Catalytic co-cracking of used cooking oil and plastic derived oils to produce circular chemicals and low carbon fuels

Abstract

A process for producing circular chemicals and low-carbon fuels includes producing a plastic derived oil stream, contacting the plastic derived oil stream with an acid gas removal catalyst in an acid gas removal unit to remove halogen compounds, sulfur compounds, or both, passing the treated plastic derived oil stream and a used cooking oil stream to a fluidized catalytic cracking (FCC) system comprising an FCC reactor, and contacting the treated plastic derived oil stream and the used cooking oil stream with a cracking catalyst in the FCC reactor. Contacting the treated plastic derived oil stream and the used cooking oil stream with the cracking catalyst at a reaction temperature causes at least a portion of hydrocarbons from the treated plastic derived oil stream and the used cooking oil stream to undergo catalytic cracking reactions to produce the circular chemicals, low-carbon fuels, or both.

Description

BACKGROUNDField

[0001] The present disclosure generally relates to catalysts and processes for producing greater value hydrocarbon products or intermediates from waste products, more specifically, catalysts and processes for co-processing used cooking oil and plastic derived oils to produce greater value circular chemicals and low carbon fuels.Technical Background

[0002] The use of plastics in commercial and industrial applications has become prolific. The increasing use of plastics worldwide has increased the generation of waste plastic, which presents a sustainability opportunity. Plastic is a synthetic or semisynthetic organic polymer composed of mainly carbon and hydrogen. Further, plastics tend to be durable, with a slow rate of degradation, therefore, plastics stay in the environment for a long time and are not prone to rapid breakdown upon disposal. Pure plastics are generally insoluble in water and nontoxic. However, some additives used in plastic preparation are toxic and may leach into the environment. Examples of toxic additives include phthalates. Other typical additives include fillers, colorants, plasticizers, stabilizers, anti-oxidants, flame retardants, ultraviolet (UV) light absorbers, antistatic agents, blowing agents, lubricants, or combinations of these, which are used during preparation of the plastics to change its composition and properties. Development of processes for converting waste plastics into reusable materials, such as chemical products, intermediates, or low carbon footprint fuels is continuing. Plastics pyrolyze at high temperatures and polymers can be converted back to their original monomers or smaller polymers, as gas or liquid, and can be recovered.

[0003] Additionally, cooking oil is widely consumed; millions of tons of cooking oil is used annually, resulting in significant waste product, known as used cooking oil. Thermal degradation during cooking can create harmful chemicals, such as hydroperoxides and fatty acid oligomers, that are then present in used cooking oil. The fatty acid oligomers make the used cooking oil unusable for human consumption or agricultural purposes. As a result, most used cooking oil is discarded, either to landfills or to sewage systems. As the need for alternative fuel sources has grown, processes to convert used cooking oil to useable materials, such as but not limited to chemical products, intermediates, or low carbon footprint fuels have started to develop.SUMMARY

[0004] Used cooking oils and oils derived from waste plastics can contain compounds useful as fuel blending components or chemical feedstocks. However, pyrolysis of used cooking oil produces oils with poor combustion quality, decreased engine performance, and increased emissions. The techniques used to improve the quality of the oils produced from pyrolysis of used cooking oil are often costly and highly sophisticated. Similarly, the additives added to the plastics during production can present challenges in effectively utilizing any products from pyrolysis of solid waste plastics. Upon pyrolysis of the solid waste plastics, the additives end-up in the pyrolysis effluent and thus require further processing to generate useful products. Additionally, the oils produced from pyrolysis of plastic waste can present a challenge due to the presence of halogen-containing compounds, such as those resulting from the presence of polyvinyl chloride (PVC) or other halogen-containing plastics. PVC is one of the most abundant plastics used for consumable goods. Waste plastic can contain from 1 weight percent (wt. %) to 5 wt. % PVC or other halogen-containing plastics. However, recycling of used PVC and other halogen-containing plastics is very difficult due to the presence of chlorine or other halogens in the structure.

[0005] Plastic derived oils have good properties and hydrocarbon constituents useful for application as fuel blending components or chemical feedstocks. However, plastic derived oils can present a processing challenge due to the presence of halogen-containing compounds (such as chlorine-containing hydrocarbon compounds) and due to the wide boiling point temperature range of the plastic derived oils, such as C5 to C25 or greater (boiling point temperatures of from 30° C. to 400° C. or even greater than 400° C.). Plastic derived oils can also include compounds with different functional groups and families of organic compounds such as but not limited to oxygenates, aromatic compounds, olefins, alkanes, other hydrocarbon compounds, or combinations of these. The direct use of plastic waste derived oil in catalytic cracking to produce circular chemicals can lead to problems downstream because of the presence of halogen-containing compounds, such as but not limited to chlorine-containing hydrocarbon compounds.

[0006] Used cooking oil is a common and widely produced waste product. As such, there is a steadily increasing demand for technologies capable of converting used cooking oil into circular chemicals and low carbon fuels. However, producing high-quality oils from used cooking oil may require sophisticated processes, such as hydrothermal cracking and hydro-deoxygenation. Further, biomass oils, such as used cooking oil, have generally been considered unsuitable for co-processing in FCC units because biomass oils produce high coke yields. The coke formation on the surfaces of the catalyst reduces the catalytic cracking activity of the cracking catalysts, thereby reducing the efficiency and yield from the catalytic cracking process.

[0007] Accordingly, an ongoing need exists for processes for co-cracking plastic derived oils and used cooking oils to produce greater value chemical products and intermediates, such as but not limited to light olefins (C2-C4 olefins), light aromatic compounds (C6-C8 aromatic compounds), light naphtha, low carbon footprint fuel components, other circular chemicals, or combinations of these. The present disclosure satisfies these needs by presenting systems and processes for co-cracking plastic derived oil and used cooking oil to produce greater value chemicals and intermediates, such as circular chemicals and low carbon fuels. In particular, the systems and methods disclosed herein include a fluidized catalytic cracking system for co-cracking plastic derived oil and used cooking oil to produce circular chemicals and low carbon fuels, which can include but are not limited to light olefins, light aromatic compounds, low carbon footprint fuel blending components, or combinations of these. The systems and methods may also include dehalogenating solid waste plastic in a dehalogenation unit to produce a liquefied plastic stream, pyrolyzing the liquefied plastic waste in a pyrolysis reactor to produce a plastic derived oil stream, and contacting the plastic derived oil stream with an acid gas removal catalyst in an acid gas removal unit to produce treated plastic derived oil. The treated plastic derived oil may then be blended with the used cooking oil and co-cracked in the FCC reactor using a cracking catalyst. The method may further include regeneration of the used cracking catalyst in a catalyst regenerator.

[0008] According to one or more aspects of the present disclosure, a process for producing circular chemicals and low-carbon fuels comprises producing a plastic derived oil stream from solid waste plastic and contacting the plastic derived oil stream with an acid gas removal catalyst disposed in an acid gas removal unit. Contacting the plastic derived oil stream with the acid gas removal catalyst may remove acid gases from the plastic derived oil stream to produce a treated plastic derived oil stream, where the treated plastic derived oil stream may have concentrations of halogen compounds, sulfur compounds, or both that are less than concentrations of the halogen compounds, sulfur compounds, or both in the plastic derived oil stream. The process further includes passing the treated plastic derived oil stream and a used cooking oil stream to a fluidized catalytic cracking (FCC) system comprising an FCC reactor and contacting the treated plastic derived oil stream and the used cooking oil stream with a cracking catalyst in the FCC reactor. Contacting the treated plastic derived oil stream and the used cooking oil stream with the cracking catalyst at a reaction temperature in the FCC reactor causes at least a portion of hydrocarbons from the treated plastic derived oil stream and the used cooking oil stream to undergo catalytic cracking reactions to produce an FCC effluent comprising circular chemicals, low-carbon fuels, or both.

[0009] According to one or more other aspects, a system for converting solid waste plastics and used cooking oil into circular chemicals and low carbon fuels comprises a plastic derived oil stream; an acid gas removal unit in fluid communication with the plastic derived oil stream, where the acid gas removal unit may comprise a reaction vessel and an acid gas removal catalyst disposed within the reaction vessel, where the acid gas removal unit may be configured to contact the plastic derived oil stream with the acid gas removal catalyst to remove halogen compounds, sulfur-containing compounds, or both from the plastic derived oil stream to produce a treated plastic derived oil stream; a fluid catalytic cracking (FCC) system disposed downstream of the acid gas removal unit and comprising an FCC reactor, where the FCC reactor may be in fluid communication with the acid gas removal unit to pass the treated plastic derived oil stream from the acid gas removal unit to the FCC reactor; and a used cooking oil stream in fluid communication with the FCC reactor to pass the used cooking oil stream to the FCC reactor. The FCC system may be configured to contact the treated plastic derived oil stream and the used cooking oil stream with a cracking catalyst under reaction conditions to produce an FCC effluent comprising circular chemicals and low carbon fuels.

[0010] Additional features and advantages of the technology described in this disclosure will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from the description or recognized by practicing the technology as described in this disclosure, including the detailed description which follows, the claims, as well as the appended drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The following detailed description of specific embodiments of the present disclosure can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:

[0012] FIG. 1 schematically depicts a generalized flow diagram of a system for converting solid waste plastic and used cooking oil to greater value circular chemicals and intermediates, according to embodiments shown and described in this disclosure;

[0013] FIG. 2 schematically depicts a generalized flow diagram of a fluidized catalytic cracking (FCC) reactor of the system of FIG. 1, where the FCC reactor is a riser reactor, according to embodiments shown and described in this disclosure;

[0014] FIG. 3 schematically depicts a test reactor system for converting hydrocarbon feeds having different ratios of used cooking oil to plastic derived oil, according to embodiments shown and described in this disclosure; and

[0015] FIG. 4 graphically depicts compositions of the reaction effluents obtained from contacting blends with different plastic derived oil stream and used cooking oil percentages with a cracking catalyst, according to embodiments shown and described in this disclosure.

[0016] For the purpose of describing the simplified schematic illustrations and descriptions of FIGS. 1-3, some of the numerous valves, temperature sensors, electronic controllers, and the like that may be employed and well known to those of ordinary skill in the art of certain chemical processing operations are not included. Further, accompanying components that are often included in chemical processing operations, such as, for example, air supplies, heat exchangers, surge tanks, catalyst hoppers, or other related systems are not depicted. It would be known that these components are within the spirit and scope of the present embodiments disclosed. However, operational components, such as those described in the present disclosure, may be added to the embodiments described in this disclosure.

[0017] It should further be noted that arrows in the drawings refer to process streams. However, the arrows may equivalently refer to transfer lines that may serve to transfer process streams between two or more system components. Additionally, arrows that connect to system components define inlets or outlets in each given system component. The arrow direction corresponds generally with the major direction of movement of the materials of the stream contained within the physical transfer line signified by the arrow. Furthermore, arrows that do not connect two or more system components signify a product stream which exits the depicted system or a system inlet stream which enters the depicted system. Product streams may be further processed in accompanying chemical processing systems or may be commercialized as end products. System inlet streams may be streams transferred from accompanying chemical processing systems or may be non-processed feedstock streams. Some arrows may represent recycle streams, which are effluent streams of system components that are recycled back into the system. However, it should be understood that any represented recycle stream, in embodiments, may be replaced by a system inlet stream of the same material, and that a portion of a recycle stream may exit the system as a system product.

[0018] Additionally, arrows in the drawings may schematically depict process steps of transporting a stream from one system component to another system component. For example, an arrow from one system component pointing to another system component may represent “passing” a system component effluent to another system component, which may include the contents of a process stream “exiting” or being “removed” from one system component and “introducing” the contents of that product stream to another system component.

[0019] It should be understood that two or more process streams are “mixed” or “combined” when two or more lines intersect in the schematic flow diagrams of FIGS. 1-3. Mixing or combining may also include mixing by directly introducing both streams into a like reactor, separation device, or other system component. For example, it should be understood that when two streams are depicted as being combined directly prior to entering a separator or reactor, that in some embodiments the streams could equivalently be introduced into the separator or reactor and be mixed in the reactor.

[0020] Reference will now be made in greater detail to various embodiments of the present disclosure, some embodiments of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or similar parts.DETAILED DESCRIPTION

[0021] Embodiments of the present disclosure are directed to systems and processes for producing greater value circular chemicals and low carbon fuels through co-processing of plastic derived oils and used cooking oils. Referring now to FIG. 1, one embodiment of a system 100 for co-processing a plastic derived oil stream 102 and a used cooking oil stream 104 is schematically depicted. The system 100 includes a plastic derived oil stream 102 and an acid gas removal unit 110 in fluid communication with the plastic derived oil stream 102. The acid gas removal unit 110 includes a reaction vessel 111 and an acid gas removal catalyst 112 disposed within the reaction vessel 111. The acid gas removal unit 110 may be configured to contact the plastic derived oil stream 102 with the acid gas removal catalyst 112 to remove halogen compounds, sulfur-containing compounds, or both from the plastic derived oil stream 102 to produce a treated plastic derived oil stream 114. The system 100 further includes a fluidized catalytic cracking (FCC) system 120 disposed downstream of the acid gas removal unit 110 and having an FCC reactor 122 containing a cracking catalyst 124. The FCC reactor 122 may be in fluid communication with the acid gas removal unit 110 to pass the treated plastic derived oil 114 from the acid gas removal unit 110 to the FCC reactor 122. The system 100 further includes a used cooking oil stream 104 in fluid communication with the FCC reactor 122 to pass the used cooking oil stream 104 to the FCC reactor 122. FCC reactor 122 may be a fluidized bed reactor configured to contact the treated plastic derived oil stream 114 and the used cooking oil stream 104 with the cracking catalyst 124 under reaction conditions to produce an FCC effluent 132 comprising circular chemicals, low carbon fuels, or both. In embodiments, the system 100 may further include a dehalogenation unit 10 and a pyrolysis unit 20 upstream of the acid gas removal unit 110, where the dehalogenation unit 10 and pyrolysis unit 20 may be configured to convert solid waste plastic 12 through dehalogenation and pyrolysis to produce the plastic derived oil stream 102.

