-ground pyrolysis residue with the ground fossil fuels in fossil fuel grinding apparatuses.

[0236] Other solid fuels (e.g., fossil fuels such as coal), pyrolysis tower underflow 40, and / or pyrolysis residue stream 44 can be ground or milled for a variety of purposes. Typically, as with fossil fuel sources, pyrolysis tower underflow 40 and / or pyrolysis residue stream 44 must be ground to a small size to (i) allow for faster reaction once inside the gasifier due to mass transfer limitations, (ii) produce a stable, fluid, and flowable slurry in the case of high coal-to-water concentrations, and (iii) pass through processing equipment with tight clearances, such as high-pressure pumps, valves, and feed injectors. Typically, this means that the solids in the feedstock can be ground to a particle size such that at least 90% of the particles have an average particle size not exceeding 4, 3, 2, 1.9, 1.8, or 1.7 mm.

[0237] As described above, the gasification feedstock can be in the form of an aqueous slurry. The concentration of solids (e.g., fossil fuels and tires) in the feedstock stream should not exceed the stability limits of the slurry, or the capacity to pump or feed the feedstock to the gasifier at the target solids concentration. In one embodiment or in combination with any of the mentioned embodiments, the solids content of the slurry should be at least 50, at least 55, at least 60, at least 65, at least 70, or at least 75 wt%, with the remainder being a liquid phase that may include water and liquid additives. There is no particular upper limit, as it depends on the design of the gasifier.

[0238] The amount and particle size of solids in the raw material slurry can be adjusted to maximize the solids content while maintaining a stable and pumpable slurry. In one embodiment or in combination with any of the mentioned embodiments, the pumpable slurry is a slurry with a viscosity of no more than 30,000 cP, no more than 25,000 cP, no more than 23,000 cP, no more than 20,000 cP, no more than 18,000 cP, no more than 15,000 cP, no more than 13,000 cP, no more than 10,000 cP, no more than 8,000 cP, or no more than 5,000 cP and / or at least 500 cP, at least 1,000 cP, at least 1,500 cP, at least 2,000 cP, or at least 2,500 cP at 25°C and 1 atm.

[0239] At higher viscosities, slurries may become too thick to be practically pumpable. Viscosity measurements are performed to determine the pumpability of the slurry as follows: the slurry sample is mixed until a uniform particle distribution is achieved, and then immediately the Brookfield viscometer with an LV-2 rotor rotating at 0.5 rpm is immersed in the well-mixed slurry, and the reading is taken immediately. Alternatively, a Brookfield R / S rheometer with a V80-40 blade rotor operating at a shear rate of 1.83 / s can be used. Measurement methods are reported because measurements at different shear rates will yield different values ​​between the two rheometers. However, the cP values ​​stated above apply to either of these rheometer setups and procedures.

[0240] In one embodiment or in combination with any of the embodiments mentioned, the gasification feedstock stream 46 comprising the pyrolysis tower bottom stream 40, the pyrolysis residue stream 44, other solid fuels, and water can be maintained at a temperature sufficient to keep the stream a pumpable liquid.

[0241] like Figure 3 As shown, Figure 3 The gasified feedstock stream 46 can be injected, along with oxygen, into the refractory-lined combustion chamber of the syngas generator gasifier. In one embodiment or in combination with any of the mentioned embodiments, the feedstock stream and oxygen are injected via an injector into the gasification zone under significant pressure, typically at least 500, 600, 800, or 1000 psig. Typically, the velocity or flow rate of the feedstock and oxygen stream injected from the injector nozzle into the combustion chamber exceeds the flame propagation rate to avoid backflash.

[0242] The operating conditions and oxygen of vaporizer unit 34 are discussed above. Figure 2 The above description of vaporizer operating conditions (e.g., temperature, pressure, and residence time) and oxygen can also be applied to... Figure 3 The gasification system depicted in the text.

[0243] Besides oxygen-producing agents, other reducible oxygen-containing gases can also be supplied to the reaction zone, such as carbon dioxide, nitrogen, or air alone. Figure 3 As shown, a carbon dioxide stream can be introduced along with the feedstock as a carrier gas to propel the feedstock into the gasification zone. Due to the pressure within the gasification zone, these carrier gases can be compressed to provide the power for their introduction into the gasification zone.

[0244] As previously mentioned, the desired gasification process is a partial oxidation gasification reaction. Typically, to increase the yield of hydrogen and carbon monoxide, the oxidation process involves partial rather than complete oxidation of the gasification feedstock; therefore, the oxidation process can operate in an oxygen-deficient environment relative to the amount required to completely oxidize 100% of the carbon and hydrogen bonds. In one embodiment or in combination with any of the mentioned embodiments, the total oxygen requirement of the gasifier can exceed the theoretically required amount by at least 5%, at least 10%, at least 15%, or at least 20% of the carbon content of the gasification feedstock to carbon monoxide. Generally, satisfactory operation is achieved when the total oxygen supply exceeds the theoretical requirement by 10% to 80%. Examples of suitable oxygen amounts per pound of carbon include 0.4 to 3.0, 0.6 to 2.5, 0.9 to 2.5, or 1.2 to 2.5 pounds of free oxygen per pound of carbon.

[0245] The mixing of the feedstock and oxygen streams can be completed entirely within the reaction zone by introducing separate feedstock and oxygen streams, allowing them to collide with each other within the reaction zone. In one embodiment or in combination with any of the mentioned embodiments, the oxygen stream is introduced into the reaction zone of the gasifier at a high speed to both exceed the flame propagation rate and improve mixing with the feedstock stream.

[0246] In one embodiment or in combination with any of the mentioned embodiments, the gasification feedstock stream and oxygen stream may optionally be preheated to a temperature of at least 200°C, at least 300°C, or at least 400°C. However, the gasification process employed does not require preheating of the feedstock stream to effectively gasify the feedstock, and the preheating step may result in reduced energy efficiency of the process.

[0247] In one embodiment or in combination with any of the mentioned embodiments, the type of gasification technology employed is a partially oxidizing fluidized bed gasifier that produces syngas.

[0248] U.S. Patent No. 3,544,291 describes a method that can be used for Figure 3 An exemplary vaporizer in the process of vaporization.

[0249] In one embodiment or in combination with any of the embodiments mentioned, the gasifier is non-catalytic, which means that the gasifier does not contain a catalyst bed and the gasification process is non-catalytic, which means that the catalyst is not introduced into the gasification zone as a discrete, unbound catalyst.

[0250] To avoid scaling in downstream equipment (scrubbers, CO / H2 shift reactors, acid gas removal, chemical synthesis) and intermediate pipelines of the gasifier, the resulting syngas may have low or no tar content. In one embodiment or in combination with any of the mentioned embodiments, based on the weight of all condensable solids in the syngas stream, from Figure 3 The syngas stream discharged from the vaporizer 34 may contain no more than 4, 3, 2, 1, 0.5, 0.2, 0.1, or 0.01 wt% tar. For measurement purposes, condensable solids are those compounds and elements that condense at 15°C and 1 atm. Examples of tar products include naphthalene, cresol, xylenol, anthracene, phenanthrene, phenol, benzene, toluene, pyridine, catechol, biphenyl, benzofuran, benzaldehyde, acenaphthene, fluorene, naphthol, benzene, phenanthrene, benzo[a]pyrene, and other high molecular weight aromatic polynuclear compounds. Tar content can be determined by GC-MSD.

[0251] Typically, the crude synthesis gas stream discharged from the gasification container 34 includes gases such as hydrogen, carbon monoxide, and carbon dioxide, and may include other gases such as methane, hydrogen sulfide, and nitrogen, depending on the fuel source and reaction conditions.

[0252] In one embodiment or in combination with any of the mentioned embodiments, the crude synthesis gas stream (the stream discharged from vaporizer 34 and prior to any further treatment by scrubbing, shifting, or acid gas removal) may have the following composition, in dry basis mole percentages, based on the number of moles of all gases (elements or compounds in gaseous state at 25°C and 1 atm) in the crude synthesis gas stream: • Hydrogen content in the range of 15mol%-60mol%, 18mol%-50mol%, 18mol%-45mol%, 18mol%-40mol%, 23mol%-40mol%, 25mol%-40mol%, 23mol%-38mol%, 29mol%-40mol%, and 31mol%-40mol%. • Carbon monoxide content of 20mol%-75mol%, 20mol%-65mol%, 30mol%-70mol%, 35mol%-68mol%, 40mol%-68mol%, 40mol%-60mol%, 35mol%-55mol% or 40mol%-52mol%; • Carbon dioxide content of 1.0 mol%-30 mol%, 2 mol%-25 mol%, 2 mol%-21 mol%, 10 mol%-25 mol%, or 10 mol%-20 mol%; • Water content of 2.0 mol%-40 mol%, 5 mol%-35 mol%, 5 mol%-30 mol%, or 10 mol%-30 mol%; • Methane content of 0.0 mol%-30 mol%, 0.01 mol%-15 mol%, 0.01 mol%-10 mol%, 0.01 mol%-8 mol%, 0.01 mol%-7 mol%, 0.01 mol%-5 mol%, 0.01 mol%-3 mol%, 0.1 mol%-1.5 mol% or 0.1 mol%-1 mol%; • H2S content of 0.01mol%-2.0mol%, 0.05mol%-1.5mol%, 0.1mol%-1mol%, or 0.1mol%-0.5mol%; • COS content of 0.05 mol%-1.0 mol%, 0.05 mol%-0.7 mol%, or 0.05 mol%-0.3 mol%; • Sulfur content of 0.015 mol%-3.0 mol%, 0.02 mol%-2 mol%, 0.05 mol%-1.5 mol%, or 0.1 mol%-1 mol%; and / or • Nitrogen content of 0.0mol%-5mol%, 0.005mol%-3mol%, 0.01mol%-2mol%, 0.005mol%-1mol%, 0.005mol%-0.5mol%, or 0.005mol%-0.3mol%.

[0253] In one embodiment or in combination with any of the mentioned embodiments, the syngas comprises a hydrogen / carbon monoxide molar ratio of at least 0.65, at least 0.68, at least 0.7, at least 0.73, at least 0.75, at least 0.78, at least 0.8, at least 0.85, at least 0.88, at least 0.9, at least 0.93, at least 0.95, at least 0.98, or at least 1.

[0254] The residual waste formed in the vaporizer 34 can be removed and eliminated from the system.

[0255] The composition of the gas can be determined by FID-GC and TCD-GC or any other recognized method for analyzing the composition of gas streams.

[0256] Back Figure 3At least a portion of the pyrolysis residue 44 from solids separator 22 can be introduced into an optional regenerator 30 for regeneration, typically by combustion. After regeneration, at least a portion of the thermally regenerated solids can be directly reintroduced into the pyrolysis reactor 18. Additionally, or alternatively, at least a portion of the solid particles recovered in solids separator 22 can be directly returned to the pyrolysis reactor 18, particularly if the solid residue contains a significant amount of unconverted plastic waste. Furthermore, residual solids can be removed by the solids removal unit 32 (regenerator 26) and discharged from the system.

[0257] In one embodiment or in combination with any of the mentioned embodiments, the waste plastic source 12, the raw material pretreatment system 14, the pyrolysis feed system 16, the pyrolysis reactor 18, the solids separator 22, the gas separation unit 26, and the POX unit 34 may be in fluid communication between all or some of the units. For example, the pyrolysis reactor 18 may be in fluid communication with the POX unit 34. In one embodiment or in combination with any of the mentioned embodiments, the fluid communication includes jacketed pipes, heat-traced pipes, and / or insulated pipes.

[0258] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis tower underflow 44 may be in the form of a pumpable liquid and may be in fluid communication with the feed injector of the POX vaporizer unit 34. Alternatively, the pyrolysis tower underflow 44 may be in the form of a pumpable liquid and may be in fluid communication with the vaporization facility at a point before the feed injector of the POX vaporizer unit 34.

[0259] In one embodiment or in combination with any of the mentioned embodiments, the pyrolysis reactor 18 is not in fluid communication with the POX unit 34.

[0260] Finally, as Figure 3 As shown, in addition to the gasified feedstock 46, a separate solid waste plastic stream 48 from the feedstock pretreatment system 14 can be separately introduced into the gasifier unit 34.

[0261] Cracking facilities Figure 4 Another exemplary chemical recycling facility or system 400 is depicted, which can be used to at least partially convert one or more waste plastics, particularly recycled plastic waste, into various useful pyrolysis derivatives. It should be understood that... Figure 4 The system 400 shown is merely one example of a system in which this disclosure may be implemented.

[0262] Figure 4A system for processing waste is shown, which typically includes a pyrolysis facility 410 and a cracking facility 420. The pyrolysis facility 410 can utilize recycled waste, such as mixed plastic waste, to provide a recycled component pyrolysis gas (r-pyrolysis gas) stream 110 and a recycled component pyrolysis oil (r-pyrolysis oil) stream 112. As used herein, the term "recycled component" refers to a composition directly and / or indirectly derived from waste plastics or a composition containing directly and / or indirectly derived from waste plastics. As used herein, the term "directly derived" means having at least one physical component derived from waste plastics, while "indirectly derived" means having a specified recycled component that i) is attributable to waste plastics but ii) is not based on having a physical component derived from waste plastics.

[0263] As used herein, “r-pyrolysis oil” refers to a composition of substances that is liquid when measured at 25°C and 1 atm, and at least a portion thereof is derived from the pyrolysis of recycled waste. As used herein, “r-pyrolysis gas” refers to a composition of substances that is gaseous when measured at 25°C and 1 atm, and at least a portion thereof is derived from the pyrolysis of recycled waste.

[0264] like Figure 4 As shown, at least a portion of the r-pyrolysis gas stream 110 and / or r-pyrolysis oil stream 112 formed in pyrolysis facility 410 can be fed to cracker facility 420, where the stream can be treated to form a stream of recovered olefins (r-olefins). As used herein, the term "cracking" refers to the process of breaking down complex organic molecules into simpler molecules by breaking carbon-carbon double bonds. As used herein, the terms "cracker facility" and "cracking plant" refer to a facility that includes all the equipment, piping, and control devices necessary for cracking feedstocks derived from waste plastics. A cracking plant may include one or more cracker furnaces and downstream separation equipment for processing cracker furnace effluents. As used herein, the terms "cracker furnace" or "cracking furnace" refer to a heated outer shell with an inner tube through which the stream undergoing thermal cracking flows.

[0265] Figure 4 The illustrated pyrolysis facility 410 may include one embodiment or a combination of embodiments mentioned herein with any of the aforementioned pyrolysis facilities. In one embodiment or in combination with any of the mentioned embodiments, pyrolysis gas 110 and / or pyrolysis oil 120 (e.g., crude pyrolysis gas and crude pyrolysis oil) directly from the pyrolysis unit may undergo one or more processing steps before being introduced into downstream units (e.g., cracking facility 420). Examples of suitable processing steps may include, but are not limited to: separation of less desirable components (e.g., nitrogen-containing compounds, oxygen-containing compounds, and / or olefins and aromatics), distillation to provide a specific pyrolysis oil composition, and preheating.

[0266] In one embodiment or in combination with any of the mentioned embodiments, the stream of pyrolysis gas 110 introduced into cracker facility 420 may primarily comprise C2 to C4 olefins and alkanes. For example, in one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the r-pyrolysis gas stream, the r-pyrolysis gas may comprise at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 and / or no more than 99, no more than 97, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, or no more than 60 wt% of C2 to C4 olefins and alkanes.

[0267] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the r-pyrolysis gas stream 110, the r-pyrolysis gas stream 110 may contain at least 20, at least 25, at least 30, at least 35, at least 40, at least 45 or at least 50 wt% and / or no more than 75, no more than 70, no more than 65, no more than 60, no more than 55 or no more than 50 wt% of ethylene and / or propylene. The r-pyrolysis gas stream 110 may also contain ethane and / or propane, based on the total weight of the r-pyrolysis gas stream 110, in amounts of at least 5, at least 10, at least 15, at least 20 or at least 25 and / or no more than 50, no more than 45, no more than 40, no more than 35, no more than 30 or no more than 25 wt% of ethane and / or propane.