[0022] The present disclosure is also directed to processes for producing circular chemicals, low-carbon fuels, or both using the systems 100. The processes of the present disclosure include passing the plastic derived oil stream 102 to the acid gas removal unit 110 and contacting the plastic derived oil stream 102 with an acid gas removal catalyst 112 disposed in the acid gas removal unit 110. Contacting the plastic derived oil stream 102 with the acid gas removal catalyst 112 may remove acid gases from the plastic derived oil stream 102 to produce a treated plastic derived oil stream 114, where the treated plastic derived oil stream 114 has concentrations of halogen compounds, sulfur compounds, or both that are less than concentrations of the halogen compounds, sulfur compounds, or both in the plastic derived oil stream 102. The processes further include passing the treated plastic derived oil stream 114 and the used cooking oil stream 104 to the FCC system 120 comprising the FCC reactor 122, and contacting the treated plastic derived oil stream 114 and the used cooking oil stream 104 with the cracking catalyst in the FCC reactor 122. Contacting the treated plastic derived oil stream 114 and the used cooking oil stream 104 with the cracking catalyst at a reaction temperature in the FCC reactor 122 may cause at least a portion of hydrocarbons from the treated plastic derived oil stream 114 and the used cooking oil stream 104 to undergo catalytic cracking reactions to produce an FCC effluent 132 comprising circular chemicals, low-carbon fuels, or both. In embodiments, the processes may further include producing the plastic derived oil stream 102, such as by melting and dehalogenating solid waste plastic 12 in a dehalogenation unit 10 to produce a liquefied plastic stream 14 and subjecting the liquefied plastic stream 14 to pyrolysis in a pyrolysis reactor 20 to produce the plastic derived oil stream 102.

[0023] Co-cracking the plastic derived oil stream 102 and the used cooking oil stream 104 may produce a high yield of circular chemicals and low carbon fuels, such as a yield of greater than 50 wt. % of C2-C4 olefins and light naphtha, where the light naphtha includes the light aromatic compounds having from 6-9 carbon atoms. The plastic derived oil and used cooking oil dilute each other, resulting in lower containment levels, which may ease the integration of alternative feeds into new and existing FCC systems. Further, plastic derived oil and used cooking oil are renewable feeds that can aid in decarbonization of FCC facilities. Co-cracking plastic derived oil and used cooking oil in existing refining assets allows refiners to introduce renewable and circular carbon into their finished products, among other features.

[0024] As used in this disclosure, the term “catalyst” refers to any substance that increases the rate of a specific chemical reaction. Catalysts and catalyst components described in this disclosure can be utilized to promote various reactions, such as, but not limited to catalytic cracking, aromatic cracking, dehalogenation, acid gas removal, pyrolysis, other chemical reactions, or combinations of these.

[0025] As used in this disclosure, the term “used catalyst” refers to catalyst that has been contacted with reactants but has not been regenerated to restore at least a portion of the catalytic activity to the catalyst. The term “regenerated catalyst” refers to a catalyst that has been regenerated in a regenerator or through a regeneration process to increase the catalytic activity, the temperature, or both of the regenerated catalyst.

[0026] As used in this disclosure, the term “aromatic compounds” refers to compounds having one or more aromatic ring structures. The term “light aromatic compounds” refers to compounds having an aromatic ring, with or without substitution, and from six to eight carbon atoms. The term “BTEX” refers to any combination of one or a plurality of benzene, toluene, ethylbenzene, para-xylene, meta-xylene, and ortho-xylene.

[0027] As used in this disclosure, the term “xylenes,” when used without a designation of the isomer, such as the prefix para, meta, or ortho, refers to one or more of meta-xylene, ortho-xylene, para-xylene, and mixtures of these xylene isomers.

[0028] As used in this disclosure, the terms “butenes” and “mixed butenes” refers to 1-butene, cis-2-butene, trans-2-butene, isobutene, and combinations of these. As used in this disclosure, the term “normal butenes” refers to 1-butene, cis-2-butene, trans-2-butene, and any combination thereof, but not including isobutene.

[0029] As used in this disclosure, the terms “low carbon footprint fuels” or “low carbon footprint fuel components” refer to fuels and fuel components derived from non-fossil origin, in contrast to conventional fuels which are produced directly from petroleum extracted from subterranean sources. The “low carbon footprint fuels” or “low carbon footprint fuel components” are produced sustainably from municipal or organic waste, sustainable biomass, renewables, or circular CO2. Production and use of the low carbon footprint fuels and fuel components result in very little or no additional CO2 generated. Low carbon footprint fuels and fuel components can help to reduce greenhouse emissions and mitigate the effects of climate change.

[0030] As used in this disclosure, the term “circular chemicals” refers to chemicals that are derived from the process of recycling waste materials back to produce useful chemical products and intermediates.

[0031] As used in this disclosure, the terms “boiling point temperature”, or “boiling temperature”, or “boiling point” refer to the temperature at which a compound or composition boils at atmospheric pressure, unless otherwise stated.

[0032] As used in this disclosure, the term “initial boiling point” or “IBP” of a composition is defined in accordance with standard test method ASTM D2887.

[0033] As used in this disclosure, the term “final boiling point” or “FBP” of a composition is defined in accordance with standard test method ASTM D2887.

[0034] As used in this disclosure, the term “separation unit” refers to any separation device that at least partially separates one or more chemicals in a mixture from one another. For example, a separation unit may selectively separate different chemical species from one another, forming one or more chemical fractions. Examples of separation units include, without limitation, distillation columns, cryogenic distillation units, fractionators, flash drums, knock-out drums, knock-out pots, centrifuges, filtration devices, traps, scrubbers, expansion devices, membranes, solvent extraction devices, pressure swing adsorption units, high-pressure separators, low-pressure separators, fluid-solid separators, and the like. It should be understood that separation processes described in this disclosure may not completely separate all of one chemical consistent from all of another chemical constituent. It should be understood that the separation processes described in this disclosure “at least partially” separate different chemical components from one another, and that even if not explicitly stated, it should be understood that separation may include only partial separation. As used in this disclosure, one or more chemical constituents may be “separated” from a process stream to form a new process stream. Generally, a process stream may enter a separation unit and be divided or separated into two or more process streams of desired composition.

[0035] As used in this disclosure, the terms “upstream” and “downstream” refer to the relative positioning of unit operations with respect to the direction of flow of the process streams through the system. A first unit operation of a system is considered “upstream” of a second unit operation if process streams flowing through the system encounter the first unit operation before encountering the second unit operation. Likewise, a second unit operation is considered “downstream” of the first unit operation if the process streams flowing through the system encounter the first unit operation before encountering the second unit operation.

[0036] As used in this disclosure, passing a stream or effluent from one unit “directly” to another unit refers to passing the stream or effluent from the first unit to the second unit without passing the stream or effluent through an intervening reaction system or separation system that substantially changes the composition of the stream or effluent. Heat transfer devices, such as heat exchangers, preheaters, coolers, or other heat transfer equipment, and pressure devices, such as pumps, pressure regulators, compressors, or other pressure devices, are not considered to be intervening systems that change the composition of a stream or effluent, unless otherwise specifically stated in the present disclosure. Combining two streams or effluents together upstream of a process unit also is not considered to comprise an intervening system that changes the composition of one or both of the streams or effluents being combined. Simply dividing a stream into two streams having the same composition is also not considered to comprise an intervening system that changes the composition of the stream.

[0037] As used in this disclosure, the term “effluent” refers to a stream that is passed out of a reactor, a reaction zone, or a separator following a particular reaction or separation process. Generally, an effluent has a different composition than the stream that entered the separator, reactor, or reaction zone. It should be understood that when an effluent is passed to another system unit, only a portion of that effluent may be passed. For example, a slip stream (having the same composition) may carry some of the effluent away, meaning that only a portion of the effluent may enter the downstream system unit. The terms “reaction effluent” or “reactor effluent” are more particularly used to refer to streams that are passed out of a reactor or reaction zone.

[0038] It should further be understood that streams may be named for the components of the stream, and the component for which the stream is named may be the major component of the stream (such as comprising from 50 weight percent (wt. %), from 70 wt. %, from 90 wt. %, from 95 wt. %, from 99 wt. %, from 99.5 wt. %, or even from 99.9 wt. % of the contents of the stream to 100 wt. % of the contents of the stream, notwithstanding any inert gases or diluents added to the stream). It should also be understood that components of a stream are disclosed as passing from one system component to another when a stream comprising that component is disclosed as passing from that system component to another. For example, a disclosed “plastic derived oil stream” passing to a first system component or from a first system component to a second system component should be understood to equivalently disclose the “plastic derived oil” passing to the first system component or passing from a first system component to a second system component.

[0039] The demand for circular chemicals, which can be used for the production of chemical intermediates used in production of polymers and plastics as well as for fuel components, is steadily increasing. Circular chemicals can include monomers, such as ethylene, propylene, butenes, benzene, xylenes, and toluene, which can be produced from used cooking oil, plastic waste, plastic derived oil, or other organic waste materials. These monomers can then be used again for the production of polymers, such as polyethylene, polypropylene, or polyethylene terephthalate. They are called circular chemicals because they are derived from the process of recycling waste materials back to produce useful chemical products and intermediates. Converting plastic waste and used cooking oil can also produce low carbon footprint fuel components, such as gasoline, jet fuels, or diesel fuels, which can provide additional sources of fuel with reduced CO2 generation, compared to fuel components derived directly from fossil fuels extracted from subterranean sources.

[0040] As previously discussed, plastic derived oils have good properties and contain hydrocarbon constituents useful for application as chemical intermediates and fuel blending components. However, plastic derived oils can include halogen-containing compounds, such as but not limited to chloro-organic compounds, and other contaminants resulting from the types of solid waste plastic and additives included in the plastics, and the plastic derived oils can have a broad boiling point temperature range, such as from 30° C. to 400° C., or even greater than 400° C. Plastic derived oils can also include compounds with different functional groups and families of organic compounds, such as but not limited to oxygenates, aromatic compounds, olefins, alkanes, other hydrocarbon compounds, or combinations of these. The direct use of plastic waste derived oils in catalytic cracking to produce chemical products, intermediates, or fuel components can lead to problems downstream because of the presence of the halogen-containing compounds. In particular, halogen-containing compounds may poison or damage catalysts, form salts that foul refinery equipment, and contaminate refined products. Additionally, the breakdown of halogen-containing compounds may cause corrosion in refinery equipment.

[0041] Used cooking oil has a high conversion and has been shown to give high yields of light olefins, making it a potentially useful feed for refinery processes. However, cracking of used cooking oil generally produces low-quality oils and techniques to improve oil quality, such as hydrothermal cracking and hydro-deoxygenation, are costly and require a high degree of sophistication. Co-processing the used cooking oils in FCC systems may aid in reducing the complexity and cost required to produce high-quality oils from used cooking oil. However, used cooking oils have generally been considered unsuitable for co-processing in FCC systems because they produce high coke yields that can inhibit catalyst function.

[0042] Thus, an ongoing need exists for more efficient processes and catalysts for co-processing plastic derived oils and used cooking oils through fluidized catalytic cracking processes (FCC processes) to produce greater value chemicals and intermediates while also decontaminating the plastic derived oils, used cooking oils, and greater value chemicals and intermediates, such as removing halogen-containing compounds (dehalogenation). The present disclosure solves these problems in the art by providing processes and systems for co-cracking plastic derived oils and used cooking oils. In embodiments, the systems for co-processing the plastic derived oil and used cooling oil may include an acid gas removal unit, in which the plastic derived oil stream contacts an acid gas removal catalyst to produce a treated plastic derived oil stream. The system may also include an FCC system, and the treated plastic derived oil stream and a used cooking oil stream may both be passed to the FCC system. The treated plastic derived oil stream and used cooking oil stream contact a cracking catalyst in an FCC reactor of the FCC system to produce an FCC effluent. The FCC system may further include a fluid-solid separation unit configured to separate the FCC effluent from a used cracking catalyst. The FCC system may include a catalyst regenerator configured to regenerate the used cracking catalyst to produce a regenerated cracking catalyst, which may be passed back to the FCC reactor as the cracking catalyst. The system may also include a dehalogenation unit and a pyrolysis unit upstream of the acid gas removal unit, where the dehalogenation unit may be configured to melt a dehalogenated solid waste plastic to produce a liquid plastic stream, and the pyrolysis reactor may be configured to subject the liquid plastic stream to pyrolysis to produce the plastic derived oil stream.

[0043] The processes of the present disclosure may include simultaneously contacting a cracking catalyst with a plastic derived oil stream and used cooking oil stream to produce greater value chemical products and intermediates, such as but not limited circular chemicals, low-carbon footprint fuels, or combinations thereof. In embodiments, the process may include dehalogenating a solid waste plastic in a dehalogenation unit to produce a liquefied plastic stream, passing the liquefied plastic stream to a pyrolysis reactor, where the liquefied plastic stream may be pyrolyzed to produce plastic derived oil stream, and passing the plastic derived oil stream to an acid gas removal unit, where the plastic derived oil stream may contact an acid gas removal catalyst to produce a treated plastic derived oil stream. The processes of the present disclosure include passing the treated plastic derived oil stream and the used cooking oil stream to the FCC reactor of the FCC system. The processes may include contacting the treated plastic derived oil stream and the used cooking oil stream with a cracking catalyst in the FCC reactor to produce an FCC effluent comprising circular chemicals, low-carbon fuels, or both, which may include but are not limited to light olefins, light aromatic compounds, naphtha range hydrocarbons, or combinations thereof. In embodiments, the process may further include separating the FCC effluent from the used cracking catalyst, and regenerating the used cracking catalyst.

[0044] The processes of the present disclosure produce greater value chemicals and intermediates that are circular chemicals. The systems and processes of co-cracking of plastic derived oil and used cooking oil of the present disclosure may also enable the recycling of a broader range of types of solid waste plastic and used cooking oils. The used cooking oil and plastic derived oil may dilute each other, reducing the level of contaminants and, as a result, reducing downstream problems caused by halogen-containing compounds (such as organochlorides) or other contaminants. The reaction products can be considered to have a low carbon footprint. Low carbon footprint fuels and fuel components can help to reduce greenhouse emissions and mitigate the effects of climate change. The systems and processes of co-cracking of the present disclosure can be easily integrated into existing petroleum refineries and petrochemical installations, such as existing FCC reactor systems, among other features. Plastic derived oil and used cooking oil are renewable feeds and can aid in decarbonizing existing refinery facilities, among other features.

[0045] Referring again to FIG. 1, one embodiment of a system 100 for co-processing a plastic derived oil stream 102 and a used cooking oil stream 104 is schematically depicted. The system 100 may include a plastic derived oil stream 102, an acid gas removal unit 110, a used cooking oil stream 104, an FCC system 120 disposed downstream of the acid gas removal unit 110, and an effluent separation system 150 disposed downstream of the FCC system 120. The acid gas removal unit 110 may be configured to contact the plastic derived oil stream 102 with an acid gas removal catalyst 112 to remove halogen compounds, sulfur compounds, or both to produce a treated plastic derived oil stream 114. The FCC system 120 may be configured to contact the treated plastic derived oil stream 114 and the used cooking oil stream 104 with a cracking catalyst 124 in an FCC reactor 122 at reaction conditions, separate an FCC effluent 132 from the used cracking catalyst 134, and regenerate the used cracking catalyst 134 to produce a regenerated cracking catalyst 142. The effluent separation system 150 may be configured to separate the FCC effluent 132 to produce a plurality of product streams, such as but not limited to an ethylene stream, a propylene stream, a mixed butenes stream, a light aromatics stream, a light naphtha stream, a gasoline stream, a jet fuel stream, a diesel stream, a heavy compounds stream, or any combination of these streams. In embodiments, the system 100 may include a dehalogenation unit 10 upstream of the acid gas removal unit 110, where solid waste plastic 12 is melted and dehalogenated in the dehalogenation unit 10 to produce a liquid plastic stream 14. The system 100 may further include a pyrolysis reactor 20 upstream of the acid gas removal unit 110, where the liquid plastic stream 14 may be pyrolyzed in the pyrolysis reactor 20 to produce the plastic derived oil stream 102.

[0046] The FCC system 120 may include the FCC reactor 122, which may be the fluidized bed reactor. The FCC reactor 122 may be configured to contact the treated plastic derived oil stream 114 and the used cooking oil stream 104 with the cracking catalyst 124 at reaction conditions sufficient to convert at least a portion of hydrocarbons in the treated plastic derived oil stream 114 and the used cooking oil stream 104 to produce the FCC effluent 132. The FCC system 120 may further comprise the fluid-solid separation unit 130 disposed at an outlet end of the FCC reactor 122. The fluid-solid separation unit 130 may be configured to separate the FCC effluent 132 from the used cracking catalyst 134. Referring again to FIG. 1, the FCC system 120 may further include a catalyst regenerator 140 disposed downstream of the fluid-solid separation unit 130. The catalyst regenerator 140 may be configured to regenerate the used cracking catalyst 134 to produce a regenerated cracking catalyst 142, which may be passed back to the FCC reactor 122 as at least a portion of the cracking catalyst 124.

[0047] The plastic derived oil stream 102 may be a liquid stream comprising hydrocarbons and produced through melting, dehalogenation, and pyrolysis of solid waste plastic. As previously discussed, the plastic derived oil stream 102 may include hydrocarbons, such as but not limited to aromatic compounds, olefins, alkanes, other hydrocarbon compounds. Additionally, the plastic derived oil stream 102 may include other organic compounds, such as but not limited to oxygenates, halogen-containing compounds such as organic halide compounds, plastic additives, and other contaminants. The plastic derived oil stream 102 may comprise a concentration of halogen-containing compounds of from 10 part per million by weight (ppmw) to 1,000 ppmw. In embodiments, the plastic derived oil stream 102 may comprise a concentration of halogen-containing compounds of from 10 ppmw to 500 ppmw, from 10 ppmw to 400 ppmw, from 10 ppmw to 300 ppmw, from 50 ppmw to 500 ppmw, from 50 ppmw to 400 ppmw, from 50 ppmw to 300 ppmw, from 100 ppmw to 1,000 ppmw, from 100 ppmw to 500 ppmw, from 100 ppm to 400 ppmw, from 100 ppmw to 300 ppmw, from 150 ppmw to 500 ppmw, from 150 ppmw to 400 ppmw, or from 150 ppmw to 300 ppmw. In embodiments, the plastic derived oil stream 102 may have a concentration of halogen-containing compounds of greater than or equal to 100 ppmw, greater than or equal to 150 ppmw, greater than or equal to 200 ppmw, or even greater than or equal to 250 ppmw.

[0048] In embodiments, the plastic derived oil stream 102 may comprise light naphtha range hydrocarbons, jet fuel constituents, diesel range constituents, heavy compounds, or combinations of these. Light naphtha range hydrocarbons refer to hydrocarbons having atmospheric boiling point temperatures of from 0° C. to 150° C., jet fuel constituents include hydrocarbons having atmospheric boiling point temperatures of from 150° C. to 300° C., diesel range constituents include hydrocarbons having atmospheric boiling point temperatures of from 300° C. to 343° C., and the heavy compounds refer to hydrocarbons having atmospheric boiling point temperatures of greater than 343° C. In embodiments, the plastic derived oil stream 102 may comprise from 10 wt. % to 35 wt. % light naphtha range hydrocarbons, such as from 15 wt. % to 30 wt. %, from 15 wt. % to 25 wt. %, from 20 wt. % to 25 wt. %, about 23.8 wt. %, or about 17.1 wt. % of the light naphtha range hydrocarbons per unit weight of the plastic derived oil stream 102. In embodiments, the plastic derived oil stream 102 may comprise from 35 wt. % to 70 wt. % jet fuel constituents, such as from 35 wt. % to 60 wt. %, from 35 wt. % to 55 wt. %, from 35 wt. % to 50 wt. %, from 40 wt. % to 60 wt. %, from 40 wt. % to 55 wt. %, from 40 wt. % to 50 wt. %, about 49.7 wt. %, or about 41.8 wt. % of the jet fuel constituents per unit weight of the plastic derived oil stream 102. In embodiments, the plastic derived oil stream 102 may comprise from 5 wt. % to 25 wt. % of the diesel range constituents, such as from 5 wt. % to 20 wt. %, from 5 wt. % to 15 wt. %, from 10 wt. % to 25 wt. %, from 10 wt. % to 20 wt. %, from 10 wt. % to 15 wt. %, about 15.2 wt. % or about 13.6 wt. % of the diesel range constituents per unit weight of the plastic derived oil stream 102. In embodiments, the plastic derived oil stream 102 may comprise from 5 wt. % to 40 wt. % heavy compounds, such as from 5 wt. % to 35 wt. %, from 5 wt. % to 30 wt. %, from 10 wt. % to 40 wt. %, from 10 wt. % to 35 wt. %, from 20 wt. % to 40 wt. %, from 20 wt. % to 35 wt. %, from 20 wt. % to 30 wt. %, about 11.3 wt. %, or about 27.5 wt. % of the heavy compounds per unit weight of the plastic derived oil stream 102.

[0049] In embodiments, the plastic derived oil stream 102 may comprise naphtha range hydrocarbons, middle distillates, heavy compounds, or combinations of these. Naphtha range hydrocarbons refer to hydrocarbons having atmospheric boiling point temperatures of from 25° C. to 221° C., middle distillates include hydrocarbons having atmospheric boiling point temperatures of from 221° C. to 343° C., and the heavy compounds refer to hydrocarbons having atmospheric boiling point temperatures of greater than 343° C. In embodiments, the plastic derived oil stream 102 may comprise from 20 wt. % to 45 wt. % naphtha range hydrocarbons, such as from 20 wt. % to 40 wt. %, from 20 wt. % to 35 wt. %, from 20 wt. % to 30 wt. %, from 30 wt. % to 45 wt. %, from 30 wt. % to 40 wt. %, from 35 wt. % to 45 wt. %, from 35 wt. % to 40 wt. %, or about 38 wt. % naphtha range hydrocarbons based on the total weight of the plastic derived oil stream 102. In embodiments, the plastic derived oil stream 102 may comprise from 40 wt. % to 70 wt. % middle distillates, such as from 40 wt. % to 60 wt. %, from 40 wt. % to 55 wt. %, from 40 wt. % to 50 wt. %, from 45 wt. % to 70 wt. %, from 45 wt. % to 60 wt. %, from 45 wt. % to 55 wt. %, from 45 wt. % to 50 wt. %, or about 48 wt. % middle distillates based on the total weight of the plastic derived oil stream 102. In embodiments, the plastic derived oil stream 102 may comprise from 5 wt. % to 25 wt. % heavy compounds, such as from 5 wt. % to 20 wt. %, from 5 wt. % to 15 wt. %, from 10 wt. % to 25 wt. %, from 10 wt. % to 20 wt. %, from 10 wt. % to 15 wt. %, or about 14 wt. % heavy compounds based on the total weight of the plastic derived oil stream 102.

[0050] The plastic derived oil stream 102 may be characterized by a boiling point distribution determined according to standard test method ASTM D2887. In embodiments, the plastic derived oil stream 102 may have an initial boiling point (IBP) of from 20° C. to 100° C., such as from 20° C. to 60° C., from 20° C. to 50° C., from 25° C. to 100° C. from 25° C. to 60° C., from 25° C. to 50° C., or from 25° C. to 40° C. In embodiments, the plastic derived oil stream 102 may have a final boiling point (FBP) of from 300° C. to 600° C., such as from 300° C. to 500° C., from 300° C. to 450° C., from 350° C. to 600° C., from 350° C. to 500° C., from 350° C. to 450° C., or from 375° C. to 425° C. In embodiments, the plastic derived oil stream 102 may have a 50% boiling point temperature of from 150° C. to 350° C., such as from 150° C. to 300° C., from 150° C. to 275° C., from 200° C. to 350° C., from 200° C. to 300° C., from 200° C. to 275° C., from 225° C. to 350° C., from 225° C. to 300° C., or from 225° C. to 275° C., where the 50% boiling point temperature is determined according to ASTM D2887 and is generally the temperature at which 50% by weight of the constituents have transitioned from the liquid phase to the vapor phase.

[0051] In embodiments, the plastic derived oil stream 102 may have a density of from 0.65 g / cm3 to 1.1 g / cm3, such as from 0.65 g / cm3 to 1.0 g / cm3, from 0.65 g / cm3 to 0.9 g / cm3, from 0.65 g / cm3 to 0.8 g / cm3, from 0.7 g / cm3 to 1.1 g / cm3, from 0.7 g / cm3 to 1.0 g / cm3, from 0.7 g / cm3 to 0.9 g / cm3, from 0.7 g / cm3 to 0.8 g / cm3, from 0.75 g / cm3 to 1.1 g / cm3, from 0.75 g / cm3 to 1.0 g / cm3, from 0.75 g / cm3 to 0.9 g / cm3, or from 0.75 g / cm3 to 0.85 g / cm3, as determined by ASTM D4052. In embodiments, the plastic derived oil stream 102 may have less than or equal to 0.1 wt. % sulfur, as determined by ASTM D4294. In embodiments, the plastic derived oil stream 102 may have less than 0.01 wt. % Conradson carbon, as determined according to ASTM D4530. In embodiments, the plastic derived oil stream 102 may have an oxygen content of from 100 ppmw to 10,000 ppmw, such as from 100 ppmw to 7,000 ppmw, from 500 ppmw to 10,000 ppmw, from 500 ppmw to 7000 ppmw, from 1000 to 10,000 ppmw, from 1000 to 7000 ppmw, or from 5000 ppm to 10,000 ppmw. In embodiments, the plastic derived oil stream 102 may have a moisture content (concentration of water) of less than or equal to 5000 ppmw, less than or equal to 2000 ppmw, less than or equal to 1000 ppmw, less than or equal to 500 ppmw, or less than or equal to 400 ppmw, as determined according to ASTM D6304A. In embodiments, the plastic derived oil stream 102 may have the properties provided in Table 1.TABLE 1Properties of one embodiment of the plastic derived oil stream 102PropertyUnitsTest MethodValueDensityg / cm3ASTM D40520.792Total Oxygen ConcentrationppmwCombustion5540basedTotal Chloride ConcentrationppmwUOP 779342Total Sulfurwt. %ASTM D42940.064Total NitrogenppmwASTM D46291135Bromine Numberg(Br2) / ASTM D115943.3100 gSilicappmwUOP 4070.109SodiumppmwUOP 4070.174IronppmwUOP 4070.097WaterppmwASTM D6304A299Conradson Carbon Residuewt. %ASTM D4530<0.01Simulated Distillation TableRecovery (wt. %)UnitsTest MethodTemperatureSIMDIST - IBP° C.ASTM D288729.4SIMDIST - 5 wt. %° C.ASTM D288777.7SIMDIST - 10 wt. %° C.ASTM D2887107.1SIMDIST - 15 wt. %° C.ASTM D2887127.3SIMDIST - 20 wt. %° C.ASTM D2887139.9SIMDIST - 25 wt. %° C.ASTM D2887158.7SIMDIST - 30 wt. %° C.ASTM D2887173.6SIMDIST - 35 wt. %° C.ASTM D2887188.7SIMDIST - 40 wt. %° C.ASTM D2887207.9SIMDIST - 45 wt. %° C.ASTM D2887225.6SIMDIST - 50 wt. %° C.ASTM D2887240.0SIMDIST - 55 wt. %° C.ASTM D2887253.9SIMDIST - 60 wt. %° C.ASTM D2887266.2SIMDIST - 65 wt. %° C.ASTM D2887279.3SIMDIST - 70 wt. %° C.ASTM D2887293.8SIMDIST - 75 wt. %° C.ASTM D2887307.1SIMDIST - 80 wt. %° C.ASTM D2887320.2SIMDIST - 85 wt. %° C.ASTM D2887333.7SIMDIST - 90 wt. %° C.ASTM D2887347.8SIMDIST - 95 wt. %° C.ASTM D2887364.7SIMDIST - FBP° C.ASTM D2887405.3

[0052] The plastic derived oil stream 102 may be produced from solid waste plastic through melting and dehalogenation followed by pyrolysis. Referring to FIG. 1, the systems 100 disclosed herein may further include the dehalogenation unit 10 and the pyrolysis reactor 20, both of which may be disposed upstream of the acid gas removal unit 110. The dehalogenation unit 10 may be operable to melt and dehalogenate the solid waste plastic 12 to produce a liquefied plastic stream 14. The liquefied plastic stream 14 may be passed to the pyrolysis reactor 20 downstream of the dehalogenation unit 10. The pyrolysis reactor 20 may be configured to subject the liquefied plastic stream 14 to pyrolysis to produce the plastic derived oil stream 102. The processes disclosed herein may include producing the plastic derived oil stream 102 from a solid waste plastic 12 by liquefying and dehalogenating the solid waste plastic 12 in the dehalogenation unit 10 to produce a liquefied plastic stream 14, passing the liquefied plastic stream 14 to the pyrolysis reactor 20, and subjecting the liquefied plastic stream 14 to pyrolysis to in the pyrolysis reactor 20 produce the plastic derived oil stream 102.