[0268] The weight ratio of ethylene to ethane in the r-pyrolysis gas stream 110 may be at least 1:1, at least 1.1:1, at least 1.2:1, at least 1.25:1, at least 1.3:1, at least 1.35:1, at least 1.4:1, at least 1.45:1, at least 1.5:1, and / or not exceeding 3:1, not exceeding 2.75:1, not exceeding 2.5:1, not exceeding 2.25:1, or not exceeding 2.1:1. Additionally, or alternatively, the weight ratio of propylene to propane in the r-pyrolysis gas stream 110 may be at least 1:1, at least 1.1:1, at least 1.2:1, at least 1.25:1, at least 1.3:1, at least 1.35:1, at least 1.4:1, at least 1.45:1, at least 1.5:1, and / or not exceeding 3:1, not exceeding 2.75:1, not exceeding 2.5:1, not exceeding 2.25:1, or not exceeding 2.1:1.

[0269] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the r-pyrolysis gas stream 110, the r-pyrolysis gas stream 110 may contain at least 20, at least 25, at least 30, at least 35, at least 40, at least 45 or at least 50 wt% and / or no more than 75, no more than 70, no more than 65, no more than 60, no more than 55 or no more than 50 wt% of ethylene, and, based on the total weight of the r-pyrolysis gas stream 110, it may also contain at least 5, at least 10, at least 15, at least 20 or at least 25 and / or no more than 50, 45, 40, 35, 30 or 25 wt% of ethane. The weight ratio of ethylene to ethane in the r-pyrolysis gas stream 110 can be at least 1:1, at least 1.1:1, at least 1.2:1, at least 1.25:1, at least 1.3:1, at least 1.35:1, at least 1.4:1, at least 1.45:1, at least 1.5:1 and / or not exceeding 3:1, not exceeding 2.75:1, not exceeding 2.5:1, not exceeding 2.25:1, or not exceeding 2.1:1.

[0270] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the r-pyrolysis gas stream 110, the r-pyrolysis gas stream 110 may contain at least 20, at least 25, at least 30, at least 35, at least 40, at least 45 or at least 50 wt% and / or no more than 75, no more than 70, no more than 65, no more than 60, no more than 55 or no more than 50 wt% of propylene, and based on the total weight of the r-pyrolysis gas stream 110, it may also contain at least 5, at least 10, at least 15, at least 20 or at least 25 and / or no more than 50, 45, 40, 35, 30 or 25 wt% of propane. The weight ratio of propylene to propane in the r-pyrolysis gas stream 110 can be at least 1:1, at least 1.1:1, at least 1.2:1, at least 1.25:1, at least 1.3:1, at least 1.35:1, at least 1.4:1, at least 1.45:1, at least 1.5:1 and / or not exceeding 3:1, not exceeding 2.75:1, not exceeding 2.5:1, not exceeding 2.25:1, or not exceeding 2.1:1.

[0271] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the r-pyrolysis gas stream 110, the methane content of the r-pyrolysis gas stream 110 may be at least 5, at least 10, at least 15, at least 20, at least 25, at least 30 or at least 35 and / or not more than 60, 55, 50, 45, 35, 30, 25 or 20 wt%. Additionally, or alternatively, based on the total weight of the composition, the r-pyrolysis gas stream 110 may contain at least 0.5, at least 1, at least 2, at least 5, at least 8, at least 10, at least 12, at least 15 and / or not more than about 35, 30, 25, 20, 15, 10, 8, 5 wt% butadiene.

[0272] In one embodiment or in combination with any of the mentioned embodiments, the r-pyrolysis gas stream 110 contains no more than about 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, or no more than 5 wt% of C5 and heavier components, based on the total weight of the composition. The r-pyrolysis gas stream 110 may also contain no more than about 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, or no more than 5 wt% of aromatic hydrocarbons, based on the total weight of stream 110. The r-pyrolysis gas stream 110 may contain at least 0.1, at least 0.5, at least 1, at least 2, at least 3, at least 4, at least 5, at least 8, at least 10, or at least 12 and / or no more than 25, no more than 20, no more than 18, no more than 15, no more than 12, no more than 10, no more than 8, or no more than 5 wt% of one or more nitrogen-containing compounds, based on the total weight of the stream.

[0273] Furthermore, in one embodiment or in combination with any of the mentioned embodiments, the r-pyrolysis gas stream 110 introduced into the cracker facility may have at least one of the following characteristics: (a) C4 hydrocarbons in amounts not exceeding 20, 15, 10, 5, 2, 1, or 0.5 wt%; (b) Hydrogen gas in amounts not exceeding 10, 8, 6, 5, 2, or 1 wt%; (c) C3+ dienes in amounts not exceeding 10, 8, 6, 5, 2, or 1 wt%; (d) C4+ olefins in amounts not exceeding 10, 8, 6, 5, 2, or 1 wt%; (e) C4 alkanes in amounts not exceeding 5, 3, 2, 1, 0.5, or 0.1 wt%; (f) Halogens in amounts not exceeding 1, 0.5, 0.1, 0.05, or 0.01 ppm; (g) Carbonyl groups in amounts not exceeding 100, 75, 50, 25, 10, or 5 ppm; (h) Carbon dioxide in amounts not exceeding 100, 75, 50, 25, 10, or 5 ppm; (i) Carbon monoxide in amounts not exceeding 2500, 2000, 1500, 1000, 750, 500, 250, 100, 50, 25, or 10 ppm; (j) Arsine and / or phosphine in amounts not exceeding 15, 10, 8, 5, 2, or 1 ppb; and (k) A sulfur-containing compound in amounts not exceeding 100, 75, 50, 25, 10, or 5 ppm, wherein each of the above amounts is by weight – based on the total weight of the composition.

[0274] The r-pyrolysis gas stream 110 introduced into the cracker facility may contain at least two, three, four, five, six, seven, eight or all of these characteristics.

[0275] In one embodiment or in combination with any of the mentioned embodiments, the pressure of the r-pyrolysis gas stream 110 may be at least 200 (13.8 barg), at least 250 (17.2 barg), at least 300 (20.7 barg), at least 350 (24.1 barg), at least 400 (27.6 barg), at least 450 (31.0 barg), or at least 500 (34.5 barg), all in psig. Additionally, or alternatively, the pressure may not exceed 500 (34.5 barg), not exceed 450 (31.0 barg), not exceed 400 (27.6 barg), not exceed 350 (24.1 barg), not exceed 300 (20.7 barg), not exceed 250 (17.2 barg), not exceed 200 (13.78 barg), not exceed 150 (10.35 barg), or not exceed 100 (6.89 barg), all in psig.

[0276] The temperature of the r-pyrolysis gas stream 110 can be at least 250, at least 300, at least 350, at least 400, at least 450, at least 500, at least 550, at least 600, or at least 650°C and / or not exceeding 1000, not exceeding 950, not exceeding 900, not exceeding 850, not exceeding 800, not exceeding 750, not exceeding 700, not exceeding 650, not exceeding 600, not exceeding 550, or not exceeding 500°C. The temperature and / or pressure of the r-pyrolysis gas can be measured before or after the compressor or heat exchanger, at the outlet of the pyrolysis facility, or at the location where the pyrolysis gas is introduced into the pyrolysis facility 420.

[0277] In one embodiment or in combination with any of the mentioned embodiments, the r-pyrolysis oil stream 112 may contain at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95 (in each case, by weight percentage) of C4 to C30 hydrocarbons, and as used herein, hydrocarbons include aliphatic, alicyclic, aromatic, and heterocyclic compounds. In one embodiment or in combination with any of the mentioned embodiments, the r-pyrolysis oil stream 112 may primarily contain C5-C25, C5-C22, or C5-C20 hydrocarbons, or may contain at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% of C5-C25, C5-C22, or C5-C20 hydrocarbons.

[0278] In one embodiment or in combination with any of the mentioned embodiments, the r-pyrolysis oil stream 112 may comprise C4-C12 aliphatic compounds (branched or unbranched alkanes and alkenes, including dienes and alicyclic hydrocarbons) and C13-C22 aliphatic compounds in a weight ratio greater than 1:1, or at least 1.25:1, or at least 1.5:1, or at least 2:1, or at least 2.5:1, or at least 3:1, or at least 4:1, or at least 5:1, or at least 6:1, or at least 7:1, 10:1, 20:1, or at least 40:1, each by weight and based on the weight of the r-pyrolysis oil stream 112.

[0279] In one embodiment or in combination with any of the mentioned embodiments, the r-pyrolysis oil stream 112 may comprise C13-C22 aliphatic compounds (branched or unbranched alkanes and alkenes, including dienes and alicyclic hydrocarbons) and C4-C12 aliphatic compounds in a weight ratio greater than 1:1, or at least 1.25:1, or at least 1.5:1, or at least 2:1, or at least 2.5:1, or at least 3:1, or at least 4:1, or at least 5:1, or at least 6:1, or at least 7:1, 10:1, 20:1, or at least 40:1, each by weight and based on the weight of the r-pyrolysis oil stream 112.

[0280] In one embodiment, the two aliphatic hydrocarbons (branched or unbranched alkanes and alkenes, and alicyclic compounds) having the highest concentrations in the r-pyrolysis oil are in the range of C5 to C18, or C5 to C16, or C5 to C14, or C5 to C10, or C5 to C8 (inclusive).

[0281] r-pyrolysis oil 112 includes one or more of alkanes, cycloalkanes or cyclic aliphatic hydrocarbons, aromatic hydrocarbons, aromatic compounds, olefins, oxygen-containing compounds and polymers, heteroatom compounds or polymers, and other compounds or polymers.

[0282] For example, in one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the r-pyrolysis oil stream 112, the r-pyrolysis oil 112 may contain at least 5, or at least 10, or at least 15, or at least 20, or at least 25, or at least 30, or at least 35, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95 (in each case, by weight percentage) and / or no more than 9. 9. Or not more than 97, or not more than 95, or not more than 93, or not more than 90, or not more than 87, or not more than 85, or not more than 83, or not more than 80, or not more than 78, or not more than 75, or not more than 70, or not more than 65, or not more than 60, or not more than 55, or not more than 50, or not more than 45, or not more than 40, or not more than 35, or not more than 30, or not more than 25, or not more than 20, or not more than 15 (in each case, by weight percentage) of alkanes (or straight-chain or branched alkanes). Examples of the range of alkanes contained in r-pyrolysis oil stream 112 based on the weight of the r-pyrolysis oil composition are 5 to 50, or 5 to 40, or 5 to 35, or 10 to 35, or 10 to 30, or 5 to 25, or 5 to 20, in each case, by weight percentage.

[0283] In one embodiment or in combination with any of the mentioned embodiments, the r-pyrolysis oil stream 112 may contain cycloalkanes or cyclic aliphatic hydrocarbons in an amount of 0, or at least 1, or at least 2, or at least 5, or at least 8, or at least 10, or at least 15, or at least 20 (in each case, by weight percentage) and / or no more than 50, or no more than 45, or no more than 40, or no more than 35, or no more than 30, or no more than 25, or no more than 20, or no more than 15, or no more than 10, or no more than 5 (in each case, by weight percentage). Examples of the range of cycloalkanes (or cyclic aliphatic hydrocarbons) contained in the r-pyrolysis oil stream 112 based on its weight are 0-35, or 1-30, or 2-25, or 2-20, or 2-15, or 2-10, or 1-10 (in each case, by weight percentage).

[0284] In one embodiment or in combination with any of the mentioned embodiments, based on the weight of the r-pyrolysis oil stream 112, the r-pyrolysis oil stream 112 contains no more than 30, or no more than 25, or no more than 20, or no more than 15, or no more than 10, or no more than 8, or no more than 5, or no more than 2, or no more than 1 (in each case, by weight) aromatic hydrocarbons. As used herein, the term "aromatic hydrocarbon" refers to the total amount (by weight) of benzene, toluene, xylene, and styrene. Based on the total weight of the r-pyrolysis oil stream 112, the r-pyrolysis oil stream 112 may contain at least 1, or at least 2, or at least 5, or at least 8, or at least 10 (in each case, by weight) aromatic hydrocarbons.

[0285] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the r-pyrolysis oil stream 112, the r-pyrolysis oil stream 112 may contain aromatic compounds in an amount not exceeding 30, or not exceeding 25, or not exceeding 20, or not exceeding 15, or not exceeding 10, or not exceeding 8, or not exceeding 5, or not exceeding 2, or not exceeding 1 (in each case, by weight percentage), or undetectable. Aromatic compounds include the aromatic hydrocarbons mentioned above and any compounds containing aromatic moieties, such as terephthalate residues and fused-ring aromatic hydrocarbons, such as naphthalene and tetrahydronaphthalene.

[0286] In one embodiment or in combination with any of the mentioned embodiments, based on the weight of the r-pyrolysis oil stream 112, the r-pyrolysis oil stream 112 may contain at least 1, or at least 2, or at least 5, or at least 8, or at least 10, or at least 15, or at least 20, or at least 30, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65 (in each case, by weight percentage) of olefins, and / or no more than 85, or no more than 80, or no more than 75, or no more than 70, or no more than 65, or no more than 60, or no more than 55, or no more than 50, or no more than 45, or no more than 40, or no more than 35, or no more than 30, or no more than 25, or no more than 20, or no more than 15, or no more than 10 (in each case, by weight percentage). The olefins include monoolefins and dienes. Examples of suitable ranges include 40 to 85, or 45 to 85, or 50 to 85, or 55 to 85, or 60 to 85, or 65 to 85, or 40 to 80, or 45 to 80, or 50 to 80, or 55 to 80, or 60 to 80, or 65 to 80, or 40 to 75, or 4 Olefins present in amounts of 5 to 75, or 50 to 75, or 55 to 75, or 60 to 75, or 65 to 75, or 40 to 70, or 45 to 70, or 50 to 70, or 55 to 70, or 60 to 70, or 65 to 70, or 40 to 65, or 45 to 65, or 50 to 65, or 55 to 65 (wt% in each case), based on the weight of r-pyrolysis oil stream 112.

[0287] In one embodiment or in combination with any of the mentioned embodiments, the r-pyrolysis oil stream 112 may contain an oxygen-containing compound or polymer in an amount based on the weight of the r-pyrolysis oil stream 112 of: 0 or at least 0.01, or at least 0.1, or at least 1, or at least 2, or at least 5 (in each case, by weight percentage) and / or no more than 20, or no more than 15, or no more than 10, or no more than 8, or no more than 6, or no more than 5, or no more than 3, or no more than 2 (in each case, by weight percentage) of the oxygen-containing compound or polymer. The oxygen-containing compound and polymer are those containing oxygen atoms. Examples of suitable ranges include oxygen-containing compounds present in amounts (wt%) within the range of 0-20, or 0-15, or 0-10, or 0.01-10, or 1-10, or 2-10, or 0.01-8, or 0.1-6, or 1-6, or 0.01-5, based on the weight of r-pyrolysis oil stream 112.

[0288] In one embodiment or in combination with any embodiment mentioned herein, based on the weight of the r-pyrolysis oil stream 112, the sulfur content of the r-pyrolysis oil stream 112 is no more than 2.5 wt%, or no more than 2, or no more than 1.75, or no more than 1.5, or no more than 1.25, or no more than 1, or no more than 0.75, or no more than 0.5, or no more than 0.25, or no more than 0.1, or no more than 0.05, and preferably no more than 0.03, or no more than 0.02, or no more than 0.01, or no more than 0.008, or no more than 0.006, or no more than 0.004, or no more than 0.002, or no more than 0.001, in each case as a weight percentage.

[0289] In one embodiment or in combination with any of the mentioned embodiments, based on the weight of the r-pyrolysis oil stream 112, the weight ratio of alkanes to cycloalkanes may be at least 1:1, or at least 1.5:1, or at least 2:1, or at least 2.2:1, or at least 2.5:1, or at least 2.7:1, or at least 3:1, or at least 3.3:1, or at least 3.5:1, or at least 3.75:1, or at least 4:1, or at least 4.25:1, or at least 4.5:1, or at least 4.75:1, or at least 5:1, or at least 6:1, or at least 7:1, or at least 8:1, or at least 9:1, or at least 10:1, or at least 13:1, or at least 15:1, or at least 17:1.