[0053] The solid waste plastic 12, which is supplied to the dehalogenation unit 10, may comprise a plastic feedstock including mixed solid waste plastic of differing compositions. The solid waste plastic 12 may be a mixture of plastics from various polymer families. In embodiments, the solid waste plastic 12 may comprise plastics representative of one or more of the polymer families, such as but not limited to olefins, carbonates, aromatic polymers, sulfones, fluorinated hydrocarbon polymers, chlorinated hydrocarbon polymers, acrylonitriles, or combinations of these families of polymers. In embodiments, the mixed waste plastics 12 may include polyethylene (PE), polypropylene (PP), diphenylcarbonate, polystyrene (PS), polyether sulfone, polyfluoroethylene (PTFE), polyvinyl chloride (PVC), polyacrylonitrile (PAN), other polymers, or combinations of these. In embodiments, solid waste plastic 12 may be a mixture of high density polyethylene (HDPE, for example, a density of about 0.93 to 0.97 grams per cubic centimeter (g / cm3)), low density polyethylene (LDPE, for example, about 0.910 g / cm3 to 0.940 g / cm3), polypropylene (PP), linear low density polyethylene (LLDPE), polystyrene (PS), polyvinyl chloride (PVC), polyethylene terephthalate (PET), or combinations of these polymers. In embodiments, the solid waste plastic 12 may include one or more chlorinated hydrocarbons, such as PVC. The plastics of the solid waste plastic 12 may be natural, synthetic, or semi-synthetic polymers. Utilization of the solid waste plastic 12 comprising a mixture of different types of plastics and polymers may allow for recycling of solid plastics without necessitating fine sorting of the plastics into different types.

[0054] The solid waste plastic 12 may be provided in a variety of different forms. In embodiments, the solid waste plastic 12 may be in the form of a powder in smaller scale operations. In embodiments, the solid waste plastic 12 may be in the form of pellets, such as pellets with a particle size of from 1 to 5 millimeter (mm) for larger scale operations. In embodiments, the solid waste plastic 12 may be provided as chopped or ground waste plastics. In embodiments, the system 100 may include a plastic grinding unit (not shown) upstream of the dehalogenation unit 10, where the plastic grinding unit may be operable to grind plastic articles into smaller pieces to produce the solid waste plastic 12. In embodiments, the solid waste plastic 12 may comprise waste plastic, manufacturing off-spec product, new plastic products, unused plastic products, or combinations of these.

[0055] The dehalogenation unit 10 may be in fluid communication with the solid waste plastic 12 to pass the solid waste plastic 12 to the dehalogenation unit 10. The dehalogenation unit 10 may be operable to increase the temperature of the solid waste plastic 12 to a temperature between 250° C. and 350° C., such as from 250° C. to 300° C., to melt the plastics and generate the liquefied plastic stream 14. When the solid waste plastic 12 include halogenated plastics, such as but not limited to PVC, melting the plastics may release some hydrogen halides, such as HCl. The dehalogenation unit 10 may also be operable to scrub HCl and other halogen halides released during melting of the solid waste plastic 12. Removal of some of the chlorine, fluorine, or other halides from the solid waste plastic 12 may reduce the concentration of halides in the liquefied plastic stream 14. As a result, the liquefied plastic stream 14 may have a reduced concentration of chlorine compounds and other halogen-containing compounds compared to the solid waste plastic 12. Reducing the concentration of organic halide compounds in the liquefied plastic stream 14 may reduce corrosion problems in the downstream pyrolysis reactor 20. However, the liquefied plastic stream 14 may still contain halogen-containing organic compounds and other contaminants. Thus, dehalogenation in the dehalogenation unit 10 removes only a portion of the halogen-containing compounds from the liquefied plastic stream 14.

[0056] In embodiments, the dehalogenation unit 10 may be operable to increase the temperature of the solid waste plastic 12 to a temperature of from 250° C. to 350° C. to melt the solid waste plastic 12 and remove at least a portion of the chlorine and other halogens from the resulting liquefied plastic stream 14. In embodiments, the dehalogenation unit 10 may be operable to increase the temperature of the solid waste plastic 12 to a temperature of from 250° C. to 300° C., from 275° C. to 350° C., from 275° C. to 325° C., or from 300° C. to 350° C. The temperature of the dehalogenation unit 10 may be controlled to remove HCl without cracking a substantial number of C—H or C—C bonds.

[0057] In embodiments, the HCl and other hydrogen halides released from the liquefied plastic stream 14 may be passed out of the dehalogenation unit 10 as a halogen-rich stream (not shown). The halogen-rich stream may include hydrogen halides, such as HCl, as well as hydrogen and light hydrocarbon gases, such as but not limited to mono aromatics, hydrogen, methane, and C2-C5 gases. In embodiments, the halogen-rich stream may be scrubbed with water or a sodium hydroxide solution in a downstream acid gas scrubbing unit (not shown) to remove the halogen compounds from the halogen-rich stream. In embodiments, the hydrogen halide compounds may be scrubbed within the dehalogenation unit 10, such as by contacting the released gases with adsorbents, such as but not limited to Al2O3, zeolites, or other chemical removers. In embodiments, the dehalogenation unit 10 may include a melting reactor and an acid gas scrubber downstream of the melting reactor. In embodiments, a single unit forming the dehalogenation unit 10 may achieve both melting of the solid waste plastic and scrubbing to remove hydrogen halides. Organic halide compounds not released during dehalogenation in the dehalogenation unit 10 may be passed onward in the liquefied plastic stream 14 to the pyrolysis reactor 20.

[0058] Referring again to FIG. 1, the pyrolysis reactor 20 may be disposed downstream of the dehalogenation unit 10 and in fluid communication with the liquefied plastic stream 14 discharged from the dehalogenation unit 10. In embodiments, the liquefied plastic stream 14 may be passed directly from the dehalogenation unit 10 to the pyrolysis reactor 20. The pyrolysis reactor 20 may be operable to increase the temperature of the liquefied plastic stream 14 to a temperature of from 300° C. to 1000° C., such as from 350° C. to 1000° C., in an anaerobic environment (no oxygen present), to convert the liquefied plastic stream 14 to the plastic derived oil stream 102. In particular, the pyrolysis of the liquefied plastic stream 14 in the pyrolysis reactor 20 may cause at least a portion of the long chain polymers in the liquefied plastic stream 14 to break apart into smaller fragments comprising organic compounds having smaller average molecular weights compared to the long chain polymers in the liquefied plastic stream 14.

[0059] The specific reactor used as the pyrolysis reactor 20 can be of different types and are not limited for the purposes of the present disclosure. Typical reactor types that can be used to serve the function of the pyrolysis reactor 20 can include but are not limited to tank reactors, rotary kilns, packed catalyst bed reactors, bubbling bed reactors, or other types of reactors. In embodiments, the pyrolysis of the liquefied plastic stream 14 in the pyrolysis reactor 20 may be performed in the presence or absence of a pyrolysis catalyst at a temperature of from 300° C. to 1000° C. or from 350° C. to 1000° C. In embodiments, the pyrolysis reactor 20 may operate at a low severity at a temperature less than or equal to 450° C. or at a high severity at a temperature greater than 450° C. In embodiments, the pyrolysis reactor 20 may be operated at a temperature of from 400° C. to 600° C., from 400° C. to 500° C., from 400° C. to 450° C., from 450° C. to 500° C., or from 425° C. to 475° C. In embodiments, the pyrolysis reactor 20 may be operated at a pressure in the range of 1 bar to 100 bars (100 kilopascals (kPa) to 10,000 kPa), from 1 bar to 50 bars (100 kPa to 5000 kPa), from 1 bar to 25 bars (1 kPa to 2500 kPa), or from 1 bar to 10 bars (1 kPa to 1000 kPa). Further, in various embodiments, the residence time of the liquefied plastic stream 14 in the pyrolysis reactor 20 may be from 1 second to 3600 seconds, from 60 seconds to 1800 seconds, or from 60 seconds to 900 seconds. The plastic derived oil stream 102 may be passed out of the pyrolysis reactor 20.

[0060] The used cooking oil stream 104 may include hydrocarbons, such as but not limited to aromatic compounds, olefins, alkanes, other hydrocarbon compounds. Additionally, the used cooking oil stream 104 may include other organic compounds, such as but not limited to oxygenates, halogen-containing compounds such as organic halide compounds, and other contaminants.

[0061] In embodiments, the used cooking oil stream 104 may comprise primarily heavy compounds, which refer to hydrocarbons having atmospheric boiling point temperatures of greater than 343° C. In embodiments, the used cooking oil stream 104 may comprise greater than or equal to 80 wt. % heavy compounds, such as greater than or equal to 85 wt. %, greater than or equal to 90 wt. %, greater than or equal to 95 wt. %, greater than or equal to 98 wt. %, greater than or equal to 99 wt. %, or even 100 wt. % heavy compounds per unit weight of the used cooking oil stream 104.

[0062] In embodiments, the used cooking oil stream 104 may comprise less than or equal to 15 wt. % light naphtha range hydrocarbons, less than or equal to 10 wt. % light naphtha range hydrocarbons, less than or equal to 5 wt. %, or even less than or equal to 1 wt. % light naphtha range hydrocarbons per unit weight of the used cooking oil stream 104. In embodiments, the used cooking oil stream 104 may comprise less than or equal to 15 wt. % jet fuel constituents, such as less than or equal to 10 wt. %, less than or equal to 5 wt. %, or even less than or equal to 1 wt. % jet fuel constituents per unit weight of the used cooking oil stream 104. In embodiments, the used cooking oil stream 104 may compromise less than or equal to 20 wt. % the diesel range constituents, such as less than or equal to 15 wt. % less than or equal to 10 wt. %, less than or equal to 5 wt. %, or even less than or equal to 1 wt. % of the diesel range constituents per unit weight of the used cooking oil stream 104.

[0063] The used cooking oil stream 104 may be characterized by a boiling point distribution determined using standard test method ASTM D2887. The used cooking oil stream 104 may have a narrow boiling point distribution of from 450° C. to 750° C., such as from 500° C. to 700° C., or from 500° C. to 650° C. In embodiments, the used cooking oil stream 104 may have an initial boiling point (IBP) of greater than or equal to 450° C., such as from 450° C. to 600° C., from 450° C. to 580° C., from 450° C. to 550° C., from 500° C. to 600° C., from 500° C. to 580° C., from 500° C. to 560° C., from 500° C. to 550° C., from 510° C. to 600° C., from 510° C. to 580° C., from 510° C. to 560° C., or from 510° C. to 550° C. In embodiments, the used cooking oil stream 104 may have a final boiling point (FBP) of less than or equal to 750° C., such as from 600° C. to 750° C., such as from 600° C. to 720° C., from 600° C. to 700° C., from 600° C. to 675° C., from 620° C. to 750° C., from 620° C. to 720° C., from 620° C. to 700° C., or from 620° C. to 675° C. In embodiments, the used cooking oil stream 104 may have a 50% boiling point temperature of from 580° C. to 620° C., such as from 550° C. to 610° C., from 590° C. to 620° C., from 590° C. to 610° C., from 600° C. to 620° C., from 600° C. to 615° C., or from 600° C. to 610° C., where the 50% boiling point temperature is defined according to test method ASTM D2887.

[0064] The used cooking oil stream 104 may have a density of from 0.8 g / cm3 to 1.1 g / cm3, such as from 0.8 g / cm3 to 1.05 g / cm3, from 0.8 g / cm3 to 1 g / cm3, from 0.8 g / cm3 to 0.95 g / cm3, from 0.85 g / cm3 to 1.1 g / cm3, from 0.85 g / cm3 to 1.05 g / cm3, from 0.85 g / cm3 to 1 g / cm3, from 0.85 g / cm3 to 0.95 g / cm3, from 0.9 g / cm3 to 1.1 g / cm3, from 0.9 g / cm3 to 1.05 g / cm3, from 0.9 g / cm3 to 1 g / cm3, from 0.9 g / cm3 to 0.95 g / cm3, or from 0.92 g / cm3 to 0.93 g / cm3, as determined by ASTM D4052. The used cooking oil stream 104 may have an API gravity of from 15 degrees to 30 degrees, such as from 15 degrees to 27 degrees, from 15 degrees to 25 degrees, from 18 degrees to 30 degrees, from 18 degrees to 27 degrees, from 18 degrees to 25 degrees, from 20 degrees to 30 degrees, from 20 degrees to 27 degrees, from 20 degrees to 25 degrees, or from 21 degrees to 23 degrees, as determined according to ASTM 287. The used cooking oil stream 104 may have less than or equal to 1.00 wt. % free fatty acid (FFA), as determined by ASTM 5555-95.

[0065] In embodiments, the used cooking oil stream 104 may have a chlorine content of from 0 (zero) ppmw to 20 ppmw, such as from 2 ppmw to 20 ppmw, from 2 ppmw to 10 ppmw, from 2 ppmw to 8 ppmw, from 5 ppmw to 20 ppmw, from 5 ppmw to 15 ppmw, from 5 ppmw to 10 ppmw, or from 12 ppm to 20 ppm, as determined by standard test method UOP 407. In embodiments, the used cooking oil stream 104 may have a sulfur content from 0 ppmw to 20 ppmw, such as from 0 ppmw to 10 ppmw, from 0 ppmw to 8 ppmw, from 1 ppmw to 20 ppmw, from 1 ppmw to 10 ppmw, from 5 ppmw to 20 ppmw, from 5 ppmw to 15 ppmw, or from 5 ppmw to 10 ppmw, as determined by ASTM D4294. In embodiments, the used cooking oil stream 104 may have a phosphorus content of from 0 ppmw to 10 ppmw, such as from 0 ppmw to 5 ppmw, from 0 ppmw to 2 ppmw, from 0.1 ppmw to 10 ppmw, such as from 0.1 ppmw to 5 ppmw, from 0.1 ppmw to 2 ppmw, from 0.1 ppmw to 1.5 ppmw, from 0.5 ppmw to 10 ppmw, from 0.5 ppmw to 5 ppmw, from 0.5 ppmw to 2 ppmw, or from 0.5 ppmw to 1.5 ppmw, as determined by UOP 407.

[0066] In embodiments, the used cooking oil stream 104 may have a total metal content less than 10 ppmw, such as from 0 ppmw to 10 ppmw, from 0 ppmw to 5 ppmw, from 1 ppmw to 10 ppmw, from 1 ppmw to 5 ppmw, from 2 ppmw to 10 ppmw, or from 2 ppmw to 5 ppmw, as determined by UOP 407. In embodiments, the used cooking oil stream 104 may include calcium, iron, potassium, sodium, silicon, tin, zinc, other metals, or combinations of metals. For example, the used cooking oil stream 104 may have a calcium content of from 0 ppmw to 1 ppmw, such as from 0.1 ppmw to 1 ppmw, from 0.1 ppmw to 0.5 ppmw, from 0.1 ppmw to 0.25 ppmw, from 0.25 ppmw to 0.5 ppmw, from 0.25 ppmw to 0.75 ppmw, from 0.25 ppmw to 0.5 ppmw, from 0.5 ppmw to 0.75 ppmw, from 0.75 ppmw to 1 ppmw, or from 0.5 ppmw to 1 ppmw, as determined by UOP 407. In embodiments, the used cooking oil stream 104 may have an iron content of less than or equal to 0.1 ppmw, less than or equal to 0.05 ppmw, or less than or equal to 0.02 ppmw, as determined UOP 407. In embodiments, the used cooking oil stream 104 may have a potassium content of from 0 ppmw to 0.2 ppmw, such as from 0.01 ppmw to 0.2 ppmw, from 0.01 ppmw to 0.1 ppmw, from 0.05 ppmw to 0.15 ppmw, from 0.05 ppmw to 0.2 ppmw, or from 0.1 ppmw to 0.2 ppmw, as determined by UOP 407. In embodiments, the used cooking oil stream 104 may have a sodium content of from 0.5 ppmw to 1.5 ppmw, such as from 0.5 ppmw to 0.75 ppmw, from 0.5 ppmw to 1 ppmw, from 0.75 ppmw to 1.25 ppmw, from 0.75 ppmw to 1 ppmw, from 1 ppmw to 1.25 ppmw, from 1 ppmw to 1.25 ppmw, from 1 ppmw to 1.5 ppmw, or from 1.25 ppmw to 1.5 ppmw, as determined by UOP 407. In embodiments, the used cooking oil stream 104 may have a silicon content of from 1.5 ppmw to 3 ppmw, such as from 1.5 ppmw to 2 ppmw, from 1.5 ppmw to 2.5 ppmw, from 2 ppmw to 2.5 ppmw, from 2 ppmw to 3 ppmw, or from 2.5 ppmw to 3 ppmw, as determined by UOP 407. In embodiments, the used cooking oil stream 104 may have a tin content of less than or equal to 0.2 ppmw, less than or equal to 0.15 ppmw, less than or equal to 0.1 ppmw, or less than or equal to 0.05 ppmw, as determined by UOP 407. In embodiments, the used cooking oil stream 104 may have a zinc content of from 0.01 ppmw to 0.3 ppmw, such as from 0.01 ppmw to 0.1 ppmw, from 0.05 ppmw to 0.15 ppmw, from 0.05 ppmw to 0.2 ppmw, from 0.1 ppmw to 0.2 ppmw, from 0.15 ppmw to 0.3 ppmw, or from 0.2 ppmw to 0.3 ppmw, as determined by UOP 407. The composition of an exemplary used cooling oil suitable for the used cooking oil stream 104 of the present disclosure is provided in Table 2.TABLE 2Properties of an exemplary used cooking oilsuitable for the used cooking oil stream 104PropertyTest MethodValueDensity (g / cm3)ASTM D40520.925API Gravity (degrees)ASTM 28722.01Free Fatty Acid (FFA) (wt. %)ASTM 5555-950.73Chlorine (ppmw)UOP 4078.00Sulfur (ppmw)ASTM D42947.91Phosphorus (ppmw)UOP 4070.78Total Metals (ppmw)UOP 4073.81Calcium (ppmw)UOP 4070.50Iron (ppmw)UOP 4070.02Potassium (ppmw)UOP 4070.10Sodium (ppmw)UOP 4071.06Silicon(ppmw)UOP 4072.13Tin (ppmw)UOP 4070.06Zinc (ppmw)UOP 4070.17SIMDIST - IBP (° C.)ASTM D2887519SIMDIST - 25 wt. % (° C.)ASTM D2887599SIMDIST - 50 wt. % (° C.)ASTM D2887607SIMDIST - 75 wt. % (° C.)ASTM D2887615SIMDIST - IBP (° C.)ASTM D2887632

[0067] Referring again to FIG. 1, the plastic derived oil stream 102 is passed to the acid gas removal unit 110. An acid gas removal catalyst 112 is disposed within the acid gas removal unit 110. The acid gas removal catalyst 112 may be a catalyst operable to remove residual HCl and sulfur-containing compounds such as H2S from the plastic derived oil stream 102 to produce the treated plastic derived oil stream 114. The acid gas removal catalyst 112 may be a solid inorganic alkali metal salt. Examples of the solid inorganic alkali metal salt may include but are not limited to sodium bicarbonate, sodium carbonate, sodium hydroxide, lime, or any combinations thereof, such as a mixture of sodium bicarbonate and lime. The reaction of HCl and H2S generates metal chlorides, metal sulfates, and water. The metal chlorides and metal sulfates are solids and stay in the acid gas removal unit 110, while the water goes out as steam with other gaseous hydrocarbons. Other acidic gases such as CO and CO2 are expelled along with the other gaseous hydrocarbons.

[0068] In various embodiments, acid gas removal unit 110 may operate as a fluidized bed, a fixed bed, a moving bed, or a packed bed reactor system. As such, the acid gas removal catalyst 112 may be provided as pellets or a powder, depending on the type of reactor used for the acid gas removal unit 110.

[0069] As previously indicated, the acid gas removal catalyst 112 within the acid gas removal unit 110 removes residual HCl and sulfur-containing compounds from the plastic derived oil stream 102 to generate the treated plastic derived oil stream 114. The treated plastic derived oil stream 114 may have a concentration of halogen-containing compounds less than the plastic derived oil stream 102 upstream of the acid gas removal unit 110. In embodiments, the treated plastic derived oil stream 114 may have a concentration of halogen-containing compounds of less than 100 ppmw, such as less than 50 ppmw, less than 20 ppmw, less than 10 ppmw. In embodiments, the treated plastic derived oil stream 114 may have a concentration of halogen-containing compounds of from 1 ppmw to 100 ppmw, from 1 ppmw to 80 ppmw, from 1 ppmw to 50 mm, from 1 ppmw to 20 ppmw, from 1 ppmw to 10 ppmw, from 5 ppmw to 100 ppmw, from 5 ppmw to 80 ppmw, from 5 ppmw to 50 ppmw, from 5 ppmw to 20 ppmw, from 5 ppmw to 10 ppmw, from 10 ppmw to 100 ppmw, from 10 ppmw to 80 ppmw, from 10 ppmw to 50 mm, from 10 ppmw to 20 ppmw, from 20 ppmw to 100 ppmw, from 20 ppmw to 80 ppmw, from 20 ppmw to 50 mm, from 50 ppmw to 100 ppmw, or from 50 ppmw to 80 ppmw per unit weight of the treated plastic derived oil stream 114. In embodiments, the treated plastic derived oil stream 114 may comprise less than 500 ppmw of sulfur-containing compounds. It will be appreciated that in embodiments, the treated plastic derived oil stream 114 may comprises less than 100 ppmw total halogen-containing compounds and less than 500 ppmw of sulfur-containing compounds, per unit weight of the treated plastic derived oil stream 114.

[0070] Referring again to FIG. 1, the used cooking oil stream 104 and the treated plastic derived oil stream 114 may be passed to the FCC system 120, such as to the FCC reactor 122. The used cooking oil stream 104 and the treated plastic derived oil stream 114 may be separately introduced to the FCC system, such as to the FCC reactor 122, or combined upstream of the FCC reactor 122. For example, the treated plastic derived oil stream 114 and used cooking oil stream 104 may be combined in a mixing tank or other mixing unit prior to entering the FCC reactor 122. In embodiments, the FCC reactor 122 of the FCC system 120 may be downstream of the pyrolysis reactor 20 and in fluid communication with the pyrolysis reactor 20 to pass the treated plastic derived oil stream 114 from the pyrolysis reactor 20 directly to the FCC reactor 122.

[0071] The hydrocarbons introduced to the FCC reactor 122 comprise a mixture of the treated plastic derived oil stream 114 and the used cooking oil stream 104. The hydrocarbons introduced to the FCC reactor 122 may comprise from 10 wt. % to 90 wt. % of the treated plastic derived oil stream 114 based on the total weight of the hydrocarbons introduced to the FCC reactor 122. In embodiments, the hydrocarbons introduced to the FCC reactor 122 may include from 10 wt. % to 80 wt. %, from 10 wt. % to 50 wt. %, from 20 wt. % to 90 wt. %, from 20 wt. % to 80 wt. %, from 20 wt. % to 50 wt. %, from 50 wt. % to 90 wt. %, from 50 wt. % to 80 wt. %, or from 80 wt. % to 90 wt. % of the treated plastic derived oil stream 114 based on the total weight of the hydrocarbons introduced to the FCC reactor 122.

[0072] The hydrocarbons introduced to the FCC reactor 122 may comprise from 10 wt. % to 90 wt. % of the used cooking oil stream 104 based on the total weight of the hydrocarbons introduced to the FCC reactor 122. In embodiments, the hydrocarbons introduced to the FCC reactor 122 may include from 10 wt. % to 80 wt. %, from 10 wt. % to 50 wt. %, from 20 wt. % to 90 wt. %, from 20 wt. % to 80 wt. %, from 20 wt. % to 50 wt. %, from 50 wt. % to 90 wt. %, from 50 wt. % to 80 wt. %, or from 80 wt. % to 90 wt. % of the used cooking oil stream 104 based on the total weight of the hydrocarbons introduced to the FCC reactor 122. A mass flow ratio of the treated plastic derived oil stream 114 to the used cooking oil stream 104 may be from 1:9 to 9:1.

[0073] Referring again to FIG. 1, the treated plastic derived oil stream 114 and the used cooking oil stream 104 may be passed to the FCC system 120, such as to the FCC reactor 122 of the FCC system 120. The FCC reactor 122 may comprise a cracking catalyst 124. Contact of the treated plastic derived oil stream 114 and the used cooking oil stream 104 with the cracking catalyst 124 may cause at least a portion of the hydrocarbons from the treated plastic derived oil stream 114 and the used cooking oil stream 104 to under catalytic cracking to produce lighter hydrocarbons and hydrocarbon gases. Contact of the treated plastic derived oil stream 114 and the used cooking oil stream 104 with the cracking catalyst 124 may produce an FCC effluent 122 that includes a greater concentration of greater-value chemicals and intermediates, such as but not limited to light olefins, light aromatic compounds, light naphtha, gasoline constituents, jet fuel constituents, diesel constituents, or combinations of these greater value chemicals and intermediates, compared to the combined treated plastic derived oil stream 114 and used cooking oil stream 104.