[0290] In one embodiment or in combination with any of the mentioned embodiments, based on the weight of the r-pyrolysis oil stream 112, the total weight ratio of alkanes and cycloalkanes to aromatics may be at least 1:1, or at least 1.5:1, or at least 2:1, or at least 2.5:1, or at least 2.7:1, or at least 3:1, or at least 3.3:1, or at least 3.5:1, or at least 3.75:1, or at least 4:1, or at least 4.5:1, or at least 5:1, or at least 7:1, or at least 10:1, or at least 15:1, or at least 20:1, or at least 25:1, or at least 30:1, or at least 35:1, or at least 40:1. In one embodiment or in combination with any of the mentioned embodiments, the ratio of total alkanes and cycloalkanes to aromatics in the r-pyrolysis oil stream 112 may be in the range of 1:1-7:1, or 1:1-5:1, 1:1-4:1 or 1:1-3:1.

[0291] In one embodiment or in combination with any of the mentioned embodiments, the r-pyrolysis oil stream 112 may have a boiling point profile defined by one or more of its 10% boiling point, its 50% boiling point, and its 90% boiling point, as defined below. As used herein, “boiling point” means the boiling point of the composition as determined by ASTM D2887-13. Additionally, as used herein, “x% boiling point” means a boiling point at which x weight percent of the composition boils, according to ASTM D-2887-13.

[0292] In one embodiment or in combination with any of the mentioned embodiments, the 90% boiling point of the r-pyrolysis oil stream 112 may be no more than 350, or no more than 325, or no more than 300, or no more than 295, or no more than 290, or no more than 285, or no more than 280, or no more than 275, or no more than 270, or no more than 265, or no more than 260, or no more than 255, or no more than 250, or no more than 245, or no more than 240, or no more than 235, or no more than 230, or no more than 225, or no more than 220. Or not more than 215, not more than 200, not more than 190, not more than 180, not more than 170, not more than 160, not more than 150 or not more than 140 (°C in each case) and / or at least 200, or at least 205, or at least 210, or at least 215, or at least 220, or at least 225, or at least 230 (°C in each case), and / or, not more than 25wt%, 20wt%, 15wt%, 10wt%, 5wt%, or 2wt% of r-pyrolysis oil stream 112 may have a boiling point of 300°C or higher.

[0293] Turn now Figure 5-8 Several embodiments of the integration of pyrolysis 410 and cracker 420 facilities are shown. Figure 5-8 Each of them shows a system for processing waste plastics, the system including a pyrolysis facility 410 and at least one cracker facility 420 configured to receive a stream of r-pyrolysis oil 112 and / or r-pyrolysis gas 110 from the pyrolysis facility.

[0294] Turn now Figure 5 Waste plastic stream 100 may be introduced into pyrolysis facility 410 to provide r-pyrolysis gas stream 110. Pyrolysis gas stream 110 may optionally be processed in a processing zone (not shown), and may subsequently be sent in whole or in part to cracker facility 420. In one embodiment or in combination with any of the mentioned embodiments, r-pyrolysis gas stream 110 (and in particular, r-pyrolysis gas stream not generated in the cracker furnace) may be introduced downstream of cracker furnace 430.

[0295] Optionally, all or part of the r-pyrolysis oil stream 112 can be combined with the cracker feed stream 116, which can be thermally cracked in the cracker furnace 430 to provide an olefin-containing effluent stream 117 from the furnace 430. For example... Figure 5 As shown, at least a portion of the r-pyrolysis gas stream 110 can be combined with the olefin-containing effluent stream 117, and the combined stream 119 can be introduced into the separation zone 440 of the cracker facility 420. In the separation zone 440, at least a portion of the combined stream 119 can be separated to form at least one recovered olefin (r-olefin) stream 118.

[0296] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the combined stream 119, the combined stream 119 containing olefin effluent and r-pyrolysis gas may include at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85 or at least 90 and / or no more than about 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35 or no more than 30 wt% of r-pyrolysis gas.

[0297] Based on the total weight of combined stream 119, the olefin-containing effluent may be present in the following amounts: at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85 or at least 90 and / or not more than about 95, not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, not more than 35 or not more than 30 wt%.

[0298] In one embodiment or in combination with any of the mentioned embodiments, the weight ratio of r-pyrolysis gas to olefin-containing effluent in the combined stream 119 downstream of the furnace outlet is at least 1:10, at least 1:8, at least 1:6, at least 1:5, at least 1:4, at least 1:3, at least 1:2.5, at least 1:2, at least 1:1.5, or at least 1:1 and / or no more than about 10:1, no more than 8:1, no more than 6:1, no more than 5:1, no more than 4:1, no more than 3:1, no more than 2.5:1, no more than 2:1, no more than 1:5:1, or no more than 1:1.

[0299] Turn now Figure 6This illustrates another system for processing waste plastics, comprising a pyrolysis facility 410 and two cracker facilities 420a, b operating in parallel. Each cracker facility 420a, b includes cracker furnaces 430a, b and separation zones 440a, b, downstream of each cracker furnace 430a, b. Figure 6 As generally shown, at least a portion of the r-pyrolysis gas stream 110 formed by the pyrolysis of the waste plastic feed stream 110 in the pyrolysis facility 410 may be introduced into one of the two cracker facilities 420a at a downstream location of the cracker furnace 430a.

[0300] In one embodiment or in combination with any of the mentioned embodiments, introducing the r-pyrolysis gas stream 110 into the separation zone 430a can reduce the required flow rate of the olefin-containing effluent 117a from the cracker furnace 430a, and in some embodiments, can make it possible to eliminate the need for operation of the cracker furnace 430a. For example, in some embodiments, the total mass flow rate of the olefin-containing effluent 117a from the outlet of the cracker furnace 430a can be reduced by at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, or at least 75% compared to introducing the r-pyrolysis gas stream 110 into the cracker facility. As a result, compared with introducing the r-pyrolysis gas stream 110 into the cracker facility 430a, the mass flow rate of the cracker feed stream 116a can be reduced by at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, or at least 75%.

[0301] In other embodiments, the cracker furnace 430a previously used to produce olefin-containing effluent 117a (which is separated in the downstream separation zone 440a) may be idle, such that the total mass flow rate of olefin-containing effluent 117a and / or cracker feed stream 116a may be at least 90%, at least 92%, at least 95%, at least 97%, or at least 99% lower than when the r-pyrolysis gas stream 110 is not introduced into the cracker facility. In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of feed stream 117a, the feed to the fractionation section (or the first column therein) of the separation facility 440a may contain no more than 20, 15, 10, 5, 2, 1, or 0.5 wt% of the olefin-containing effluent stream from cracker furnace 430a.

[0302] In one embodiment or in combination with any of the mentioned embodiments, cracker furnace 430a may be idle, and at least 80%, at least 85%, at least 90%, at least 95%, at least 97%, at least 99%, or at least 100% of the feed to the separation zone of cracker facility 430a may originate from a pyrolysis facility (e.g., r-pyrolysis gas stream 110). In other embodiments, cracker furnace 430a may be operational, but less than 80, not exceeding 75, not exceeding 70, not exceeding 65, not exceeding 60, not exceeding 55, not exceeding 50, not exceeding 45, not exceeding 40, not exceeding 35, or not exceeding 30 wt% of the feed to downstream separation zone 440a of cracker furnace 430a. In one embodiment or in combination with any of the mentioned embodiments, olefin-containing effluent from cracker furnace of second cracker facility may constitute at least 90%, at least 95%, at least 99%, or all of the feed to second separation zone.

[0303] Similarly, in some embodiments, where the cracker facility comprises two or more furnaces operating in parallel that share a common separation zone, the introduction of r-pyrolysis gas can result in a reduction of olefin-containing effluent from at least one cracker furnace and / or cracker feedstock to at least one cracker furnace. Figure 7 The document provides a schematic description of this facility 600.

[0304] In one embodiment or in combination with any of the mentioned embodiments, introducing the r-pyrolysis gas stream 110 into at least one downstream location of the furnace outlet of furnaces 430a and 430b can result in a reduction in the mass flow rate of the olefin-containing effluents 117a, b from one or both of furnaces 430a and 430b, based on the total mass flow rate of the olefin-containing effluents 117a, b from one or both of furnaces 430a and 430b, by an amount of at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 45%, at least 50%, at least 55%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, at least 90%, or at least 95%.

[0305] In one embodiment or in combination with any of the mentioned embodiments, one or more furnaces 430a, b may operate at the same or reduced feed or product rates, while one or more other furnaces 430a, b may be idle. Although shown as including only two furnaces 430a, b, it should be understood that the cracking facility 420a, b according to this disclosure may include at least two, three, four, five, six, seven, eight, or nine or more furnaces feeding into a single separation zone 440.

[0306] In one embodiment or in combination with any of the embodiments mentioned, the cracker facility 420 includes two or more furnaces 430, and the outflow stream 117 from the furnaces 430 can be sent to two or more separation zones 440a, b. Figure 8 An example of such a system is provided in the document.

[0307] like Figure 8 As shown, two or more cracker furnaces 430a, b (in the same or different cracker facilities) may share a common compressor 450, which directs a compressed olefin-containing stream 117 to one or more separation zones. In one embodiment or in combination with any of the mentioned embodiments, when the r-pyrolysis gas stream 110 is introduced into the cracker facility, it may be added upstream of the first stage of the compressor 450, and the compressed r-pyrolysis gas may be introduced into one or both separation zones, for example, separate fractionation sections 460a, b. As described in detail above, one or both of the cracker furnaces 430a, 430b may be idle, operational, or operational but at reduced feed and / or product rates.

[0308] Turn now Figure 9 This describes a system for processing waste plastics, comprising a pyrolysis facility 410 and a cracker facility 420, with particular emphasis on various aspects of the cracker facility. (For example...) Figure 9 As shown, the r-pyrolysis stream 110 can be combined with the olefin-containing effluent 117 from cracker furnace 430a, and the combined stream can then be introduced into the separation zone 440 of the cracker facility. In the separation zone 440, the stream can be separated to form one or more olefin streams and one or more alkane streams. The recovered olefin component (r-olefins) can be removed from the cracker facility as a product or intermediate stream 118, while at least a portion of the recovered alkane component (r-alkane) stream 130 can be recycled to the inlet of at least one cracker furnace for use as cracker feedstock. The cracker furnace can be the same cracker furnace 430a from which the olefin-containing stream is extracted, and / or it can be a separate cracker furnace, such as... Figure 9 As shown in 430c. Additionally, or alternatively, at least a portion of the alkane stream 130 may be fed as feedstock to downstream alkane processing facility 460 and / or used for further storage or sale, as shown in pipeline 132.

[0309] In one embodiment or in combination with any of the mentioned embodiments, cracker feed stream 116 may be introduced into cracker furnace 430. In one embodiment or in combination with any of the mentioned embodiments, cracker feed stream 116 may comprise a composition containing predominantly C2 to C4 hydrocarbons, or a composition containing predominantly C5 to C22 hydrocarbons. As used herein, the term "predominantly C2 to C4 hydrocarbons" means a stream or composition containing at least 50 wt% C2 to C4 hydrocarbon components. Examples of specific types of C2 to C4 hydrocarbon streams or compositions include propane, ethane, butane, and LPG. In one embodiment or in combination with any of the mentioned embodiments, the cracker feed stream 116 may contain at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95 (wt% in each case – based on the total weight of the feed) and / or no more than 100, or no more than 99, or no more than 95, or no more than 92, or no more than 90, or no more than 85, or no more than 80, or no more than 75, or no more than 70, or no more than 65 or no more than 60 (weight percentage in each case) of C2 to C4 hydrocarbons or linear alkanes – based on the total weight of the feed. The cracker feed stream 116 may contain primarily propane, primarily ethane, primarily butane, or a combination of two or more of these components.

[0310] In one embodiment or in combination with any of the mentioned embodiments, the cracker feed stream 116 may comprise a composition containing primarily C5 to C22 hydrocarbons. As used herein, “primarily C5 to C22 hydrocarbons” means a stream or composition containing at least 50 wt% of C5 to C22 hydrocarbon components.

[0311] Examples include gasoline, naphtha, middle distillate, diesel, and kerosene. In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of stream 116, the cracker feed stream 116 may contain at least 20, or at least 25, or at least 30, or at least 35, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95 (by weight in each case) and / or no more than 100, or no more than 99, or no more than 95, or no more than 92, or no more than 90, or no more than 85, or no more than 85, or no more than 75, or no more than 70, or no more than 65, or no more than 60 (by weight in each case) of C5 to C22, or C5 to C20 hydrocarbons.

[0312] In one embodiment or in combination with any embodiment mentioned herein, based on the total weight of the feed stream 116, the C15 and heavier (C15+) content of the cracker feed stream 116 may be at least 0.5, or at least 1, or at least 2, or at least 5 (in each case, by weight percentage) and / or no more than 40, or no more than 35, or no more than 30, or no more than 25, or no more than 20, or no more than 18, or no more than 15, or no more than 12, or no more than 10, or no more than 5, or no more than 3 (in each case, by weight percentage).

[0313] In one embodiment or in combination with any of the embodiments mentioned, based on the total weight of stream 116, the C15 and heavier (C15+) content of cracker feed stream 116 may be at least 20, or at least 25, or at least 30, or at least 35, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95 (wt%) in each case and / or no more than 100, or no more than 99, or no more than 95, or no more than 92, or no more than 90, or no more than 85, or no more than 80, or no more than 75, or no more than 70, or no more than 65, or no more than 60 (weight percentage) of C5 to C22, or C5 to C20 hydrocarbons in each case. Examples of these types of hydrocarbons may include, but are not limited to, vacuum gas oil (VGO), hydrogenated vacuum gas oil (HVGO), and atmospheric gas oil (AGO).

[0314] In one embodiment or in combination with any of the mentioned embodiments, the 90% boiling point of the cracker feedstock or stream or composition may be at least 350°C, the 10% boiling point may be at least 60°C, and the 50% boiling point may be in the range of 95°C to 200°C. In one embodiment or in combination with any of the mentioned embodiments, the 90% boiling point of the cracker feedstock stream 116 may be at least 150°C, the 10% boiling point may be at least 60°C, and the 50% boiling point may be in the range of 80°C to 145°C. The 90% boiling point of the cracker feedstock stream 116 may be at least 350°C, the 10% boiling point may be at least 150°C, and the 50% boiling point may be in the range of 220°C to 280°C.

[0315] In one embodiment or in combination with any of the mentioned embodiments, cracker furnace 430 may be a gas furnace. A gas furnace is a furnace having at least one coil that receives (or is operated to receive or is configured to receive) a predominantly gaseous feed (more than 50% by weight of the feed is steam) (“gas coil”) at a coil inlet at the inlet of the convection zone. In one embodiment or in combination with any of the mentioned embodiments, the gas coil may receive a predominantly C2 to C4 feed, or predominantly C2 and / or C3 feed, at the coil inlet in the convection section, or alternatively, having at least one coil that receives more than 50 wt% ethane and / or more than 50% propane and / or more than 50% LPG, or in any of these cases, at least 60 wt%, or at least 70 wt%, or at least 80 wt%, based on the weight of the cracker feed to the coil, or alternatively based on the weight of the cracker feed to the convection zone.

[0316] The gas furnace may have more than one gas coil. In one embodiment or in combination with any of the mentioned embodiments, at least 25%, or at least 50%, or at least 60%, or all of the coils in the convection zone or convection box of the furnace may be gas coils. The gas coil may receive a gaseous feed at a coil inlet at the inlet of the convection zone, wherein at least 60 wt%, or at least 70 wt%, or at least 80 wt%, or at least 90 wt%, or at least 95 wt%, or at least 97 wt%, or at least 98 wt%, or at least 99 wt%, or at least 99.5 wt%, or at least 99.9 wt% of the feed may be vapor.

[0317] In one embodiment or in combination with any of the mentioned embodiments, the furnace may be a cracking furnace. A cracking furnace is a gas furnace. The cracking furnace contains at least one gas coil and at least one liquid coil within the same furnace, or within the same convection zone, or within the same convection box. The liquid coil may be a coil (“liquid coil”) that receives a feed that is primarily liquid (more than 50% by weight of the feed is liquid) at a coil inlet at the convection zone inlet.

[0318] In one embodiment or in combination with any of the mentioned embodiments, the cracker may be a thermal gas cracker.

[0319] In one embodiment or in combination with any of the mentioned embodiments, the cracker feed can be thermally cracked in a hot steam gas cracker in the presence of steam. Steam cracking refers to the high-temperature cracking (decomposition) of hydrocarbons in the presence of steam.

[0320] When the cracker feed stream is combined with one or more other streams (e.g., r-pyrolysis oil), this combination can occur upstream of the cracker, inside the cracker, or within a single coil or tube. Alternatively, the feed stream containing r-pyrolysis oil and the cracker feed can be introduced into the furnace separately and can pass through part or all of the furnace simultaneously, while being isolated from each other by feeding into separate tubes within the same furnace (e.g., a cracking furnace).

[0321] Turn now Figure 10 A schematic diagram of a cracker furnace applicable to one or more embodiments is shown. Figure 7 As shown, the cracking furnace may include a convection section 746, a radiation section 748, and a cross section 750 located between the convection section 746 and the radiation section 748. The cross section 750 is located between the convection section 746 and the radiation section 748 and is in fluid flow communication with the convection section 746 and the radiation section 748.

[0322] The convection section 746 is part of the furnace 742, which receives heat from the hot flue gas and includes a set of tubes or coils 752a, b through which the cracker stream 160 passes. In the convection section 746, the cracker stream 160 is heated by convection from the hot flue gas passing through it. Although in Figure 10 The diagram shows a horizontally oriented convection section tube 752a and a vertically oriented radiation section tube 752b, but it should be understood that the tube 752 can be oriented in any suitable configuration. For example, in one embodiment or in combination with any of the mentioned embodiments, the convection section tube 752a may be vertical. In one embodiment or in combination with any of the mentioned embodiments, the radiation section tube 752b may be horizontal. Additionally, although shown as a single tube, the cracker furnace may include one or more tubes or coils 752, which may include at least one split, bend, U-shape, elbow, or combination thereof. When multiple tubes or coils are present, they may be arranged in parallel and / or in series.

[0323] The radiant section 748 is a section of the furnace 742, where heat is primarily transferred via radiation from the high-temperature gases to the heating tubes. The radiant section 748 also includes multiple burners 756 for introducing heat into the lower part of the furnace 742. The furnace 742 includes a firebox 754 that surrounds and houses the tubes 752b within the radiant section 748, and the burners 756 are oriented into this firebox. The cross section 750 includes conduits for connecting the convection section 746 and the radiant section 748, and allows the transfer of heated cracker stream 160 from one section to another, either inside or outside the furnace.

[0324] As the hot combustion gases rise through the furnace, they can pass through the convection section 746, where at least a portion of the waste heat can be extracted and used to heat the cracker stream 116 passing through the convection section.

[0325] In one embodiment or in combination with any of the mentioned embodiments, the cracking furnace 742 may have a single convection (preheating) section and a single radiant section, while in other embodiments, the furnace may include two or more radiant sections sharing a common convection section. At least one induced draft fan 760 near the furnace body (not shown) can control the flow of hot flue gas through the furnace 742, thereby controlling its heating distribution. Additionally, in one embodiment or in combination with any of the mentioned embodiments, one or more of the heat exchangers 760 may be used to cool the furnace effluent 119. In one or more embodiments (not shown), besides Figure 7 The heat exchanger shown at the furnace outlet (e.g., a delivery line heat exchanger or TLE), or alternatively with... Figure 10 Together with the exchanger at the furnace outlet shown, the cracked olefin-containing furnace effluent 119 can be cooled using a liquid quenching stream.

[0326] A cracker facility may have a single cracking furnace, or it may have at least two, three, four, five, six, seven, eight, or more cracking furnaces operating in parallel. Any furnace or each furnace may be a gas cracker, a liquid cracker, or a cracking furnace. In one embodiment, or in combination with any of the embodiments mentioned herein, the furnace is a gas cracker that receives a cracker feed stream through the furnace, or through at least one coil in the furnace, or through at least one tube in the furnace, the cracker feed stream containing at least 50 wt%, or at least 75 wt%, or at least 85 wt%, or at least 90 wt% of ethane, propane, LPG, or combinations thereof, based on the total weight of all cracker feed to the furnace.

[0327] In one embodiment or in combination with any of the mentioned embodiments, the furnace may be a liquid or naphtha cracker receiving a cracker feed stream, based on the weight of all cracker feed to the furnace, the cracker feed stream containing at least 50 wt%, or at least 75 wt%, or at least 85 wt% of liquid hydrocarbons having a carbon number of C5 to C22 (when measured at 25°C and 1 atm) passing through the furnace, or through at least one coil in the furnace, or through at least one tube in the furnace.

[0328] In one embodiment or in combination with any of the mentioned embodiments, the furnace may be a cracking furnace that receives a cracker feed stream containing at least 50 wt%, or at least 75 wt%, or at least 85 wt%, or at least 90 wt% of ethane, propane, LPG or a combination thereof passing through the furnace, or at least one coil in the furnace, or at least one tube in the furnace, and receives a cracker feed stream containing at least 0.5 wt%, or at least 0.1 wt%, or at least 1 wt%, or at least 2 wt%, or at least 5 wt%, or at least 7 wt%, or at least 10 wt%, or at least 13 wt%, or at least 15 wt%, or at least 20 wt% liquid and / or r-pyrolysis oil (when measured at 25°C and 1 atm), each based on the weight of all cracker feed to the furnace.

[0329] When the cracker furnace feed contains r-pyrolysis oil, the r-pyrolysis oil may be introduced into the cracker furnace or the furnace coils or tubes alone (e.g., in a stream containing at least 85, or at least 90, or at least 95, or at least 99, or 100 [wt% in each case] of pyrolysis oil – based on the weight of the cracker feed stream) or in combination with one or more other cracker furnace feed streams.

[0330] When introduced into the cracker furnace, coil, or tube along with the non-recovery cracker feed stream, the amount of r-pyrolysis oil present may be at least 1, or at least 2, or at least 5, or at least 8, or at least 10, or at least 12, or at least 15, or at least 20, or at least 25, or at least 30 (wt% in each case) and / or no more than 40, or no more than 35, or no more than 30, or no more than 25, or no more than 20, or no more than 15, or no more than 10, or no more than 8, or no more than 5, or no more than 2 (weight percentage in each case), based on the total weight of the combined stream.

[0331] Therefore, other cracker feed streams may be present in the combined stream in the following amounts: at least 20, or at least 25, or at least 30, or at least 35, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90 (in each case, by weight percentage) and / or no more than 99, or no more than 95, or no more than 90, or no more than 85, or no more than 80, or no more than 75, or no more than 70, or no more than 65, or no more than 60, or no more than 55, or no more than 50, or no more than 45, or no more than 40 (in each case, by weight percentage), based on the total weight of the combined stream. Unless otherwise stated herein, the characteristics of the cracker feed streams described below apply to cracker feed streams prior to (or not present in) combination with a stream containing r-pyrolysis oil, and to combined cracker streams comprising both another cracker feed and r-pyrolysis oil feed.

[0332] Back Figure 10 The cracker feed stream 160 can be introduced into the furnace coil 752 at or near the inlet of the convection section 746. The cracker feed stream 160 can then pass through at least a portion of the furnace coil 752a in the convection section 746, and dilution steam 162 can be added at some points to control the temperature and cracking severity in the radiant section 748.

[0333] The amount of steam added may depend on furnace operating conditions, including feed type and desired product distribution, but may be added to achieve a steam-to-hydrocarbon ratio in the range of 0.1 to 1.0, 0.15 to 0.9, 0.2 to 0.8, 0.3 to 0.75, or 0.4 to 0.6. The ratio of steam to hydrocarbons may be at least 0.25:1, at least 0.27:1, at least 0.30:1, at least 0.32:1, at least 0.35:1, at least 0.37:1, at least 0.40:1, at least 0.42:1, at least 0.45:1, at least 0.47:1, at least 0.50:1, at least 0.52:1, at least 0.55:1, at least 0.57:1, at least 0.60:1, at least 0.62:1, at least 0.65:1 and / or not exceeding 0.80:1, not exceeding 0.75:1, not exceeding 0.72:1, not exceeding 0.70:1, not exceeding 0.67:1, not exceeding 0.65:1, not exceeding 0.62:1, not exceeding 0.60:1, not exceeding 0.57:1, not exceeding 0.55:1, not exceeding 0.52:1, not exceeding 0.50:1.

[0334] In one embodiment or in combination with any of the mentioned embodiments, steam 162 can be used in the same furnace. Figure 10The separate boiler feed water / steam pipe (not shown) generates heat in the convection section. Steam can be added to the cracker feed stream 160 (or any intermediate cracker feed stream in the furnace) when the steam fraction of the cracker feed stream 160 is 0.60-0.95, or 0.65-0.90, or 0.70-0.90.

[0335] The heated cracker stream typically has the following temperatures: at least 500, or at least 510, or at least 520, or at least 530, or at least 540, or at least 550, or at least 560, or at least 570, or at least 580, or at least 590, or at least 600, or at least 610, or at least 620, or at least 630, or at least 640, or at least 650, or at least 660, or at least 670, or at least 680 (in °C in each case) and / or not exceeding 850, or not exceeding 840, or not exceeding 830, or not exceeding 820, or not exceeding 810, or not exceeding 800, or not exceeding 790, or not exceeding 780. The feed stream can then be delivered from the convection section of the furnace to the radiation section via the cross section, or within the range of 500 to 770, or 760, or 750, or 740, or 730, or 720, or 710, or 705, or 700, or 695, or 690, or 685, or 680, or 675, or 670, or 660, or 665, or 655°C, or 650°C (in each case, °C), or within the range of 500 to 710°C, 620 to 740°C, 560 to 670°C, or 510 to 650°C. At least a portion of the feed stream 160 (e.g., r-pyrolysis oil, when used) can be added to the cracker stream at the cross section 750.

[0336] The cracker feed stream then passes through a radiant section 748, where it is thermally cracked to form lighter hydrocarbons, including olefins such as ethylene, propylene, and / or butadiene. The residence time of the cracker feed stream in the radiant section 748 may be at least 0.1, or at least 0.15, or at least 0.2, or at least 0.25, or at least 0.3, or at least 0.35, or at least 0.4, or at least 0.45 (in seconds in each case) and / or no more than 2, or no more than 1.75, or no more than 1.5, or no more than 1.25, or no more than 1, or no more than 0.9, or no more than 0.8, or no more than 0.75, or no more than 0.7, or no more than 0.65, or no more than 0.6, or no more than 0.5 (in seconds in each case).

[0337] The temperature at the inlet of the furnace coil is at least 500, or at least 510, or at least 520, or at least 530, or at least 540, or at least 550, or at least 560, or at least 570, or at least 580, or at least 590, or at least 600, or at least 610, or at least 620, or at least 630, or at least 640, or at least 650, or at least 660, or at least 670, or at least 680 (in °C in each case) and / or not exceeding 850, or not exceeding 840, or not exceeding 830, or not exceeding 820, or not exceeding 810, or not exceeding 800, or not exceeding 790, or not exceeding 780, or not exceeding The temperature is above 770, or not exceeding 760, or not exceeding 750, or not exceeding 740, or not exceeding 730, or not exceeding 720, or not exceeding 710, or not exceeding 705, or not exceeding 700, or not exceeding 695, or not exceeding 690, or not exceeding 685, or not exceeding 680, or not exceeding 675, or not exceeding 670, or not exceeding 665, or not exceeding 660, or not exceeding 655, or not exceeding 650 (in each case, in °C), or within the range of 550 to 710 °C, 560 to 680 °C, or 590 to 650 °C, or 580 to 750 °C, 620 to 720 °C, or 650 to 710 °C.

[0338] The coil outlet temperature may be at least 640, or at least 650, or at least 660, or at least 670, or at least 680, or at least 690, or at least 700, or at least 720, or at least 730, or at least 740, or at least 750, or at least 760, or at least 770, or at least 780, or at least 790, or at least 800, or at least 810, or at least 820 (in °C in each case) and / or not exceeding 1000, or not exceeding 990, or not exceeding 980. Or not exceeding 970, or not exceeding 960, or not exceeding 950, or not exceeding 940, or not exceeding 930, or not exceeding 920, or not exceeding 910, or not exceeding 900, or not exceeding 890, or not exceeding 880, or not exceeding 875, or not exceeding 870, or not exceeding 860, or not exceeding 850, or not exceeding 840, or not exceeding 830 (in each case, °C), within the range of 730 to 900 °C, 750 to 875 °C, or 750 to 850 °C.

[0339] In one embodiment or in combination with any of the mentioned embodiments, the mass velocity of the cracker flow through the radiant coil is 60-165 kg / s per square meter (m²). 2 Cross-sectional area (kg / s / m) 2 ), 70-110 (kg / s / m 2 ) or 80-100 (kg / s / m 2Within the range of ), when steam is present, the mass velocity is based on the total flow rate of hydrocarbons and steam.

[0340] In one embodiment or in combination with any of the mentioned embodiments, the burner 756 in the radiant zone 748 provides an average heat flux of 60-160 kW / m² to the coil. 2 or 70-145kW / m 2 or 75-130kW / m 2 The maximum (hottest) coil surface temperature is within the range of 1035 to 1150°C, or 1060 to 1180°C. The pressure at the inlet of the furnace coil in radiant section 748 is within the range of 1.5 to 8 bar absolute pressure (bara) or 2.5 to 7 bara, while the outlet pressure of furnace coil 752b in radiant section 748 is within the range of 15 to 40 psia or 15 to 30 psia. The pressure drop across furnace coil 752b in radiant section 748 can be 1.5 to 5 bara, or 1.75 to 3.5 bara, or 1.5 to 3 bara, or 1.5 to 3.5 bara.

[0341] In one embodiment or in combination with any of the mentioned embodiments, the yield of olefins—ethylene, propylene, butadiene, or combinations thereof—may be at least 15, or at least 20, or at least 25, or at least 30, or at least 35, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, in each case as a percentage. As used herein, the term “yield” means the mass of the product produced from the feedstock / the mass of the feedstock × 100%. Based on the total weight of the effluent stream, the olefin-containing effluent 119 contains at least about 30, or at least 40, or at least 50, or at least 60, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 97, or at least 99 (in each case as a weight percentage) of ethylene, propylene, or ethylene and propylene.

[0342] In one embodiment or in combination with any of the embodiments mentioned, the olefin-containing effluent stream 119 may contain at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, or at least 90 wt% of C2 to C4 olefins. Based on the total weight of the olefin-containing stream, the stream may primarily contain ethylene, primarily contain propylene, or primarily contain both ethylene and propylene. The weight ratio of ethylene to propylene in the olefin-containing effluent may be at least 0.2:1, at least 0.3:1, at least 0.4:1, at least 0.5:1, at least 0.6:1, at least 0.7:1, at least 0.8:1, at least 0.9:1, at least 1:1, at least 1.1:1, at least 1.2:1, at least 1.3:1, at least 1.4:1, at least 1.5:1, at least 1.6:1, at least 1.7:1, at least 1.8:1, at least 1.9:1, or at least 2:1 and / or not exceeding 3:1, 2.9:1, 2.8:1, 2.7:1, 2.5:1, 2.3:1, 2.2:1, 2.1:1, 2:1, 1.7:1, 1.5:1, or 1.25:1.

[0343] In one embodiment or in combination with any of the mentioned embodiments, the cracked olefin-containing effluent 119 may include relatively small amounts of aromatic hydrocarbons and other heavy components. For example, based on the total weight of the stream, the olefin-containing effluent may include at least 0.5, at least 1, at least 2, or at least 2.5 wt% and / or no more than about 20, no more than 19, no more than 18, no more than 17, no more than 16, no more than 15, no more than 14, no more than 13, no more than 12, no more than 11, no more than 10, no more than 9, no more than 8, no more than 7, no more than 6, no more than 5, no more than 4, no more than 3, no more than 2, or no more than 1 wt% of aromatic hydrocarbons.