[0074] The FCC reactor 122 may be a fluidized bed reactor. The FCC reactor 122 may include one or a plurality of fluidized bed reactors. When the FCC reactor 122 comprises a plurality of reactors, the plurality of reactors may be parallel, such as for purposes of increasing capacity of the FCC system 120 for upgrading the treated plastic derived oil stream 114 and used cooking oil stream 104. In embodiments, the FCC reactor 122 is a fluidized bed reactor in which treated plastic derived oil stream 114, used cooking oil stream 104, and the cracking catalyst 114 are combined together at one end of the reactor and flow co-currently through the fluidized bed reactor to an outlet of the FCC reactor 122. The FCC reactor 122 may be a riser reactor or a downer reactor. In embodiments, the FCC reactor 122 may be a riser reactor.

[0075] The cracking catalyst 124 utilized in the FCC reactor 122 may be any conventional cracking catalyst known to those skilled in the art for catalyzing cracking reactions of hydrocarbons. The cracking catalyst 124 is different from the acid gas removal catalyst 112. In embodiments, the cracking catalyst 124 may comprise a commercial catalyst for FCC applications. In embodiments, the cracking catalyst 124 may comprise one or more commercial catalysts for FCC applications. Alternatively, or additionally, the cracking catalyst 124 may comprise other suitable solid acid catalysts. In embodiments, the cracking catalyst 124 may comprise one or more binders, cracking promoters, matrix materials, or other constituents to modify the physical or chemical properties such as catalyst attrition index and catalyst density. In embodiments, the cracking catalyst 124 may be an equilibrium catalyst (ECAT) and may include a cracking additive to increase the yield of light olefins. Other cracking catalysts may also be suitable for the cracking catalyst 124 in the FCC reactor 122. In embodiments, the cracking catalyst 124 may comprise an equilibrium catalyst and a cracking additive, where the equilibrium catalyst may comprise a Y-type zeolite or a USY zeolite, and the cracking additive may include an mordenite framework inverted (MFI) zeolite, such as but not limited to a ZSM-5 zeolite.

[0076] In embodiments, the cracking catalyst 124 may comprise from 65 wt. % to 85 wt. % ECAT, per unit weight of the cracking catalyst. For example, the cracking catalyst 124 may comprise ECAT in amounts from 65 wt. % to 85 wt. %, from 65 wt. % to 80 wt. %, 70 wt. % to 85 wt. %, from 70 wt. % to 80 wt. %, or any combination of these ranges per unit weight of cracking catalyst. Further, in embodiments, the cracking catalyst 124 may comprise a cracking additive in amounts from 15 wt. % to 35 wt. %, from 20 wt. % to 35 wt. %, from 15 wt. % to 30 wt. %, from 20 wt. % to 30 wt. %, or any combination of these ranges per unit weight of cracking catalyst. In embodiments, the cracking catalyst 124 may comprise from 20 wt. % to 30 wt. % light olefin additives, per unit weight of the cracking catalyst 124.

[0077] In embodiments, the cracking catalyst 124 may be a simple mixture or blend of ECAT particles and cracking additive particles. In embodiments, the ECAT and cracking additives of the cracking catalyst, in the form of a powder or slurry, may be combined with other materials, such as but not limited to binder materials, matrix materials, or other materials, and formed into composite particles of the cracking catalyst 124. The combined materials may be extruded to produce the cracking catalyst 124 in the form of composite particles comprising the various constituents of the cracking catalyst 124. In embodiments, cracking catalyst 124 may be prepared through a spray drying process, which may include forming a slurry comprising the ECAT, cracking additives, the binder materials, and the matrix materials and then spray drying the slurry to produce the composite particles of the cracking catalyst 124. In embodiments, the cracking catalyst 124 may be prepared through extrusion and pelletizing or other process for forming composite catalyst particles.

[0078] The binder materials may comprise silica, alumina, silica-alumina, or any combinations of these. The alumina may comprise an acid peptized alumina. The silica-alumina may comprise an amorphous silica-alumina. In embodiments, the cracking catalyst 124 may comprise from 10 wt. % to 20 wt. % of the binder, per unit weight of the cracking catalyst. For example, the cracking catalyst 124 may comprise the binder in amounts of from 10 wt. % to 18 wt. %, from 10 wt. % to 16 wt. %, from 10 wt. % to 14 wt. %, from 12 wt. % to 20 wt. %, from 14 wt. % to 20 wt. %, from 16 wt. % to 20 wt. %, or any combination of these ranges, per unit weight of the cracking catalyst. In embodiments, the cracking catalyst 124 may comprise from 10 wt. % to 20 wt. % of the acid peptized alumina binder, per unit weight of the cracking catalyst 124.

[0079] Matrix materials may include clays, such as but not limited to kaolin, montmorilonite, halloysite, bentonite, or combinations of these. In embodiments, the cracking catalyst 124 may comprise from 20 wt. % to 60 wt. % of the matrix material, per unit weight of the cracking catalyst. For example, the cracking catalyst may comprise the matrix material in amounts of from 20 wt. % to 55 wt. %, from 20 wt. % to 50 wt. %, from 20 wt. % to 45 wt. %, from 20 wt. % to 40 wt. %, from 20 wt. % to 35 wt. %, from 25 wt. % to 60 wt. %, from 30 wt. % to 60 wt. %, from 35 wt. % to 60 wt. %, from 40 wt. % to 60 wt. %, from 45 wt. % to 60 wt. %, or any combination of these ranges, per unit weight of the cracking catalyst. In embodiments, the cracking catalyst 124 may comprise from 20 wt. % to 60 wt. % kaolin clay per unit weight of the cracking catalyst 124.

[0080] The FCC reactor 122 may be configured to contact the treated plastic derived oil stream 114 and used cooking oil stream 104 with the cracking catalyst 124 at a reaction temperature of from 500 degrees Celsius (C) to 650° C., such as from 500° C. to 600° C., from 550° C. to 650° C., from 550° C. to 600° C., or from 600° C. to 650° C. The FCC reactor 122 may be configured to contact the treated plastic derived oil stream 114 and used cooking oil stream 104 with the cracking catalyst 124 at a pressure of from 101 kilopascals (kPa) to 303 kPa, such as from 125 kPa to 303 kPa, from 150 kPa to 303 kPa, from 200 kPa to 303 kPa, from 250 kPa to 303 kPa, from 101 kPa to 250 kPa, from 101 kPa to 200 kPa, from 101 kPa to 150 kPa, at atmospheric pressure (˜101 kPa), or any combination of these ranges. In embodiments, the FCC reactor 122 may be configured to contact the treated plastic derived oil stream 114 and used cooking oil stream 104 with the cracking catalyst 124 at a gas hourly space velocity (GHSV) of from 0.2 per hour (h−1) to 100 h−1, such as from 1 h−1 to 100 h−1, from 5 h−1 to 100 h−1, from 10 h−1 to 100 h−1, from 25 h−1 to 100 h−1, from 50 h−1 to 100 h−1, from 0.2 h−1 to 80 h−1, from 0.2 h−1 to 50 h−1, from 0.2 h−1 to 25 h−1, from 0.2 h−1 to 10 h−1, or any combinations of these ranges. In embodiments, the FCC reactor 122 may be operable to contact the treated plastic derived oil stream 114 and used cooking oil stream 104 with the cracking catalyst 124 at a catalyst-to-oil weight ratio of greater than or equal to 2, such as from 2 to 40, from 2 to 35, from 2 to 30, from 2 to 25, from 2 to 20, from 2 to 15, from 2 to 12, from 2 to 10, from 2 to 8, from 4 to 10, from 4 to 40, from 8 to 40, from 15 to 40, from 20 to 40, from 30 to 40, or any combination of these ranges. The catalyst-to-oil weight ratio in the FCC reactor 122 is equal to an average ratio of a mass flow rate of the cracking catalyst 124 through the FCC reactor 122 divided by a mass flow rate of the hydrocarbons (treated plastic derived oil stream 114+used cooking oil stream 104) in the FCC reactor 122 during steady state operation of the FCC system 120.

[0081] In embodiments, the FCC effluent 132 may be separated from the used cracking catalyst 134 at or proximate to an outlet end of the FCC reactor 122. Referring again to FIG. 1, in embodiments, the reaction mixture, which may include the FCC effluent 132 and the used cracking catalyst 134, may be passed out of the FCC reactor 122 to the fluid-solid separation unit 130. As previously discussed, the fluid-solid separation unit 130 may be disposed at the outlet end of the FCC reactor 122. The fluid-solid separation unit 130 may be configured to separate the FCC effluent 132 from the solid particles of the used cracking catalyst 134. The FCC effluent 132 is in a fluid phase (generally a vapor phase at the reaction conditions of the FCC reactor). In FIG. 1, the fluid-solid separation unit 130 is depicted as a vessel disposed at the outlet end of the FCC reactor 122, where the vessel reduces the fluid velocity of the FCC effluent 132 to allow the solid particles of the used cracking catalyst 134 to separate and settle out from the fluid phase of the FCC effluent 132. The used cracking catalyst 134 may settle in the bottom of the fluid-solid separation unit 130, and the FCC effluent 132 may pass out of a top portion of the fluid-solid separation unit 130. In embodiments, the fluid-solid separation unit 130 may further include one or more downstream cyclones, filters, or other unit operation (not shown) that may be configured to remove catalyst fines from the FCC effluent 132. Other types of fluid-solid separation devices are contemplated for the fluid-solid separation unit 130. The used cracking catalyst 134 may be passed from the fluid-solid separation unit 130 to the catalyst regenerator 140.

[0082] Referring again to FIG. 1, as previously discussed, the FCC system 120 includes the catalyst regenerator 140. The used cracking catalyst 134 may be passed from the fluid-solid separation unit 130 to the catalyst regenerator 140 and regenerated to produce a regenerated cracking catalyst 142. The regenerated cracking catalyst 142 may be passed back to the FCC reactor 122 as at least a portion of or all of the cracking catalyst 124. The catalyst regenerator 140 may be disposed downstream of the solid-fluid separation unit 130 and in fluid communication with an outlet of the solid-fluid separation unit 130 to pass the used cracking catalyst 134 from the solid-fluid separation unit 130 directly to the catalyst regenerator 140.

[0083] During the reactions in the FCC reactor 122, coke may deposit on the used cracking catalyst 134 as a result of the cracking reactions. The coke may block reactive sites on the cracking catalyst and reduce the catalytic activity of the cracking catalyst for catalyzing the cracking reactions. The catalyst regenerator 140 may be configured to heat the used cracking catalyst 134 to a temperature sufficient to remove coke from the cracking catalyst 134 to produce the regenerated cracking catalyst 142. In embodiments, the catalyst regenerator 140 may be configured to contact the used cracking catalyst 134 with the regeneration gas 144 at the regeneration temperature, which may be sufficient to combust coke deposits on the used cracking catalyst 134, increase the temperature of the regenerated cracking catalyst 142, or combinations thereof.

[0084] The regeneration temperature in the catalyst regenerator 140 may be sufficient to combust the coke deposits, increase the temperature of the catalyst particles, or both to produce the regenerated cracking catalyst 142. The regeneration gas 144 may be an oxygen-containing gas, such as but not limited to air. In embodiments, the regeneration gas 144 may include a fuel gas in addition to the oxygen-containing gas. The fuel gas may be added to increase the heat produced in the catalyst regenerator 140, which can increase combustion of coke deposits, further increase the temperature of the cracking catalyst, or both. In embodiments, the regeneration temperature in the catalyst regenerator 140 may be greater than the operating temperature of the FCC reactor 122. In embodiments, the regeneration temperature in the catalyst regenerator 140 may be from 500° C. to 900° C., such as from 500° C. to 800° C., from 500° C. to 750° C., from 550° C. to 900° C., from 550° C. to 800° C., or from 550° C. to 750° C.

[0085] Combustion gases produced through combustion of the coke deposits, and optionally any supplemental fuels added to the catalyst regenerator 140, may be passed out of the catalyst regenerator 140 in a flue gas 146. The flue gas 146 may exit from a top portion of the catalyst regenerator 140. The flue gas 146 may be passed to one or more downstream treatment systems for properly handling of the combustion gases to reduce environmental impact, such as through acid gas removal systems, scrubbing, carbon capture, and the like.

[0086] The removal of coke deposits from the used cracking catalyst 134 produces the regenerated cracking catalyst 142. Referring again to FIG. 1, the catalyst regenerator 140 may be in fluid communication with the inlet end of the FCC reactor 122 to pass the regenerated cracking catalyst 142 back to the FCC reactor 122 as a portion of or all of the cracking catalyst 124. The system 100 may further include a regenerated cracking catalyst transfer line 148 fluidly coupling the catalyst regenerator 140 and the inlet of the FCC reactor 122. The regenerated cracking catalyst transfer line 148 may be operable to pass the regenerated cracking catalyst 142 from the catalyst regenerator 140 to the FCC reactor 122. In embodiments, the system 100 may further include a catalyst valve 149 disposed in the regenerated cracking catalyst transfer line 148 and operable to control a mass flow rate of the regenerated cracking catalyst 142 from the catalyst regenerator 140 to the FCC reactor 122.

[0087] The FCC effluent 132 may comprise fuel gases, light olefins, C2-C4 alkanes, light aromatic compounds, light naphtha, jet fuel constituents, diesel constituents, heavy compounds, or any combination of these constituents. The FCC effluent 132 may comprise a greater concentration of light olefins, light aromatic compounds, light naphtha range hydrocarbons, or combinations of these constituents compared to the treated plastic derived oil stream 114 and used cooking oil stream 104. The FCC effluent 132 may have reduced concentrations of jet fuel constituents, diesel constituents, and heavy compounds compared to the treated plastic derived oil stream 114 and may have reduced concentrations of heavy compounds compared to the used cooking oil stream 104.