[0344] The ratio of olefins to aromatics (by weight) in the olefin-containing effluent may be at least 1.25:1, at least 1.5:1, at least 2:1, at least 3.1, at least 4:1, at least 5:1, at least 6:1, at least 7:1, at least 8:1, at least 9:1, at least 10:1, at least 11:1, at least 12:1, at least 13:1, at least 14:1, at least 15:1, at least 16:1, at least 17:1, at least 18:1, at least 19:1, at least 20:1, at least 21:1, at least 22:1, at least 23:1, at least 24:1, at least 25:1, to... The ratios are: at least 26:1, at least 27:1, at least 28:1, at least 29:1, or at least 30:1 and / or no more than 100:1, no more than 90:1, no more than 85:1, no more than 80:1, no more than 75:1, no more than 70:1, no more than 65:1, no more than 60:1, no more than 55:1, no more than 50:1, no more than 45:1, no more than 40:1, no more than 35:1, no more than 30:1, no more than 25:1, no more than 20:1, no more than 15:1, no more than 10:1, no more than 5:1, no more than 4:1, or no more than 3:1. As used herein, “olefin to aromatic hydrocarbon ratio” is the ratio of the total weight of C2 and C3 olefins to the total weight of aromatic hydrocarbons, as defined above. In one embodiment or in combination with any of the mentioned embodiments, the ratio of olefins to aromatics in the effluent stream can be at least 2.5:1, at least 2.75:1, at least 3.5:1, at least 4.5:1, at least 5.5:1, at least 6.5:1, at least 7.5:1, at least 8.5:1, at least 9.5:1, at least 10.5:1, at least 11.5:1, at least 12.5:1, or at least 13:5:1.

[0345] Additionally, or alternatively, the ratio of olefins to C6+ in the olefin-containing effluent may be at least 1.5:1, at least 1.75:1, at least 2:1, at least 2.25:1, at least 2.5:1, at least 2.75:1, at least 3:1, at least 3.25:1, at least 3.5:1, at least 3.75:1, at least 4:1, at least 4.25:1, at least 4.5:1, at least 4.75:1, at least 5:1, at least 5.25:1, at least 5.5:1, at least 5.75:1, at least 6:1, at least 6.25:1, at least 6.5:1, at least 6.75:1, at least 7:1, at least 7.25:1, at least 7.5:1, at least 7.75:1, at least 8:1, at least 8.25:1, at least 8.5:1, at least 8.75:1, or at least 9:1.

[0346] The olefin-containing stream may also include trace amounts of aromatic hydrocarbons. For example, the benzene content of the composition may be at least 0.25, at least 0.3, at least 0.4, at least 0.5 wt% and / or not more than about 2, 1.7, 1.6, 1.5 wt%. Additionally, or alternatively, the toluene content of the composition may be at least 0.005, at least 0.010, at least 0.015, or at least 0.020 and / or not more than 0.5, not more than 0.4, not more than 0.3, or not more than 0.2 wt%. Both percentages are based on the total weight of the composition. Alternatively, or additionally, the benzene content of the effluent may be at least 0.2, at least 0.3, at least 0.4, at least 0.5, or at least 0.55 and / or not more than about 2, 1.9, 1.8, 1.7, or 1.6 wt%, and / or the toluene content may be at least 0.01, at least 0.05, or at least 0.10 and / or not more than 0.5, not more than 0.4, not more than 0.3, or not more than 0.2 wt%.

[0347] In one embodiment or in combination with any of the mentioned embodiments, the olefin-containing effluent may contain acetylene. Based on the total weight of the effluent from the furnace, the amount of acetylene may be at least 2000 ppm, at least 5000 ppm, at least 8000 ppm, or at least 10,000 ppm. It may also not exceed 50,000 ppm, not exceed 40,000 ppm, not exceed 30,000 ppm, or not exceed 25,000 ppm.

[0348] In one embodiment or in combination with any of the mentioned embodiments, the olefin-containing effluent may contain methylacetylene and propadiene (MAPD). Based on the total weight of the effluent, the amount of MAPD may be at least 2 ppm, at least 5 ppm, at least 10 ppm, at least 20 ppm, at least 50 ppm, at least 100 ppm, at least 500 ppm, at least 1000 ppm, at least 5000 ppm, or at least 10,000 ppm. It may also not exceed 50,000 ppm, not exceed 40,000 ppm, or not exceed 30,000 ppm.

[0349] In some embodiments, the separation zone of a cracking facility may be divided into a processing section and a fractionation section. As used herein, the term "processing section" is a portion of the separation zone of a cracking facility used to cool, process, and compress an olefin-containing stream (which may include olefin-containing effluent from the cracking furnace) in preparation for fractionation in the fractionation section. The processing section may extend from the furnace outlet to the inlet of the first fractionation column in the fractionation section.

[0350] As used herein, the term "fractionation" refers to the separation of a mixture into its pure or purified components. Examples of equipment used to perform fractionation may include, but are not limited to: distillation columns, flash distillation columns, extraction vessels, stripping columns, rectification columns, membrane units, adsorption columns or vessels, and combinations thereof. In cracker facilities, a fractionation section may be configured to separate olefin-containing streams removed from the processing section to form various purified olefin and / or alkane streams. In one embodiment or in combination with any of the mentioned embodiments, a fractionation section may be configured to separate a stream comprising an olefin-containing effluent from the cracker furnace and / or a stream of r-pyrolysis gas.

[0351] Turning now to Figure 11a, a block diagram illustrating the main components of the separation zone processing section in the cracker facility is shown. Additionally, Figure 11b provides a schematic diagram of several steps in the quenching and compression zones depicted in Figure 11a.

[0352] Turning first to Figure 11a, when present, the olefin-containing effluent 119 from cracker 430 can be rapidly cooled (e.g., quenched) to prevent the generation of large amounts of undesirable byproducts and to minimize fouling in downstream equipment. In one embodiment or in combination with any of the mentioned embodiments, the temperature of the effluent 119 from the furnace can be reduced by 35 to 485°C, 35 to 375°C, or 90 to 550°C, down to a temperature of 500 to 760°C. The cooling step can occur immediately after the effluent leaves the furnace 430, for example within 1 to 30, 5 to 20, or 5 to 15 milliseconds. In summary, the cooling step can reduce the temperature of the olefin-containing effluent 119 by at least 25, at least 50, at least 75, at least 100, at least 125, at least 150, at least 175, at least 200, at least 225 or at least 250 °C and / or not more than 700, not more than 650, not more than 600, not more than 550, not more than 500, not more than 450 or not more than 400 °C.

[0353] In one embodiment or in combination with any of the mentioned embodiments, the quenching step may be carried out via indirect heat exchange with high-pressure water or steam in a heat exchanger, while in other embodiments, the quenching step is carried out by bringing the effluent into direct contact with the quenching liquid in stream 121 of a quenching tower (with or without internal tower components). The temperature of the quenching liquid stream 121 may be at least 65, or at least 80, or at least 90, or at least 100 (°C in each case) and / or not more than 210, or not more than 180, or not more than 165, or not more than 150, or not more than 135 (°C in each case).

[0354] When quenching liquid stream 121 is used, contact can occur in the quench tower of quenching zone 510, and the liquid stream containing gasoline and other hydrocarbon components with similar boiling ranges can be removed from the quench tower. In some cases, quenching liquid stream 121 can be used in quenching zone 510 when the cracker feed is mainly liquid, and a heat exchanger (not shown) can be used in quenching zone 510 when the cracker feed is mainly vapor.

[0355] As shown in Figure 11b, in one embodiment or in combination with any of the mentioned embodiments, the quenching zone 510 may include at least one fractionating column 612 (shown in Figure 11b) for separating at least a portion of the liquid phase of the cooled olefin-containing effluent, which is removed from the transfer line exchanger (TLE) 610 at the furnace outlet. The fractionating column 612 may be configured to separate the partially cooled olefin-containing effluent into an overhead vapor stream 180 rich in C6 and lighter, C7 and lighter, or C8 and lighter components, and a bottom liquid stream 182 rich in C7 and heavier, C8 and heavier, or C9 and heavier components (referred to as pyrolysis tar in Figure 11b). The resulting overhead vapor stream 180 may then be introduced into the quenching column 614, where, as discussed above, it may be further cooled by contact with the quenching liquid. The bottom liquid stream 182 from fractionation column 612, also known as pyrolysis tar, can be sent for further processing, transportation, storage and / or use.

[0356] Referring again to Figures 11a and 11b, the resulting cooled effluent from the quench tower 614 can then be separated in a knock-out drum (not shown in Figures 11a and 11b) so that the resulting vapor can be compressed in a gas compressor 620 having, for example, 1 to 10, 2 to 8, or 2 to 6 compression stages, each with optional interstage cooling and liquid removal. The pressure of the gas flow at the outlet of the first set of compression stages is in the range of 19 to 59 psig (1.3 to 4.0 barg), 21 to 49 psig (1.4 to 3.3 barg), or 24 to 46 psig (1.6 to 2.7 barg).

[0357] In one embodiment or in combination with any of the mentioned embodiments, the system may further include at least one additional separator (not shown in FIG. 11b) for further separating at least a portion of the liquid stream containing heavy components removed from one or more vapor-liquid separators located before or between compression stages of a gas compressor (shown as a single vapor-liquid separator 618 in FIG. 11b). Although shown in FIG. 11b as including only a single compression stage and vapor-liquid separator, it should be understood that the compression system includes multiple compression stages, with the vapor-liquid separator preceding each stage or group of stages. The vapor-liquid separator may be upstream of one or more of the first, second, third, fourth, fifth, sixth, or seventh compression stages of the gas compressor 620. The liquid stream from the vapor-liquid separator 1188 may include condensate, such as aqueous condensate and / or organic condensate.

[0358] When present, liquid streams 188 from each of these vapor-liquid separators can be combined with each other (and optionally with all or part of the bottom stream from the gasoline fractionation column in stream 182) to form combined streams. Alternatively, liquid streams 188 may originate from a single container.

[0359] Additionally, all or part of the heavy fraction removed from the gas-liquid separator in line 182 can be further separated into at least a top vapor stream and a bottom liquid stream in another separator (not shown in Figure 11b). The liquid fraction removed from the bottom of separator 612 may primarily contain C4 and heavier, C5 and heavier, or C6 and heavier hydrocarbons, and may include or be used to form a recovered component gasoline composition (r-pyrolysis gasoline).

[0360] In some cases, based on the total weight of the flow 182, the liquid flow in the pipeline 182 may contain at least 1, at least 2, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90 or at least 95 wt% and / or no more than 99, no more than 97, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40 or no more than 35 wt% of r-pyrolytic gasoline. In one embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the r-pyrolysis gasoline stream 182 can be further separated into light and heavy fractions in another fractionating column (not shown in FIG. 11b), and one or both can be used in downstream processes, such as for forming resins used in adhesives, fuels, polymers, plasticizers, or combinations thereof.

[0361] Turn now Figure 12An embodiment of a chemical recovery facility including a pyrolysis facility 410 and a cracker facility 420 is provided, with particular illustration of various locations downstream of the cracker furnace 430 where a stream containing r-pyrolysis gas 110 can be introduced into the cracker facility 420. Typically, as... Figure 12 As shown, the r-pyrolysis gas stream 110 can be introduced into the cracker facility at a location downstream of the cracker furnace outlet. In one embodiment or in combination with any of the mentioned embodiments, this location can be upstream of the fractionation section (e.g., upstream of the inlet of the first vessel or tower in the fractionation section).

[0362] like Figure 12 As shown, a stream 100 containing waste plastics can be introduced into a pyrolysis facility 410, where it can be pyrolyzed to form an r-pyrolysis gas stream 110 and an r-pyrolysis oil stream 112. The pyrolysis facility 410 can be any pyrolysis facility suitable for processing waste plastics or streams derived from waste plastics, and can include one or more features or characteristics described herein.

[0363] In some embodiments, pyrolysis facility 410 may be part of a larger chemical recycling facility that may include one or more upstream facilities. For example, the larger chemical recycling facility may be configured to receive mixed plastic waste, which may be sorted in a pretreatment facility to provide a stream of PET-enriched waste plastics and a stream of PO-enriched waste plastics. At least a portion of the mixed plastic waste, PET-enriched waste plastics, and / or PO-enriched plastics may be introduced into pyrolysis facility 410 in or as feed stream 100.

[0364] In one embodiment or in combination with any of the mentioned embodiments, the PET enrichment stream is rich in PET concentration relative to the PET concentration in the MPW stream or the PET-depleted stream, or both, on an undiluted solids dry basis. For example, if the PET enrichment stream is diluted with a liquid or other solid after separation, the enrichment will be based on the concentration in the undiluted PET enrichment stream, on a dry basis. In one embodiment or in combination with any of the mentioned embodiments, the percentage of PET enrichment in the PET enrichment stream relative to the MPW stream, the PET-depleted stream, or both, is determined by the following formula: and Where PETe is the concentration of PET in the PET enrichment stream, based on undiluted dry weight; and PETm is the concentration of PET in the MPW stream, based on dry weight; and PETd is the concentration of PET in the PET-depleted stream, based on dry weight. In one embodiment or in combination with any of the mentioned embodiments, the PET enrichment stream is also enriched with halogens, such as fluorine (F), chlorine (Cl), bromine (Br), iodine (I), and astatine (At), and / or halogen-containing compounds, such as PVC, relative to the halogen concentration in the MPW stream or the PET depleted stream or both. In one embodiment or in combination with any of the mentioned embodiments, the PVC enrichment percentage of the PET enrichment stream relative to the MPW stream is determined by the following formula: and Where PVCe is the concentration of PVC in the PET enriched stream, based on undiluted dry weight; and PVCm is the concentration of PVC in the MPW stream, based on undiluted dry weight, and Where PVCd is the concentration of PVC in the PET lean stream, based on undiluted dry weight; and Due to the separation of polyolefins from PET, the PET-deficient stream is rich in polyolefins on an undiluted solids dry basis relative to the concentration of polyolefins in the MPW feed or the PET enriched stream or both. In one embodiment or in combination with any of the mentioned embodiments, the percentage of polyolefin enrichment in the PET-deficient stream relative to the MPW stream or relative to the PET enriched stream or both is determined by the following formula: and Where POd is the concentration of polyolefin in the PET lean stream, based on undiluted dry weight; and POm is the concentration of PO in the MPW stream, based on dry weight, and POe is the concentration of PO in the PET enrichment stream.

[0365] In one embodiment or in combination with any other embodiment, the PET depleted stream is also depleted of halogens, such as fluorine (F), chlorine (Cl), bromine (Br), iodine (I), and astatine (At), and / or halogen-containing compounds, such as PVC, relative to the halogen concentration in the MPW stream, the PET enriched stream, or both. In one embodiment or in combination with any of the mentioned embodiments, the PVC depletion percentage of the PET depleted stream relative to the MPW stream or the PET enriched stream is at least 1%, at least 3%, at least 5%, at least 7%, at least 10%, at least 15%, at least 20%, at least 25%, at least 30%, at least 35%, at least 40%, at least 50%, at least 60%, at least 65%, at least 70%, at least 75%, at least 80%, at least 85%, or at least 90%, determined by the following formula: and Where PVCm is the concentration of PVC in the MPW stream, based on undiluted dry weight; PVCd is the concentration of PVC in the PET lean stream, based on undiluted dry weight; and PVCe is the concentration of PVC in the PET enriched stream, based on undiluted dry weight.

[0366] In one embodiment or in combination with any other embodiment, the PET-depleted stream is also PET-depleted relative to the PET concentration of the MPW stream, the PET-enriched stream, or both. In one embodiment or in combination with any mentioned embodiment, the PET depletion percentage of the PET-depleted stream relative to the MPW stream or the PET-enriched stream is determined by the following formula: and Where PETm is the concentration of PET in the MPW stream, based on undiluted dry weight; PETd is the concentration of PET in the PET-deficient stream, based on undiluted dry weight; and PETe is the concentration of PET in the PET enriched stream, based on undiluted dry weight.

[0367] In one embodiment or in combination with any of the mentioned embodiments, the PET enrichment stream 20 is depleted of nylon relative to the PET depletion stream 30. The PET enrichment stream 20 may be depleted in terms of nylon atoms by at least 10%, or at least 25%, or at least 40%, or at least 50%, or at least 60%, or at least 70%, or at least 80%, or at least 85%, or at least 90%, or at least 95%, or at least 97%, or at least 98%, in each case, based on the weight percentage of nitrogen atoms in a single stream relative to the nylon atom concentration in the PET depletion stream 30. Sampling methods may include random sampling from each stream, optionally taking two samples from each stream every 24 hours over two weeks, and drying to a moisture content of less than 10 wt%. The formula for performing this calculation is shown in Formula 1: in: wt%N is the weight percentage of nylon atoms in the stream. dPET is a PET-deficient flow, and ePET is a PET enrichment stream. Compared to MPW 10 stream, PET enrichment stream 20 can be depleted of nylon atom concentration, using the same concentration as stated above, and the same formula, replacing wt%NePET in Formula 1 with wt%NMPW (weight percentage of nylon atoms in MPW stream).

[0368] In one embodiment or in combination with any of the embodiments mentioned, the PET depleted stream 30 is enriched with nylon atom concentration relative to the PET enriched stream 20. The nylon atom concentration of the PET depleted stream 30 may be enriched to at least 10%, or at least 25%, or at least 50%, or at least 75%, or at least 100%, or at least 150%, or at least 200%, or at least 250%, or at least 300%, or at least 350%, or at least 400%, or at least 450%, or at least 500%, or at least 600%, or at least 700%, or at least 800%, or at least 1000%, in each case calculated based on the weight percentage of nitrogen atoms in a single stream relative to the nylon atom concentration in the PET enriched stream 20. Sampling methods may include random sampling from each stream, optionally taking two samples from each stream every 24 hours over two weeks. The formula for performing this calculation is according to Formula 2: in: wt%N is the weight percentage of nylon atoms in the stream. dPET is a PET-deficient flow, and ePET is a PET enrichment stream. Using the same Formula 2, but replacing wt%NePET in Formula 2 with wt%NMPW (weight percentage of nylon atoms in the MPW stream), the PET-depleted stream 30 can enrich the nylon atom concentration by at least 10%, or at least 25%, or at least 40%, or at least 50%, or at least 60%, or at least 70%, or at least 80%, or at least 85%, or at least 90%, relative to the nylon atom concentration in the MPW 10 stream.

[0369] In any of the above embodiments, the percentage of enrichment or depletion can be an average over one week, three days, or one day, and can be measured to reasonably correlate the sample taken out at the process outlet with the MPW volume, taking into account the residence time of the MPW from the inlet flow to the outlet in the MPW sample. For example, if the average residence time of the MPW is 2 minutes, the outlet sample is taken out two minutes after the inlet sample, thus correlating the samples with each other.

[0370] In one embodiment or in combination with any of the mentioned embodiments, at least a portion of PET-enriched waste plastics and / or at least a portion of PO-enriched waste plastics may be fed to another chemical recycling facility, and one or more streams from that chemical recycling facility may be introduced as feed or together with the feed into a pyrolysis facility. Examples of other chemical recycling facilities may include, but are not limited to: solvent decomposition facilities, partial oxidation (POX) vaporization facilities, curing facilities, and combinations thereof.

[0371] Additionally, or alternatively, at least one stream from pyrolysis facility 410 may be introduced as feed to or as part of the feed to the facility into one or more of the solvent decomposition facility, partial oxidation (POX) gasification facility, and solidification facility. The stream introduced into one or more of these facilities may contain γ-pyrolysis oil, γ-pyrolysis gas, or a combination thereof.

[0372] Back Figure 12 The r-pyrolysis gas stream 110 can be introduced into one or more locations within the cracker facility 420. In one embodiment or in combination with any of the mentioned embodiments, at least a portion of the r-pyrolysis gas stream 110 can be introduced into a location within the cracker facility 420 upstream of the compressor 450 within the processing section. When introduced upstream of the compressor 450, the r-pyrolysis gas can optionally be combined with an olefin-containing effluent stream from the cracker furnace 430. The combined stream can be introduced into a compressor, heat exchanger, vessel such as an alkaline scrubber, or a combination thereof.

[0373] In one embodiment or in combination with any of the mentioned embodiments, the compressor 450 in the processing section of the pyrolysis facility may be a multi-stage compressor having, for example, at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9 or at least 10 stages and / or no more than 15, no more than 14, no more than 13, no more than 12, no more than 11, no more than 10, no more than 9, no more than 8, no more than 7, no more than 6 or no more than 5 compression stages.

[0374] At least a portion of the r-pyrolysis gas flow 110 may be introduced upstream of one or more compression stages and / or downstream of at least one compression stage. In one embodiment or in combination with any of the mentioned embodiments, at least a portion of the r-pyrolysis gas flow 110 may be introduced upstream of the last stage of the compressor. In one embodiment or in combination with any of the mentioned embodiments, at least a portion of the r-pyrolysis gas flow may be introduced between stages 1-3, between stages 3-5, and / or between stages 5-7 of a multi-stage compressor. In one or more other embodiments, at least a portion of the r-pyrolysis gas flow 110 may be introduced downstream of the compressor 450 outlet and may optionally be compressed in a separate compressor 452 prior to introduction into the cracker facility.

[0375] In one embodiment or in combination with any of the mentioned embodiments, at least a portion of the r-pyrolysis gas flow 110 may be introduced downstream of the heat exchanger 610 and / or downstream of at least one fractionation tower or vessel. For example, at least a portion of the r-pyrolysis gas may be introduced upstream of the quench tower 614 and / or the gasoline fractionation tower 612, while in other embodiments, at least a portion of the r-pyrolysis gas may be introduced downstream of the quench tower 614 and / or the gasoline fractionation tower 612.

[0376] In one embodiment or in combination with any of the mentioned embodiments, at least a portion of the r-pyrolysis gas stream 110 may be introduced into the cracker facility immediately upstream of the outlet of the cracker furnace 430, including, for example, an outlet heat exchanger 610 (e.g., a delivery line exchanger or TLE). Alternatively, or additionally, at least a portion of the r-pyrolysis gas stream 110 may be introduced into the cracker facility 420 downstream of the furnace outlet exchanger 610 and / or may optionally have passed through a separate heat exchanger 611 prior to being introduced into the cracker facility 420.

[0377] In one embodiment or in combination with any of the mentioned embodiments, the temperature of at least a portion of the r-pyrolysis gas stream 110 introduced at a location within the cracker facility 420 may be at least 300, at least 350, at least 400, at least 450, at least 500, at least 550 and / or not exceeding about 700, not exceeding 650, not exceeding 600, not exceeding 550, not exceeding 500, not exceeding 450°C. Alternatively, or additionally, the temperature of at least a portion of the r-pyrolysis gas stream introduced at a location within the cracker facility 420 may be at least 100, at least 150, at least 200 and / or not exceeding 350, not exceeding 300, not exceeding 250°C.

[0378] The temperature of at least a portion of the r-pyrolysis gas stream 110 introduced into a location of cracker facility 420 may be at least 500, at least 550, at least 600, at least 650, at least 700, at least 750°C and / or not exceeding about 1000, not exceeding 950, not exceeding 900, not exceeding 850, not exceeding 800°C. In one embodiment or in combination with any of the mentioned embodiments, the temperature of at least a portion of the r-pyrolysis gas stream 110 introduced into a location of cracker facility 420 may be at least 25, at least 50, at least 75 and / or not exceeding 150, not exceeding 100, not exceeding 75°C.

[0379] In one embodiment or in combination with any of the embodiments mentioned, the pressure of at least a portion of the r-pyrolysis gas flow 110 introduced at a location within the cracker facility 420 may be at least 25 (1.73 barg), at least 50 (3.5 barg), at least 75 (5.2 barg) and / or no more than 100 (6.89 barg), no more than 75 (5.1 barg), no more than 50 (3.45 barg), all in psig. Additionally, or alternatively, the pressure of at least a portion of the r-pyrolysis gas flow 110 introduced upstream of the compressor 450 may not exceed 350 (24.1 barg), 300 (20.67 barg), 275 (18.9 barg), 250 (17.2 barg), 225 (15.5 barg), 200 (13.78 barg), 175 (12.1 barg), 150 (10.3 barg), or 125 (8.6 barg), 100 (6.89 barg), 75 (5.2 barg), 50 (3.5 barg), 25 (1.73 barg), or 10 (0.69 barg), all in psig or at atmospheric pressure.

[0380] In one embodiment or in combination with any of the mentioned embodiments, the pressure of at least a portion of the r-pyrolysis gas flow 110 may be at least 450 (31 barg), 500 (34.5 barg), 550 (37.9 barg) and / or no more than about 650 (44.8 barg), no more than 600 (41.3 barg), and no more than 550 (37.9 barg), all in psig. The pressure of at least a portion of the r-pyrolysis gas flow 110 may be no more than 500 (34.5 barg), no more than 450 (31.0 barg), no more than 400 (27.6 barg), no more than 350 (24.1 barg), no more than 300 (20.7 barg), no more than 250 (17.2 barg), no more than 200 (13.8 barg), no more than 150 (10.3 barg), or no more than 100 (6.89 barg), all in psig.

[0381] like Figure 12 As shown, the r-pyrolysis gas stream 110 can also be combined with a portion of the recovered alkane stream 130 taken from the fractionation section 460 and returned to the inlet of the cracker furnace 430. The recovered alkane stream 130 may be enriched with at least one alkane, such as ethane or propane, and may be returned in whole or in part to the inlet of the cracker furnace 430 for additional processing.

[0382] Turn now Figure 13-15 A schematic diagram of the main steps of fractionation section 460 is provided, which is used to separate the olefin-containing stream 119 leaving the quench zone.

[0383] In one embodiment or in combination with any of the embodiments mentioned, the feed stream 119 to the initial column of the fractionation section 460 of the cracker facility may include at least a portion of the olefin-containing effluent 119 from the quench zone (downstream of the furnace) and may also include at least a portion of the r-pyrolysis gas stream 110.

[0384] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the stream, the feed stream to the first tower comprises at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90 or at least 95 and / or no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25 or no more than 20 wt% of olefins. The olefins may consist primarily of propylene and / or primarily of ethylene.

[0385] Based on the total weight of the stream, the feed stream contains at least about 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50 and / or no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40 or no more than 35 wt% of ethylene. Based on the total weight of the stream, the feed stream may contain at least about 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50 and / or no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40 or no more than 35 wt% of propylene.

[0386] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the stream, the feed stream contains at least 5, at least 10, at least 15, at least 20, or at least 25 and / or no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, or no more than 20 wt% ethane. The weight ratio of ethylene to ethane in the feed stream can be greater than 1:1, greater than 1.01:1, greater than 1.05:1, greater than 1.10:1, greater than 1.15:1, or greater than 1.2:1.

[0387] In one embodiment or in combination with any of the mentioned embodiments, the feed stream contains at least about 5, at least 10, at least 15, at least 20, at least 25 and / or no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25 or no more than 20 wt% propane, based on the total weight of the stream. In one embodiment or in combination with any of the mentioned embodiments, the weight ratio of propylene to propane in the feed stream may be greater than 1:1, at least 1.01:1, at least 1.05:1, at least 1.10:1, at least 1.15:1 or at least 1.2:1.

[0388] In one embodiment or in combination with any of the mentioned embodiments, the feed stream contains at least about 5, at least 10, at least 15, at least 20, at least 25 and / or no more than 60, no more than 55, no more than 50, no more than 45, no more than 40 or no more than 35 wt% propane, based on the total weight of the stream.

[0389] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the stream, the feed stream to the first column of the fractionation section contains at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55 and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15 or no more than 10 wt% of methane and lighter components. Based on the total weight of the stream, the feed stream contains at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55 and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15 or no more than 10 wt% of C2 and heavier components.

[0390] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the stream, the feed stream to the first column of the fractionation section contains at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55 and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15 or no more than 10 wt% of C2 and lighter components.

[0391] Based on the total weight of the stream, the feed stream may contain at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55 and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15 or no more than 10 wt% of C3 and heavier components.

[0392] In one embodiment or in combination with any of the embodiments mentioned, based on the total weight of the stream, the feed stream to the first column of the fractionation section may contain at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55 and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15 or no more than 10 wt% of C3 and lighter components. Based on the total weight of the stream, the feed stream contains at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55 and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15 or no more than 10 wt% of C4 and heavier components.

[0393] In one embodiment or in combination with any of the mentioned embodiments, the feed stream may have no more than about 5, no more than 3, no more than 2, no more than 1, no more than 0.5, no more than 0.1, no more than 0.05, or no more than 0.01 wt% aromatic hydrocarbons, based on the total weight of the stream. In some cases, if the column feed stream does not contain r-pyrolysis gas, all other things being equal, the feed stream may contain at least 1, at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95% less aromatic hydrocarbons.

[0394] Based on the total weight of the stream, the feed stream may contain no more than 1, 0.75, 0.50, 0.25, or 0.10 ppm of water. Based on the total weight of the stream, the feed stream may contain no more than 1500, 1250, 1000, 750, 500, 250, 100, 75, 50, or 25 ppm of benzene.

[0395] In one embodiment or in combination with any of the mentioned embodiments, the vapor fraction of the feed stream to the first column of the fractionation section may be at least 0.90, at least 0.92, at least 0.95, at least 0.97, or at least 0.99. The feed stream may be compressed gas or, when introduced into the column, may be pressurized liquid. The pressure of the feed flow to the tower can be at least 150 (10.3 barg), at least 200 (13.8 barg), at least 250 (17.2 barg), at least 300 (20.7 barg), at least 350 (24.1 barg), at least 400 (27.6 barg), or at least 450 (31.0 barg) and / or not exceeding 1000 (68.9 barg), not exceeding 950 (65.5 barg), not exceeding 900 (62.0 barg), not exceeding 850 (58.6 barg), not exceeding 800 (55.1 barg), not exceeding 750 (51.7 barg), not exceeding 700 (48.2 barg), not exceeding 650 (44.7 barg), not exceeding 600 (41.3 barg), not exceeding 550 (37.8 barg), not exceeding 500 (34.5 barg), not exceeding 450 (31.0 barg) (barg), not exceeding 400 (27.6 barg), or not exceeding 350 (24.1 barg), all in psig.

[0396] The combined stream can then be introduced into the dealkylation tower, which may contain at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90 or at least 95 wt% and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10 or no more than 5 wt% of an olefin-containing stream or a pyrolysis stream.

[0397] As used herein, the term "dealkylation column" refers to a fractionating column used to separate a feed stream into a top stream rich in the target alkane and a bottom stream leaning in the target alkane. For example, a demethanization column is a fractionating column used to separate a feed stream into a top stream rich in methane and a bottom stream leaning in methane. Examples of dealkylation columns suitable for embodiments of this technology may include, but are not limited to: demethanization columns (target alkane is methane), deethanerization columns (target alkane is ethane), depropanization columns (target alkane is propane), and debutanization columns (target alkane is butane). One or more dealkylation columns may be used in combination to provide a product stream of the desired composition.

[0398] In one embodiment or in combination with any of the mentioned embodiments, based on the total weight of the feed stream, the feed to the dehydrogenator may contain at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90 or at least 95 wt% and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10 or no more than 5 wt% of olefins.

[0399] In some cases, at least some or most of the olefins may end up in the overhead stream, while in other cases, at least some or most of the olefins may end up in the bottom stream. In one embodiment or in combination with any of the embodiments mentioned, based on the total weight of the overhead or bottom stream, at least one of the bottom and overhead streams from the dealkylation column may contain at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50 or at least 55 wt% and / or no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10 or no more than 5 wt% of olefins.

[0400] The separation zone 440 can have any configuration suitable for separating the desired components from the feed stream and providing one or more olefin and alkane product streams. Figure 13-15 Several possible configurations are illustrated in the diagrams. Specifically, Figure 13 First, let's describe the separation zone with a demethanizer. Figure 14 First, let's explain the separation zone with the ethane stripper. Figure 15 First, the separation zone with a propane stripper will be described. The common components of these configurations and the operating conditions of each configuration will be discussed in further detail below.

[0401] In one embodiment or in combination with any of the mentioned embodiments, the overhead stream 190 from the demethanizer 210 may contain no more than 35, 30, 25, 20, 15, 10, 5, 2, or 1 wt% olefins, based on the total weight of the overhead stream 190. The bottom stream 192 from the demethanizer 210 may contain at least 5, 10, 15, 20, 25, 30, 35, 40, or 45 wt% and / or no more than 85, 80, 75, 70, 65, 60, 55, 50, 45, or 40 wt% olefins, based on the total weight of the bottom stream 192. Based on the total weight of the olefins in the bottom stream 192, the olefins in the bottom stream 192 may contain at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% of ethylene and propylene.

[0402] In one embodiment or in combination with any of the mentioned embodiments, the overhead stream 194 from the deethanizer 220 may contain at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40 or at least 45 wt% and / or no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45 or no more than 40 wt% of olefins, based on the total weight of the overhead stream 194. Based on the total weight of the olefins in the overhead stream 194, the olefins in the overhead stream 194 may contain at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75 or at least 80 and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80 or no more than 75 wt% of ethylene.