[0088] In embodiments, a yield of light olefins, such as but not limited to ethylene, propylene, mixed butenes, and combinations thereof, in the FCC effluent 132 may be from 10 wt. % to 30 wt. %, from 10 wt. % to 20 wt. %, from 10 wt. % to 26 wt. %, from 10 wt. % to 23 wt. %, from 19 wt. % to 26 wt. %, or from 20 wt. % to 30 wt. % based on the mass flow rate of the treated plastic derived oil stream 114 and used cooking oil stream 104 introduced to the FCC reactor 122. In embodiments, the FCC effluent 132 may comprise from 10 wt. % to 30 wt. %, from 10 wt. % to 20 wt. %, from 10 wt. % to 26 wt. %, from 10 wt. % to 23 wt. %, from 19 wt. % to 26 wt. %, or from 20 wt. % to 30 wt. % light olefins per unit weight of the FCC effluent 132.

[0089] In embodiments, a yield of light naphtha in the FCC effluent 132 may be greater than or equal to 25 wt. %, such as greater than or equal to 28 wt. %, greater than or equal to 29 wt. %, greater than or equal to 30 wt. %, from 25 wt. % to 45 wt. %, from 25 wt. % to 40 wt. %, from 25 wt. % to 38 wt. %, from 28 wt. % to 45 wt. %, from 28 wt. % to 40 wt. %, from 28 wt. % to 38 wt. %, from 29 wt. % to 45 wt. %, from 29 wt. % to 40 wt. %, or from 29 wt. % to 38 wt. % based on the mass flow rate of the treated plastic derived oil stream 114 and used cooking oil stream 104 introduced to the FCC reactor 122. In embodiments, the FCC effluent 132 may comprise greater than or equal to 25 wt. %, such as greater than or equal to 29 wt. %, greater than or equal to 29 wt. %, greater than or equal to 30 wt. %, from 25 wt. % to 45 wt. %, from 25 wt. % to 40 wt. %, from 25 wt. % to 38 wt. %, from 28 wt. % to 45 wt. %, from 28 wt. % to 40 wt. %, from 28 wt. % to 38 wt. %, from 29 wt. % to 45 wt. %, from 29 wt. % to 40 wt. %, or from 29 wt. % to 38 wt. % light naphtha per unit weight of the FCC effluent 132.

[0090] In embodiments, a yield of light naphtha and C2-C4 paraffins in the FCC effluent may be from 35 wt. % to 55 wt. %, from 40 wt. % to 50 wt. %, from 42 wt. % to 47 wt. %, or from 40 wt. % to 48 wt. % based on the mass flow rate of the treated plastic derived oil stream 114 and used cooking oil stream 104 introduced to the FCC reactor 122. In embodiments, the FCC effluent 132 may comprise from 35 wt. % to 55 wt. %, from 40 wt. % to 50 wt. %, from 42 wt. % to 47 wt. %, or from 40 wt. % to 48 wt. % of the light naphtha and C2-C4 paraffins per unit weight of the FCC effluent 132.

[0091] In embodiments, a yield of C2-C4 paraffins in the FCC effluent 132 may be from 5 wt. % to 15 wt. %, from 5 wt. % to 10 wt. %, from 5 wt. % to 8 wt. %, from 7 wt. % to 12 wt. %, or from 10 wt. % to 15 wt. % based on the mass flow rate of the treated plastic derived oil stream 114 and used cooking oil stream 104 introduced to the FCC reactor 122. In embodiments, the FCC effluent 132 may comprise from 5 wt. % to 15 wt. %, from 5 wt. % to 10 wt. %, from 5 wt. % to 8 wt. %, from 7 wt. % to 12 wt. %, or from 10 wt. % to 15 wt. % the C2-C4 paraffins per unit weight of the FCC effluent 132.

[0092] In embodiments, a yield of jet fuel constituents in the FCC effluent 132 may be less than or equal to 40 wt. %, such as from 10 wt. % to 40 wt. %, from 10 wt. % to 35 wt. %, from 10 wt. % to 30 wt. %, from 10 wt. % to 26 wt. %, from 15 wt. % to 40 wt. %, from 15 wt. % to 35 wt. %, from 15 wt. % to 30 wt. %, from 15 wt. % to 26 wt. %, from 18 wt. % to 40 wt. %, from 18 wt. % to 35 wt. %, from 18 wt. % to 30 wt. %, from 18 wt. % to 26 wt. %, or from 20 wt. % to 30 wt. %, based on the mass flow rate of the treated plastic derived oil stream 114 and used cooking oil stream 104 introduced to the FCC reactor 122. In embodiments, the FCC effluent 122 may comprise less than or equal to 40 wt. %, such as from 10 wt. % to 40 wt. %, from 10 wt. % to 35 wt. %, from 10 wt. % to 30 wt. %, from 10 wt. % to 26 wt. %, from 15 wt. % to 40 wt. %, from 15 wt. % to 35 wt. %, from 15 wt. % to 30 wt. %, from 15 wt. % to 26 wt. %, from 18 wt. % to 40 wt. %, from 18 wt. % to 35 wt. %, from 18 wt. % to 30 wt. %, from 18 wt. % to 26 wt. %, or from 20 wt. % to 30 wt. % jet fuel constituents per unit weight of the FCC effluent 132.

[0093] In embodiments, a yield of constituents having boiling point temperature greater than 300° C. may be less than or equal to 20 wt. %, such as less than or equal to 15 wt. %, from 1 wt. % to 20 wt. %, from 1 wt. % to 15 wt. %, from 1 wt. % to 14 wt. %, from 1 wt. % to 13 wt. %, from 1 wt. % to 12 wt. %, from 1 wt. % to 10 wt. %, from 5 wt. % to 20 wt. %, from 5 wt. % to 15 wt. %, from 5 wt. % to 14 wt. %, from 5 wt. % to 13 wt. %, from 5 wt. % to 12 wt. %, from 5 wt. % to 10 wt. %, from 7 wt. % to 20 wt. %, from 7 wt. % to 15 wt. %, from 7 wt. % to 14 wt. %, from 7 wt. % to 13 wt. %, from 7 wt. % to 12 wt. %, or from 7 wt. % to 10 wt. % based on the mass flow rate of the treated plastic derived oil stream 114 and used cooking oil stream 104 introduced to the FCC reactor 112. In embodiments, the FCC effluent 132 may comprise less than or equal to 20 wt. %, such as less than or equal to 15 wt. %, from 1 wt. % to 20 wt. %, from 1 wt. % to 15 wt. %, from 1 wt. % to 14 wt. %, from 1 wt. % to 13 wt. %, from 1 wt. % to 12 wt. %, from 1 wt. % to 10 wt. %, from 5 wt. % to 20 wt. %, from 5 wt. % to 15 wt. %, from 5 wt. % to 14 wt. %, from 5 wt. % to 13 wt. %, from 5 wt. % to 12 wt. %, from 5 wt. % to 10 wt. %, from 7 wt. % to 20 wt. %, from 7 wt. % to 15 wt. %, from 7 wt. % to 14 wt. %, from 7 wt. % to 13 wt. %, from 7 wt. % to 12 wt. %, or from 7 wt. % to 10 wt. % constituents having boiling point temperature greater than 300° C. per unit weight of the FCC effluent 132.

[0094] Referring again to FIG. 1, the FCC effluent 132 may be passed to the FCC effluent separation system 150. In embodiments, the FCC effluent 132 may be passed directly from the fluid-solid separation unit 130 to the FCC effluent separation system 150. The FCC effluent 132 may be separated in the FCC effluent separation system 150 to produce at least one product stream. The effluent separation system 150 may be disposed downstream of the FCC reactor 122, such as downstream of the fluid-solid separation unit 130. The FCC effluent separation system 150 can include one or a plurality of separation units, which, collectively, operate to separate the FCC effluent 132 into the plurality of product streams. In embodiments, the FCC effluent separation system 150 may include one or more fractionation units. Other types of separation units are contemplated, such as but not limited to extraction units, distillation units, crystallization units, or other separation unit operations. The FCC effluent separation system 150 may be in fluid communication with the fluid-solid separation unit 130 to pass the FCC effluent 132 directly to the FCC effluent separation system 150.

[0095] The plurality of product streams can include one or more of a light olefin stream 152, a light naphtha stream 154, a jet fuel stream 156, a diesel stream 158, a heavy bottom stream 160, or any combination of these streams. The light olefin stream 152 can include one or more olefin streams comprising olefin compounds having from 2-4 carbon atoms. The light olefin streams 152 may include an ethylene stream, a propylene stream, a mixed butenes stream, or combinations of these. The light naphtha stream 154 may comprise constituents having boiling point temperatures of from 0° C. to 150° C. The light naphtha stream 154 may contain light aromatic compounds (aromatic compounds having from 6-8 carbon atoms) and gasoline components. The light naphtha stream 154 may include aromatic compounds having from 6 to 8 carbon atoms, such as benzene, toluene, xylenes, and / or ethylbenzene, which may be used as chemical intermediates for producing circular polymer materials (polymers made from recovered hydrocarbons instead of hydrocarbons produced from subterranean sources and therefore having a lower environmental footprint). In embodiments, the plurality of product streams may include the jet fuel stream 156, which may include constituents having boiling point temperatures of from 150° C. to 300° C. In embodiments, the plurality of product streams may include the diesel stream 158, which may include constituents having boiling point temperatures of from 300° C. to 343° C. The heavy bottom stream 160 may comprise heavy compounds, such as hydrocarbon compounds having boiling point temperatures greater than 343° C. In embodiments, the effluent separation system 150 further may be operable to produce a light gas stream (not shown) comprising light gases such as but not limited to hydrogen, methane, or both produced in the FCC reactor 122. In embodiments, the FCC effluent separation system 150 may be further operable to produce a light paraffin stream (not shown) comprising saturated hydrocarbons having from 2 to 4 carbon atoms (ethane, propane, butane, isobutane, or combinations thereof). Other product streams may be produced by the effluent separation system 150.

[0096] Referring now to FIG. 2, one embodiment of a fluidized bed reactor 300 that comprises a riser reactor (upflow reactor) is schematically depicted. FIG. 2 also schematically depicts one embodiment of a catalyst regenerator 400 for the fluidized bed reactor 300. In a riser reactor, the catalyst and reactants flow co-currently in an upward direction through the reaction zone. Although described in the context of riser reactors, it is understood that, in embodiments, the FCC reactor 122 may be a downer (downflow) fluidized bed reactor. In a downer or downflow fluidized bed reactor, the catalyst and reactants flow co-currently in the downward direction. Upward and downward are relative to the direction of the force of gravity.

[0097] The fluidized bed reactor 300 can include a riser 302, a reaction zone 304 downstream of the riser 302, and a separation zone 306 downstream of the reaction zone 304. The separation zone 306 in FIG. 2 corresponds to the fluid-solid separation unit 130 in FIG. 1. In operation of the fluidized bed reactor 300 of FIG. 2, the hydrocarbon feed 310 is introduced to the riser 302. For the FCC reactor 122, the hydrocarbon feed 310 is the combination of the treated plastic derived oil stream 114 and the used cooking oil stream 104. In embodiments, the hydrocarbon feed 310 may be combined with steam (not shown) upstream of the riser 302. The hydrocarbon feed 310 may be combined with an effective quantity of heated catalyst 320 in the riser 302. For the FCC reactor 122, the catalyst 320 may be the cracking catalyst 124.

[0098] The hydrocarbon feed 310 and the catalyst 320 (with optional steam) are contacted in the riser 302 and passed upward through the riser 302 into the reaction zone 304. In the riser 302 and the reaction zone 304, the hydrocarbons from the hydrocarbon feed 310 are contacted with the catalyst 320 at reaction conditions, which may cause at least a portion of the hydrocarbons to undergo one or more chemical reactions to produce a reaction mixture comprising a reactor effluent and the used catalyst. The reaction mixture comprising the used catalyst and reactor effluent may then be passed to the separation zone 306 downstream of the reaction zone 304. In the separation zone 306, the reaction mixture is separated to produce the reactor effluent 312 and the used catalyst 322. The separation zone 306 may include one or a plurality of solid-fluid separation devices, which may have any suitable configuration known in the art. Referring again to FIG. 1, the separation zone for the FCC reactor 122 may comprise the fluid-solid separation unit 130.

[0099] During the reaction, the catalyst 320 can become coked resulting in used catalyst 322, and the coke deposits can reduce access to the active catalytic sites on the used catalyst 322. The used catalyst 322 may also have a reduced temperature compared to the catalyst 320 introduced to the riser 302. The used catalyst 322 may be passed from the separation zone 306 to the catalyst regenerator 400.

[0100] Referring to FIG. 2, one embodiment of a catalyst regenerator 400 for a fluidized bed reactor 300 is schematically depicted. The catalyst regenerator 400 may be a riser catalyst regenerator comprising a riser 410 and a separation zone 420 disposed at the outlet end of the riser 410. During operation of the catalyst regenerator 400, the used catalyst 322 may be passed to the inlet 411 of the riser 410. A regeneration gas 412 may also be introduced to the inlet 411 of the riser 410. In embodiments, the regeneration gas 412 may be an oxygen-containing gas, such as air, compressed oxygen, or other oxygen-containing gas. In embodiments, the regeneration gas 412 may also include a fuel gas in addition to the oxygen-containing gas. The regeneration gas 412 and used catalyst 322 may be contacted at regeneration conditions, which may cause reaction between the used catalyst 322 and the regeneration gas 412. In embodiments, the regeneration gas 412 is the oxygen-containing gas and the reaction may include combustion of coke deposits, fuel gas, or both, which may cause removal of at least a portion of the coke deposits from the used catalyst, increase the temperature of the used catalyst, or both to produce the regenerated catalyst 422. The regenerated catalyst 422 may have reduced coke deposits, greater temperature, or both compared to the used catalyst 322.