[0403] In one embodiment or in combination with any of the mentioned embodiments, the bottom stream 196 from the deethanizer 220 may contain at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40 or at least 45 wt% and / or no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45 or no more than 40 wt% of olefins, based on the total weight of the bottom stream 196. Based on the total weight of the olefins in the bottom stream 196, the olefins in the bottom stream 196 may contain at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75 or at least 80 and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80 or no more than 75 wt% of propylene.

[0404] In one embodiment or in combination with any of the mentioned embodiments, the bottom stream 200 from the depropanizer 230 may contain no more than 35, 30, 25, 20, 15, 10, 5, 2, or 1 wt% olefins, based on the total weight of the bottom stream 200. The overhead stream 202 from the depropanizer 230 may contain at least 5, 10, 15, 20, 25, 30, 35, 40, or 45 wt% and / or no more than 85, 80, 75, 70, 65, 60, 55, 50, 45, or 40 wt% olefins, based on the total weight of the overhead stream 202. Based on the total weight of olefins in the overhead stream 202, the olefins in the overhead stream 202 may contain at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% of ethylene and propylene.

[0405] In one embodiment or in combination with any of the mentioned embodiments, the fractionation zone of the cracker facility may include at least one olefin-alkane fractionation column for separating the target olefin from a stream containing the target olefin and a corresponding number of alkanes. For example, the olefin-alkane fractionation column may be an ethylene-ethane fractionation column (or an ethylene splitter or ethylene fractionation column) configured to provide an ethylene-rich overhead stream and an ethylene-lean bottom stream. Using an ethylene splitter, the bottom stream can be ethane-rich, while the overhead stream can be ethylene-lean.

[0406] Similarly, when an olefin-alkane fractionation column is configured to separate propylene (propylene-propane fractionation column, propylene splitter, or propylene fractionation column), the overhead stream can be rich in propylene (and the bottom stream can be lean in propylene), and the bottom stream can be rich in propane (and the overhead stream can be lean in propane).

[0407] Start Reference Figure 13-15 From the rapid cooling zone ( Figure 13-15 An olefin-containing feed stream 119 (not shown) can be introduced into the initial column of the fractionation zone or fractionation system. In one embodiment or in combination with any of the mentioned embodiments, the initial column of the fractionation system can be as follows: Figure 13 The demethanizer shown, such as Figure 14 The deethaner shown or such Figure 15 The depropane tower shown can be another tower, such as a debutane tower.

[0408] When the tower is a demethanizing tower ( Figure 13In this process, methane and lighter (CO, CO2, H2) components are separated from ethane and heavier components. The demethanizer 210 can operate at temperatures of at least -145, or at least -142, or at least -140, or at least -135 (°C in each case) and / or no more than -120, no more than -125, no more than -130, no more than -135°C. The bottom stream 192 from the demethanizer 210 is then introduced into the deethanizer 220, which comprises at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 99% of the total amount of ethane and heavier components introduced into the deethanizer 210, as a percentage in each case. In the deethanizer 220, C2 and lighter components are separated from C3 and heavier components by fractionation.

[0409] Deethanizer 220 can operate at the following overhead temperatures and pressures: overhead temperatures of at least -35, or at least -30, or at least -25, or at least -20 (°C in each case) and / or not exceeding -5, not exceeding -10, not exceeding -15, or not exceeding -20°C; and overhead pressures of at least 3, or at least 5, or at least 7, or at least 8, or at least 10 (barg in each case) and / or not exceeding 20, or not exceeding 18, or not exceeding 17, or not exceeding 15, or not exceeding 14, or not exceeding 13 (barg in each case). Deethanizer 220 recovers at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 97, or at least 99 (percentage in each case) of the total amount of C2 and lighter components introduced into 220 in the overhead stream.

[0410] In one embodiment or in combination with any of the embodiments mentioned, the overhead stream 194 removed from the deethaner 220 contains at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95 (in each case, by weight percentage) of ethane and ethylene, based on the total weight of the overhead stream 194.

[0411] like Figure 13 As shown, C2 and the lighter overhead stream from the deethaner 220 can be further separated in the ethane-ethylene fractionation column 222 (ethylene fractionation column). In the ethane-ethylene fractionation column 222, ethylene and the lighter component stream 198 can be taken from the top of the column or as a side stream from the upper part of the column, while ethane and any remaining heavier components can be removed in the bottom stream 199.

[0412] Ethylene fractionation column 222 can operate at the following overhead temperatures and pressures: overhead temperatures of at least -45, or at least -40, or at least -35, or at least -30, or at least -25, or at least -20 (°C in each case) and / or not exceeding -15, or not exceeding -20, or not exceeding -25 (°C in each case); and overhead pressures of at least 10, or at least 12, or at least 15 (barg in each case) and / or not exceeding 25, not exceeding 22, not exceeding 20 barg. The ethylene-rich overhead stream 198 may contain at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 97, or at least 98, or at least 99 (by weight in each case) of ethylene—based on the total weight of stream 198—and may be sent to downstream processing units for further processing, storage, or sale. The overhead ethylene stream 198 may contain an γ-ethylene composition or stream. In one embodiment or in combination with any of the embodiments mentioned, the r-ethylene stream can be used to prepare one or more petrochemical products.

[0413] The bottom stream 199 from the ethane-ethylene fractionation column 222 may include at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 98 (in each case, by weight percentage) of ethane, based on the total weight of the bottom stream 199. As discussed above, all or part of the recovered ethane may be recycled to the cracker furnace as an additional feedstock, either alone or in combination with the cracker feed stream.

[0414] The liquid bottom stream 196 discharged from the deethaner 220 may be rich in C3 and heavier components, which can be separated in the depropanizer 230, such as... Figure 13 As shown. In the propane stripper 230, C3 and lighter components are removed as overhead vapor stream 202, while C4 and heavier components can exit the column in liquid bottom stream 200. The propane stripper 230 can operate at the following overhead temperatures and pressures: overhead temperature of at least 20, or at least 35, or at least 40 (°C in each case) and / or not exceeding 70, not exceeding 65, not exceeding 60, not exceeding 55°C; and overhead pressure of at least 10, or at least 12, or at least 15 (barg in each case) and / or not exceeding 20, or not exceeding 17, or not exceeding 15 (barg in each case).

[0415] The depropanizer 230 recovers at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 97, or at least 99 (in each case, a percentage) of the total amount of C3 and lighter components introduced into the 230 in the overhead stream 202. In one embodiment or in combination with any of the mentioned embodiments, the overhead stream 202 removed from the depropanizer 230 contains at least or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 98 (in each case, a weight percentage) of propane and propylene based on the total weight of the overhead stream 202.

[0416] The overhead stream 202 from the propane stripper 230 is introduced into the propane-propylene fractionation column 232 (propylene fractionation column), where propylene and any lighter components are removed in the overhead stream 204, while propane and any heavier components exit the column in the bottom stream 206. The propylene fractionation column 232 can operate at the following overhead temperatures and pressures: an overhead temperature of at least 20, or at least 25, or at least 30, or at least 35 (°C in each case) and / or not exceeding 55, not exceeding 50, not exceeding 45, not exceeding 40°C; and an overhead pressure of at least 12, or at least 15, or at least 17, or at least 20 (barg in each case) and / or not exceeding 20, or not exceeding 17, or not exceeding 15, or not exceeding 12 (barg in each case).

[0417] The propylene-rich overhead stream 204 may contain at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 97, or at least 98, or at least 99 (in each case, by weight percentage) of propylene—based on the total weight of stream 204—and may be sent to downstream processing units for further processing, storage, or sale. The overhead propylene stream 204 generated during the cracking of a cracker feedstock containing r-pyrolysis oil is an r-propylene composition or stream. This stream can be used to manufacture one or more petrochemical products.

[0418] The bottom stream 206 from the propane-propylene fractionation column 232 may include at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 98 (in each case, by weight percentage) of propane – based on the total weight of the bottom stream 206. As discussed above, all or part of the recovered propane may be recycled to the cracker as an additional feedstock, either alone or in combination with r-pyrolysis oil.

[0419] In one embodiment or in combination with any of the mentioned embodiments, the bottom stream 200 from the depropanizer 230 may be fed to the debutanizer for separating the C4 component (including butene, butane, and butadiene) from the C5+ component. The debutanizer (when present) may operate at the following top temperature and pressure: a top temperature of at least 20, or at least 25, or at least 30, or at least 35, or at least 40 (°C in each case) and / or not exceeding 60, or not exceeding 65, or not exceeding 60, or not exceeding 55, or not exceeding 50 (°C in each case); and a top pressure of at least 2, or at least 3, or at least 4, or at least 5 (barg in each case) and / or not exceeding 8, or not exceeding 6, or not exceeding 4, or not exceeding 2 (barg in each case). The butane removal column recovers at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 97, or at least 99 (in each case, as a percentage) of the total amount of C4 and lighter components introduced into the column in the overhead stream.

[0420] In one embodiment or in combination with any of the mentioned embodiments, the overhead stream removed from the debutanizer contains at least 30, or at least 35, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95 (in each case, by weight percentage) of butadiene—based on the total weight of the overhead stream. The overhead stream generated during the cracking of the cracker feedstock may be a composition of γ-butadiene or a stream. The bottom stream from the debutanizer primarily comprises C5 and heavier components, in an amount of at least 50, or at least 60, or at least 70, or at least 80, or at least 90, or at least 95 wt% based on the total weight of the stream. The bottom stream from the debutanizer may be sent for further separation, processing, storage, sale, or use.

[0421] The overhead stream from the butane debutane tower or multiple C4 streams can be subjected to any conventional separation method—such as extraction or distillation—to recover a more concentrated butadiene stream.

[0422] like Figure 13-15As shown, at least a portion of the r-pyrolysis gas stream 110 can be combined with the olefin-containing effluent stream 119 introduced into the first fractionation tower. In one embodiment or in combination with any of the mentioned embodiments, the feed stream to the first fractionation tower may contain at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, or at least 70 wt% and / or no more than about 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, or no more than 35 wt% of r-pyrolysis gas. The remaining feed, when present, may contain olefin-containing effluent 119 from one or more cracker furnaces as previously discussed in detail.

[0423] In one embodiment or in combination with any of the embodiments mentioned, the capacity and / or efficiency of one or more distillation columns in the fractionation zone can be increased by introducing r-pyrolysis gas into the cracker facility, said distillation columns including, for example, demethanizers, deethaners or ethylene splitters (or fractionation columns), depropanizers or propylene splitters (or fractionation columns) and / or debutanizers.

[0424] For example, in one embodiment or in combination with any of the mentioned embodiments, a column feed stream comprising r-pyrolysis gas may be introduced into a fractionating column, examples of which include demethanizers, deethaners, and depropanizers. The column feed comprising r-pyrolysis gas may contain C2-C4 olefins, and may primarily contain propylene and / or ethylene. The feed stream to the fractionating column may include at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, or at least 80 and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75, no more than 70, no more than 65, no more than 60, no more than 55, no more than 50, no more than 45, no more than 40, or no more than 35 wt% of ethylene and / or propylene, based on the total weight of the feed stream. Based on the total weight of the feed stream, the feed stream may include at least 1, at least 2, at least 5, at least 10, at least 15 or at least 20 and / or no more than 50, no more than 45, no more than 40, no more than 35, no more than 30, no more than 25, no more than 20 or no more than 15 wt% of methane and lighter components.

[0425] In one embodiment or in combination with any of the mentioned embodiments, the feed stream introduced into the deethanizer 220 can be separated into a light overhead stream 194 rich in C2 and lighter components and a heavier bottom stream 196 lean in C2 and lighter components (or rich in C3 and heavier components). The C2 enrichment column overhead stream 194 may contain at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 92, at least 95, at least 97, or at least 99 wt% of the total weight of C2 and lighter components present in the feed stream, while the C2 depleted column bottom stream 196, which may mainly contain C3 and heavier components, contains at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 92, at least 95, at least 97, or at least 99 wt% of the total weight of C3 and heavier components present in the feed stream.

[0426] The overhead stream 194 may include at least 0.01, at least 0.05, at least 0.10, at least 0.50, at least 1, at least 1.5, at least 2, at least 5, at least 8 or at least 10 wt% and / or no more than 10, no more than 8, no more than 5, no more than 3, no more than 2 or no more than 1 wt% of C3 and heavier components present in the feed stream, while the bottom stream 196 from the deethanizer 220 may include at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65 or at least 70 wt% and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75 or no more than 70 wt% of C3 and heavier components present in the feed stream.

[0427] The bottom stream 196 may include at least 0.01, at least 0.05, at least 0.10, at least 0.50, at least 1, at least 1.5, at least 2, at least 5, at least 8 or at least 10 wt% and / or no more than 10, no more than 8, no more than 5, no more than 3, no more than 2 or no more than 1 wt% of C2 and lighter components present in the feed stream, while the top stream 194 from the deethanizer 220 may include at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65 or at least 70 wt% and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75 or no more than 70 wt% of C2 and lighter components present in the feed stream.

[0428] Based on the total weight of the overhead stream 194, the overhead stream 194 may contain at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65 or at least 70 wt% and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75 or at least 70 wt% of C2 and lighter components, and based on the total weight of the overhead stream 194, the overhead stream 194 may contain at least 0.01, at least 0.05, at least 0.10, at least 0.50, at least 1, at least 1.5, at least 2, at least 5, at least 8 or at least 10 wt% and / or no more than 10, no more than 8, no more than 5, no more than 3, no more than 2 or no more than 1 wt% of C3 and heavier components.

[0429] Based on the total weight of bottom stream 196, bottom stream 196 may include at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65 or at least 70 wt% and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75 or no more than 70 wt% of C3 and heavier components, and based on the total weight of bottom stream 196, bottom stream 196 may include at least 0.01, at least 0.05, at least 0.10, at least 0.50, at least 1, at least 1.5, at least 2, at least 5, at least 8 or at least 10 wt% and / or no more than 10, no more than 8, no more than 5, no more than 3, no more than 2 or no more than 1 wt% of C2 and lighter components.

[0430] In one embodiment or in combination with any of the mentioned embodiments, the feed stream introduced into the deethaner 220 can be separated into a light overhead stream rich in C2 and lighter components and a heavier bottom stream leaning in C2 and lighter components (or rich in C3 and heavier components). The C2 enrichment column overhead stream may contain at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 92, at least 95, at least 97, or at least 99 wt% of the total weight of C2 and lighter components present in the feed stream, while the C2 depletion column bottom stream, which may mainly contain C3 and heavier components, contains at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 92, at least 95, at least 97, or at least 99 wt% of the total weight of C3 and heavier components present in the feed stream.

[0431] The overhead stream 194 may include at least 0.01, at least 0.05, at least 0.10, at least 0.50, at least 1, at least 1.5, at least 2, at least 5, at least 8 or at least 10 wt% and / or no more than 10, no more than 8, no more than 5, no more than 3, no more than 2 or no more than 1 wt% of C3 and heavier components present in the feed stream, while the bottom stream 196 from the deethanizer 220 may include at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65 or at least 70 wt% and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75 or no more than 70 wt% of ethylene and heavier components present in the feed stream.

[0432] The bottom stream 196 may include at least 0.01, at least 0.05, at least 0.10, at least 0.50, at least 1, at least 1.5, at least 2, at least 5, at least 8 or at least 10 wt% and / or no more than 10, 8, 5, 3, 2 or 1 wt% of C2 and lighter components present in the feed stream, while the overhead stream 194 from the deethanizer may include at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65 or at least 70 wt% and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75 or no more than 70 wt% of C2 and lighter components present in the feed stream.

[0433] Based on the total weight of the overhead stream, the overhead stream 194 may contain at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65 or at least 70 wt% and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75 or no more than 70 wt% of C2 and lighter components, and based on the total weight of the overhead stream 194, the overhead stream 194 may include at least 0.01, at least 0.05, at least 0.10, at least 0.50, at least 1, at least 1.5, at least 2, at least 5, at least 8 or at least 10 wt% and / or no more than 10, no more than 8, no more than 5, no more than 3, no more than 2 or no more than 1 wt% of C3 and heavier components.

[0434] Based on the total weight of the bottom stream 196, the bottom stream 196 may contain at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65 or at least 70 wt% and / or no more than 99, no more than 95, no more than 90, 85, 80, 75 or 70 wt% of C3 and heavier components, and based on the total weight of the bottom stream 196, the bottom stream 196 may include at least 0.01, at least 0.05, at least 0.10, at least 0.50, at least 1, at least 1.5, at least 2, at least 5, at least 8 or at least 10 wt% and / or no more than 10, no more than 8, no more than 5, no more than 3, no more than 2 or no more than 1 wt% of C2 and lighter components.

[0435] In one embodiment or in combination with any of the mentioned embodiments, the feed stream introduced into the demethanizer 210 can be separated into a light overhead stream 190 rich in C1 and lighter components and a heavier bottom stream 192 lean in C1 and lighter components (or rich in C2 and heavier components).

[0436] In one embodiment or in combination with any of the embodiments mentioned, the C1 enrichment column overhead stream 190 may contain at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 92, at least 95, at least 97, or at least 99 wt% of the total weight of C1 and lighter components present in the feed stream, while the C1 leaning column bottom stream 192, which may primarily contain C2 and heavier components, contains at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 92, at least 95, at least 97, or at least 99 wt% of the total weight of C2 and heavier components present in the feed stream.

[0437] The overhead stream 190 may include at least 0.01, at least 0.05, at least 0.10, at least 0.50, at least 1, at least 1.5, at least 2, at least 5, at least 8 or at least 10 wt% and / or no more than 10, no more than 8, no more than 5, no more than 3, no more than 2 or no more than 1 wt% of C2 and heavier components present in the feed stream, while the bottom stream 192 from the demethanizer 210 may include at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65 or at least 70 wt% and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75 or no more than 70 wt% of ethylene and heavier components present in the feed stream.

[0438] The bottom stream 192 may include at least 0.01, at least 0.05, at least 0.10, at least 0.50, at least 1, at least 1.5, at least 2, at least 5, at least 8 or at least 10 wt% and / or no more than 10, 8, 5, 3, 2 or 1 wt% of C1 and lighter components present in the feed stream, while the top stream 190 from the demethanizer 210 may include at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65 or at least 70 wt% and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75 or no more than 70 wt% of C1 and lighter components present in the feed stream.

[0439] Based on the total weight of the overhead stream 190, the overhead stream 190 may contain at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65 or at least 70 wt% and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75 or at least 70 wt% of C1 and lighter components, and based on the total weight of the overhead stream 190, the overhead stream 190 may contain at least 0.01, at least 0.05, at least 0.10, at least 0.50, at least 1, at least 1.5, at least 2, at least 5, at least 8 or at least 10 wt% and / or no more than 10, no more than 8, no more than 5, no more than 3, no more than 2 or no more than 1 wt% of C2 and heavier components.

[0440] Based on the total weight of the bottom stream 192, the bottom stream 192 may contain at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65 or at least 70 wt% and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75 or at least 70 wt% of C2 and heavier components, and based on the total weight of the bottom stream 192, the bottom stream 192 may contain at least 0.01, at least 0.05, at least 0.10, at least 0.50, at least 1, at least 1.5, at least 2, at least 5, at least 8 or at least 10 wt% and / or no more than 10, no more than 8, no more than 5, no more than 3, no more than 2 or no more than 1 wt% of C1 and lighter components.

[0441] In one embodiment or in combination with any of the mentioned embodiments, the feed stream introduced into the propane depropanizer 230 can be separated into a light overhead stream 202 rich in C3 and lighter components and a heavier bottom stream 200 lean in C3 and lighter components (or rich in C4 and heavier components). The C3 enrichment column overhead stream 202 may contain at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 92, at least 95, at least 97, or at least 99 wt% of the total weight of C3 and lighter components present in the feed stream, while the C3 depleted column bottom stream 200, which may mainly contain C4 and heavier components, contains at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 92, at least 95, at least 97, or at least 99 wt% of the total weight of C4 and heavier components present in the feed stream.

[0442] The overhead stream 202 may include at least 0.01, at least 0.05, at least 0.10, at least 0.50, at least 1, at least 1.5, at least 2, at least 5, at least 8 or at least 10 wt% and / or no more than 10, 8, 5, 3, 2 or 1 wt% of C4 and heavier components present in the feed stream, while the bottom stream 200 from the depropanizer 230 may include at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65 or at least 70 wt% and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75 or no more than 70 wt% of ethylene and heavier components present in the feed stream.

[0443] The bottom stream 200 may include at least 0.01, at least 0.05, at least 0.10, at least 0.50, at least 1, at least 1.5, at least 2, at least 5, at least 8 or at least 10 wt% and / or no more than 10, no more than 8, no more than 5, no more than 3, no more than 2 or no more than 1 wt% of C3 and lighter components present in the feed stream, while the top stream 202 from the depropanizer 230 may include at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65 or at least 70 wt% and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75 or no more than 70 wt% of C3 and lighter components present in the feed stream.

[0444] Based on the total weight of the overhead stream 202, the overhead stream 202 may contain at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65 or at least 70 wt% and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75 or at least 70 wt% of C3 and lighter components, and based on the total weight of the overhead stream 202, the overhead stream 202 may contain at least 0.01, at least 0.05, at least 0.10, at least 0.50, at least 1, at least 1.5, at least 2, at least 5, at least 8 or at least 10 wt% and / or no more than 10, no more than 8, no more than 5, no more than 3, no more than 2 or no more than 1 wt% of C4 and heavier components.

[0445] Based on the total weight of the bottom stream 200, the bottom stream 200 may include at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65 or at least 70 wt% and / or no more than 99, no more than 95, no more than 90, no more than 85, no more than 80, no more than 75 or at least 70 wt% of C4 and heavier components, and based on the total weight of the bottom stream 200, the bottom stream 200 may include at least 0.01, at least 0.05, at least 0.10, at least 0.50, at least 1, at least 1.5, at least 2, at least 5, at least 8 or at least 10 wt% and / or no more than 10, no more than 8, no more than 5, no more than 3, no more than 2 or at least 1 wt% of C3 and lighter components.

[0446] In one embodiment or in combination with any of the mentioned embodiments, introducing the r-pyrolysis gas stream 110 into the fractionation zone of a cracker facility can improve the operation of one or more columns in the fractionation zone. For example, at least one of the olefin fractionation columns (e.g., ethylene splitter 222 and / or propylene splitter 232) can operate more efficiently than when the feed to these columns consists only of cracked effluent from the cracker furnace. This efficiency may include, for example, better separation and / or increased capacity.

[0447] In one embodiment or in combination with any of the mentioned embodiments, a feed stream including r-pyrolysis gas 110 may be introduced into an olefin fractionation column, wherein the feed stream may be separated into an overhead stream rich in at least one olefin and a bottom stream leaning in at least one olefin. For example, when the olefin fractionation column is an ethylene fractionation column 222, the overhead stream 198 may be rich in ethylene, and the bottom stream 199 may be leaning in ethylene and rich in ethane. Similarly, when the olefin fractionation column is a propylene fractionation column 232, the overhead stream 204 may be rich in propylene, and the bottom stream 206 may be leaning in propylene and rich in propane.

[0448] In one embodiment or in combination with any of the mentioned embodiments, the olefin-rich overhead streams 198 and 204 may contain at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, or at least 90 wt% olefins, based on the total weight of the stream. The olefins may primarily comprise ethylene, primarily comprise propylene, or may comprise a combination thereof. Based on the total weight of the olefins in the stream, overhead stream 198 may contain at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, or at least 90 wt% ethylene. Based on the total weight of the olefins in the stream, overhead stream 204 may contain at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, or at least 90 wt% propylene.

[0449] In one embodiment or in combination with any of the mentioned embodiments, the total amount of ethylene in the overhead stream 198 from the olefin fractionation column (ethylene fractionation column 222) may be at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, at least 97, or at least 99 wt%, based on the total weight of the stream. Additionally, or alternatively, the overhead stream 198 from the olefin fractionation column 222 may contain no more than about 25, no more than 20, no more than 15, no more than 10, no more than 8, no more than 5, no more than 3, no more than 2, no more than 1, or no more than 0.5 wt% of ethane, based on the total weight of the stream.

[0450] In one embodiment or in combination with any of the mentioned embodiments, the total amount of propylene in the overhead stream 202 from the olefin fractionation column (propylene fractionation column 232) may be at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, at least 97, or at least 99 wt%, based on the total weight of the stream. Additionally, or alternatively, the overhead stream 202 from the olefin fractionation column 232 may contain no more than about 25, no more than 20, no more than 15, no more than 10, no more than 8, no more than 5, no more than 3, no more than 2, no more than 1, or no more than 0.5 wt% of ethane, based on the total weight of the stream.

[0451] In one embodiment or in combination with any of the embodiments mentioned, the overhead streams 198 and 204 from olefin fractionation columns 222 and 232 contain at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 wt% of the total amount of olefins introduced into fractionation columns 222 and 232, while the bottom streams 199 and 206 from olefin fractionation columns 222 and 232 contain no more than about 35, no more than 30, no more than 25, no more than 20, no more than 15, no more than 10, no more than 5, no more than 2, or no more than 1 wt% of the olefins introduced into the fractionation columns.

[0452] When the feed to the fractionation tower contains the amount of r-pyrolysis gas described above, one or more of the following conditions can be met: • The molar ratio of the at least one olefin to its corresponding alkane in the tower feed stream is at least 0.1% higher than that if the tower feed stream does not include the r-pyrolysis gas but has the same mass flow rate; • The mass flow rate of the corresponding alkane of the at least one olefin in the overhead stream is at least 0.1% lower than that if the feed stream does not include the r-pyrolysis gas but has the same mass flow rate; • The reflux ratio used in the separation is at least 0.1% lower than the reflux ratio used if the column feed stream does not include the r-pyrolysis gas but has the same mass flow rate; • The pressure drop across the column is at least 0.1% lower than if the column feed stream did not include the r-pyrolysis gas but had the same mass flow rate; • The mass flow rate of the liquid within the column is at least 0.1 wt% lower than if the column feed stream did not include the r-pyrolysis gas but had the same mass flow rate; and • The energy input into the column is at least 0.1% lower than if the column feed stream did not include the r-pyrolysis gas but had the same mass flow rate.

[0453] In one embodiment or in combination with any of the mentioned embodiments, at least two, three, four, five, or all of the above may be true....

Claims

1. A method for preparing an olefin product, the method comprising: Pyrolysis recovers waste to provide recovered pyrolysis gas (r-pyrolysis gas) and recovered pyrolysis oil (r-pyrolysis oil), wherein the r-pyrolysis gas contains at least 90 wt% olefins and alkanes. All or part of the r-pyrolysis oil is combined with a cracker feed stream and fed into a gas cracker furnace to form an olefin-containing effluent, wherein the cracker feed stream contains at least 60 wt% non-recovered C2 to C4 hydrocarbons. Based on the total weight of the combined r-pyrolysis oil / feed stream, a column feed stream containing the r-pyrolysis gas is separated in at least one fractionation column downstream of the gas cracker furnace. The tower feed stream comprises at least a portion of the olefin-containing effluent stream drawn from the cracker furnace. The r-pyrolysis gas is introduced downstream of the cracker furnace, and the introduced r-pyrolysis gas is not generated in the cracker furnace. Furthermore, the total mass flow rate of the olefin-containing effluent from the cracker furnace outlet is reduced by at least 5% compared to when the r-pyrolysis gas is not introduced into the cracker facility. The recycled waste is pyrolyzed in the presence of H-ZSM-5 zeolite.

2. The method of claim 1, wherein the cracker furnace is idle during at least a portion of the pyrolysis.

3. The method according to claim 1, further comprising: The pyrolysis stream containing the r-pyrolysis gas is compressed and introduced into the fractionation tower downstream of the furnace.

4. The method according to claim 3, further comprising: Prior to compression, the pyrolysis gas stream is combined with an olefin-containing effluent stream from the cracker furnace, and the combined stream is compressed.

5. The method according to claim 1, further comprising: Cooling the r-pyrolysis gas stream to form a cooled r-pyrolysis gas stream, wherein the feed stream comprises at least a portion of the cooled r-pyrolysis gas stream.

6. The method of claim 5, further comprising: Before cooling, the r-pyrolysis gas stream is combined with the olefin-containing effluent stream from the cracker furnace, and the combined stream is cooled.

7. The method according to claim 1, wherein the fractionation tower is selected from the group consisting of a demethanizer, a deethaner, and a depropanizer.

8. The method according to claim 1, wherein the fractionation tower is selected from the group consisting of an ethane-ethylene splitter and a propane-propylene splitter.

9. The method according to claim 1, wherein, The tower feed contains at least 5 wt% and no more than 60 wt% olefins – based on the total weight of the stream.

10. A method for preparing an olefin product, the method comprising: (a) Pyrolysis recovers waste to provide recovered component pyrolysis gas (r-pyrolysis gas) and recovered component pyrolysis oil (r-pyrolysis oil), said r-pyrolysis gas containing at least 90 wt% olefins and alkanes, and combines all or part of said r-pyrolysis oil with cracker feed stream into a gas cracker furnace to form an olefin-containing effluent, said cracker feed stream containing at least 60 wt% non-recovered C2 to C4 hydrocarbon stream, based on the total weight of the combined r-pyrolysis oil / feed stream; (b) Introducing a tower feed stream containing alkanes and olefins into a dealkylation tower, wherein the tower feed stream contains pyrolysis gas (r-pyrolysis gas) as a recovered component. and (c) Separating the column feed stream into a top stream rich in the target alkane and a bottom stream leaning in the target alkane, wherein at least one of the top stream and the bottom stream contains at least 5 wt% olefins—based on the total weight of the streams. The tower feed stream comprises at least a portion of the olefin-containing effluent stream drawn from the cracker furnace. The r-pyrolysis gas is introduced downstream of the cracker furnace, and the introduced r-pyrolysis gas is not generated in the cracker furnace. Furthermore, the total mass flow rate of the olefin-containing effluent from the cracker furnace outlet is reduced by at least 5% compared to when the r-pyrolysis gas is not introduced into the cracker facility. The recycled waste is pyrolyzed in the presence of H-ZSM-5 zeolite.

11. The method according to claim 10, wherein, The olefins in the tower feed stream mainly comprise ethylene, and the alkanes mainly comprise ethane.

12. The method according to claim 10, wherein, The olefins in the tower feed stream mainly comprise propylene, and the alkanes mainly comprise propane.

13. The method according to any one of claims 10-12, wherein the tower is a splitter and the overhead stream contains at least 5 wt% olefins – based on the total weight of the stream.

14. A method for preparing an olefin product, the method comprising: (a) Pyrolysis recovers waste to provide recovered component pyrolysis gas (r-pyrolysis gas) and recovered component pyrolysis oil (r-pyrolysis oil), said r-pyrolysis gas containing at least 90 wt% olefins and alkanes, and combines all or part of said r-pyrolysis oil with cracker feed stream into a gas cracker furnace to form an olefin-containing effluent, said cracker feed stream containing at least 60 wt% non-recovered C2 to C4 hydrocarbon stream, based on the total weight of the combined r-pyrolysis oil / feed stream; (b) Introducing a column feed stream containing alkanes and olefins into an olefin-alkane fractionation column, wherein the column feed stream contains pyrolysis gas (r-pyrolysis gas) as a recovered component. and (c) In the olefin-alkane fractionation column, the feed stream is separated into an olefin enrichment column overhead stream and an alkane enrichment column bottom stream. The tower feed stream comprises at least a portion of the olefin-containing effluent stream drawn from the cracker furnace. The r-pyrolysis gas is introduced downstream of the cracker furnace, and the introduced r-pyrolysis gas is not generated in the cracker furnace. Furthermore, the total mass flow rate of the olefin-containing effluent from the cracker furnace outlet is reduced by at least 5% compared to when the r-pyrolysis gas is not introduced into the cracker facility. The recycled waste is pyrolyzed in the presence of H-ZSM-5 zeolite.

15. The method according to claim 14, wherein, The alkanes mainly comprise ethane, and the olefins mainly comprise ethylene.

16. The method of claim 14, wherein, The alkanes mainly comprise propane, and the olefins mainly comprise propylene.

17. The method of claim 14, further comprising: A mixed plastic waste stream comprising polyethylene terephthalate (PET) and polyolefin (PO) is separated to form a PET enriched stream and a PO enriched stream, wherein the pyrolysis comprises subjecting at least a portion of the PO enriched stream and at least one stream derived from the PET enriched stream to pyrolysis to form the r-pyrolysis gas.

18. The method of claim 14, wherein at least a portion of the bottom product of the alkane enrichment tower is introduced into the cracker furnace.

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