[0101] The regenerated catalyst 422 may be separated from combustion gases in the catalyst separation zone 420, which is disposed at the outlet end of the riser 410. The combustion gases may be removed from the catalyst regenerator 400 as a flue gas 424. The flue gas 424 may include unreacted regeneration gases 412 as well as combustion gases, which may be the reaction products produced through combustion of coke deposits and / or fuel gas in the riser 410. The regenerated catalyst 422 may be passed back to the fluidized bed reactor 300 as at least a portion of the catalyst 320. Although depicted in FIG. 2 as a riser-type catalyst regenerator, is it understood that other configurations for the catalyst regenerator 400 may be employed, such as but not limited to downer catalyst regenerators, fixed bed catalyst regenerators, or other type of catalyst regenerator.

[0102] Referring again to FIG. 1, the system 100 can be used in processes for producing circular chemicals and low carbon fuels from plastic derived oil 102 and used cooking oil 104. The processes include passing a plastic derived oil stream 102 to an acid gas removal unit 110, where the plastic derived oil stream 102 contacts an acid gas removal catalyst 112, which may be a solid alkali metal salt. Contacting the plastic derived oil stream 102 with the acid gas removal catalyst 112 removes acid gases from the plastic derived oil stream 102 to produce a treated plastic oil stream 114. The acid gas removal unit 110 may have any of the features, configurations, catalysts, or operating conditions described in the present disclosure for the acid gas removal unit 110. The plastic derived oil stream 102 may have any of the compositions, properties, or other features previously discussed for the plastic derived oil stream 102.

[0103] The processes include contacting the treated plastic derived oil stream 114 and the used cooking oil stream 104 with the cracking catalyst 124 in the FCC reactor 122 at reaction conditions. Contact of the treated plastic derived oil stream 114 and the used cooking oil stream 104 with the cracking catalyst 124 at reaction conditions produces the FCC effluent 122 comprising the circular chemicals (olefins, light aromatic compounds or both), low-carbon fuels (light naphtha, jet fuel, diesel), or combinations thereof. The FCC system 120 may have any of the features, configurations, catalysts, or operating conditions described in the present disclosure for the FCC system 120. The used cooking oil stream 104 may have any of the compositions, properties, or other features previously discussed in the present disclosure for the used cooking oil stream 104. Additionally, the cracking catalyst 124 may contact heavy hydrocarbon molecules in the treated plastic derived oil stream 114 and the used cooking oil stream 104 and crack at least a portion of the heavy hydrocarbon molecules, which may produce greater value circular chemicals and low-carbon fuels, such as but not limited to the light olefins, light naphtha, and jet fuel constituents. Further, the processes disclosed herein may include combining the treated plastic derived oil stream 114 and the used cooking oil stream 104 prior to entering the FCC reactor 122 or at the inlet end of the FCC reactor 122.

[0104] The processes may include separating the FCC effluent 132 from the used cracking catalyst 134 downstream of the FCC reactor 122. Separating the FCC effluent 132 from the used cracking catalyst 134 may be accomplished by the fluid-solid separation unit 130 disposed at the outlet end of the FCC reactor 122. The processes may include passing the contents of the FCC reactor 122 to the fluid-solid separation unit 130 that separates the contents of the FCC reactor 122 into the FCC effluent 132 from the used cracking catalyst 134. The FCC effluent 132 may comprise light olefins, light naphtha, jet fuel constituents, diesel constituents, or combinations of these constituents. The FCC effluent 132 may have a greater concentration of light olefins, such as but not limited to ethylene, propylene, mixed butenes, or combinations thereof; light naphtha; or combinations thereof compared the treated plastic derived oil stream 114 and the used cooking oil stream 104.

[0105] The processes of the present disclosure may include passing the used cracking catalyst 134 to the catalyst regenerator 140, and regenerating the used cracking catalyst 134 in the catalyst regenerator 140 to produce the regenerated cracking catalyst 142. The regenerated cracking catalyst 142 may have a reduced concentration of halogens compared to the used cracking catalyst 134 prior to regeneration. The regenerated cracking catalyst 142 may also have reduced coke deposits, greater temperature, or both compared to the used cracking catalyst 134 prior to regeneration. In embodiments, regenerating the used cracking catalyst 134 may include contacting the used cracking catalyst 134 with the regeneration gas 144 at a regeneration temperature sufficient to remove coke deposits from the cracking catalyst, increase the temperature of the cracking catalyst, or both. In embodiments, the regeneration gas 144 may be an oxygen-containing gas, such as but not limited to air. In embodiments, regenerating the used cracking catalyst 134 may include contacting the used cracking catalyst 134 with the regeneration gas 144 in the catalyst regenerator 140 at the regeneration temperature that is greater than the operating temperature of the FCC reactor 122, such as at a regeneration temperature of from 500° C. to 800° C., from 500° C. to 750° C., from 500° C. to 700° C., from 550° C. to 800° C., from 550° C. to 750° C., from 550° C. to 700° C., from 600° C. to 800° C., from 600° C. to 750° C., from 600° C. to 700° C., or from 650° C. to 800° C. In embodiments, the regeneration gas 144 for the catalyst regenerator 140 may also include a fuel gas or a fuel oil. Combustion of the fuel gas and / or fuel oil in the catalyst regenerator 140 may increase the heat generated in the catalyst regenerator 140, thereby increasing the regeneration temperature in the catalyst regenerator 140.

[0106] The processes may further include passing a flue gas 146 out of the catalyst regenerator 140, wherein the flue gas 146 may comprise halogen compounds, such as but not limited to Cl2 or HCl. The flue gas 146 may also include unreacted regeneration gases and combustion gases produced from combustion of the coke deposits and any fuel gases added to the catalyst regenerator 140. The processes may include passing the flue gas 146 to a downstream treatment system for properly handling the hydrogen halides in the flue gas 146. The catalyst regenerator 140 may have any of the other features, configuration, or operating conditions described herein for the catalyst regenerator 140.

[0107] Referring again to FIG. 1, the processes disclosed herein may include combining the treated plastic derived oil stream 114 and the used cooking oil stream 104 and the cracking catalyst 124, such as the regenerated cracking catalyst 134, at the inlet end of the FCC reactor 122, where the treated plastic derived oil stream 114, the used cooking oil stream 104, and the cracking catalyst 124 may be contacted and may travel together through the FCC reactor 122. In embodiments, the processes may include contacting the treated plastic derived oil stream 114, the used cooking oil stream 104, and the cracking catalyst 124 in the FCC reactor 122 at a reaction temperature of from 500° C. to 700° C., such as from 500° C. to 650° C., from 500° C. to 600° C., from 550° C. to 650° C., from 550° C. to 600° C., or from 600° C. to 650° C. The processes may include contacting the treated plastic derived oil stream 114, the used cooking oil stream 104, and the cracking catalyst 124 may be contacted in the FCC reactor 122 at a pressure of from 100 kPa to 1000 kPa, from 101 kPa to 303 kPa, or at about atmospheric pressure (i.e., about 101.3 kPa). The processes may include contacting the treated plastic derived oil stream 114, the used cooking oil stream 104, and the cracking catalyst 124 in the FCC reactor 122 at a GHSV of from 0.2 h−1 to 100 h−1. The treated plastic derived oil stream 114, the used cooking oil stream 104, and the cracking catalyst 124 may be introduced to the FCC reactor 122 at a catalyst-to-oil weight ratio of greater than or equal to 2. The catalyst-to-oil weight ratio in the FCC reactor 122 is equal to a mass flow rate of the cracking catalyst 124 divided by a mass flow rate of the treated plastic derived oil stream 114 and used cooking oil stream 104 in the FCC reactor 122 during steady state operation. In embodiments, the catalyst-to-oil weight ratio in the FCC reactor 122 may be from 2 to 40, from 2 to 35, from 2 to 30, from 2 to 25, from 2 to 20, from 2 to 15, from 2 to 12, from 2 to 10, from 2 to 8, from 4 to 10, from 4 to 40, from 8 to 40, from 15 to 40, from 20 to 40, from 30 to 40, or any combination of these ranges. In embodiments, the FCC effluent 132 may comprise less than 100 ppmw halogen-containing compounds based on the total weight of the FCC effluent 132, such as less than 50 ppmw, less than 40 ppmw, less than 30 ppmw, less than 20 ppmw, or less than 10 ppmw of the halogen-containing compounds based on the total weight of the FCC effluent 132.

[0108] The processes of the present disclosure may further include separating the FCC effluent 132 in the effluent separation system 150 to produce a plurality of product streams, such as but not limited to an ethylene stream, a propylene stream, a mixed butenes stream, a light naphtha stream, a jet fuel stream, a diesel stream, or combinations of these product streams. In embodiments, the product streams may include one or more light olefin streams 152, a light naphtha stream 154, a jet fuel stream 156, a diesel stream 158, a heavy bottom stream 160, or any combinations of these product streams.

[0109] The processes may include providing the plastic derived oil stream 102 comprising hydrocarbons and from 10 parts per million by weight (ppmw) to 500 ppmw of halogen-containing compounds based on the total weight of the treated plastic derived oil stream 102. In embodiments, the processes may include producing the plastic derived oil stream 102 from solid waste plastic. Producing the plastic derived oil stream 102 may include passing solid waste plastic 12 to a dehalogenation unit 10, which melts the solid waste plastic 12 and removes some halogen compounds from the solid waste plastic 12 to produce the liquefied plastic stream 14. The processes may further include passing the liquefied plastic stream 14 to the pyrolysis unit 20 and subjecting the liquefied plastic stream 14 to pyrolysis in the pyrolysis unit 20 to produce the plastic derived oil stream 102.Examples

[0110] The various embodiments of systems and processes of the present disclosure will be further clarified by the following examples. The examples are illustrative in nature, and should not be understood to limit the subject matter of the present disclosure.Catalyst Testing

[0111] In these examples, the feed compositions (plastic derived oil, used cooking oil, and combinations of plastic derived oil and used cooking oil) were catalytically cracked according to an Advanced Cracking Evaluation (ACE) test procedure. The ACE tests were conducted using a micro-activity cracking testing (MAT) unit. The MAT unit and ACE testing process is described more in detail in U.S. Pat. No. 6,069,012.

[0112] Referring to FIG. 3, the MAT unit 200 used in these examples is schematically depicted. The MAT unit 200 includes a fluidized reactor 210 configured to simulate reaction in an FCC reactor. Fluidization gas 212 is introduced to the bottom of the fluidized reactor 210 to maintain the catalyst 204 in a fluidized state. The catalyst 204 is loaded into the fluidized reactor 210 from the catalyst hopper 206. The feed 202 is introduced to the top of the fluidized reactor 210 and flows downward into the catalyst 204 fluidized within the fluidized reactor 210. After contacting the feed 202 with the catalyst 204 in the reactor, the reaction effluent 216 is passed out of the fluidized reactor 210 to the product liquid receivers 220, which separate the liquid products from the gaseous products. The gaseous product stream 222 is passed to a product gas receiver 230. The composition of the gaseous product stream 222 is analyzed using a micro gas chromatograph 240 having a GC control unit 242. The catalyst 204 is regenerated by introducing a regeneration gas 214 into the bottom of the fluidized reactor 210. The flue gas is treated in a catalytic converter 260 and passed through a flow meter 262 and CO2 analyzer 264 for quantifying the amount of coke produced during the reactions. The MAT unit 200 can include an ACE control system 270 for controlling operation of the MAT unit 200.Examples 1-5: Co-Cracking of Plastic Derived Oil and Used Cooking Oil

[0113] In Examples 1-5, a used cooking oil was co-processed with plastic derived oil through fluidized catalytic cracking using a commercially available cracking catalyst (UMIX75 catalyst), which comprised 75 wt. % equilibrium catalyst and 25 wt. % cracking additive. The cracking additive was OLEFINSULTRA® cracking additive available from W.R. Grace and Company. The composition for the plastic derived oil stream (PDO) produced from solid waste plastic and the composition for the used cooking oil stream (UCO) for Example 1 are provided in Table 3. In Examples 1-5, the plastic derived oil and the used cooking oil were combined in various weight ratios, which are provided in Table 4.TABLE 3Plastic Derived Oil and Used Cooking Oil CompositionsFractionPDOUCONaphtha (0-150° C.) (wt. %)17.10Jet Fuel (150-300° C.) (wt. %)41.80Diesel (300-343° C.) (wt. %)13.60Heavy Compounds (343+ ° C.) (wt. %)27.5100

[0114] The ACE testing for the co-cracking was performed using steam-deactivated UMIX75 catalyst. The UMIX75 catalyst was first deactivated under hydrothermal conditions (100% steam, 810° C., 6 hours) before being used for catalyst evaluations. The ACE testing was performed with an effective catalyst-to-oil weight ratio of 8 and an injection time of 75 seconds. The ACE testing of the combined feed comprising a mixture of plastic derived oil and used cooking oil in the MAT unit was conducted at a reaction temperature of 550° C.

[0115] Prior to each experiment, the steam-deactivated catalyst was loaded into the reactor and heated to the desired reaction temperature. N2 gas was fed through the feed injector from the bottom to keep the catalyst particles fluidized. Once the catalyst bed temperature reached between 248° C.-552° C., the reaction was started by injecting the feed. For each evaluation, the feed was injected for a predetermined time (time-on-stream (TOS)) of 75 seconds. The desired catalyst-to-feed ratio of 8 was maintained by controlling the feed pump for the feed. The gaseous product was routed to the liquid receiver (220 in FIG. 3), where C5+ hydrocarbons were condensed. The remaining product gases were routed to the gas receiver (230 in FIG. 3) in the product gas stream 222. The used catalyst in the reactor was then stripped with a stripping gas (N2) to removing any residual liquid or gaseous products, reactants, or both from the catalyst. The stripping gases and residual products were also passed to the gas receiver (230 in FIG. 3). After catalyst stripping was completed, the reactor was heated to 700° C., and air injected to regenerate the used catalyst to produce regenerated catalyst. During regeneration, the released gas was routed to a CO2 analyzer (catalytic converter 260, flow meter 262 and CO2 analyzer 264 in FIG. 3). Coke yield was calculated from the flue gas flow rate and CO2 concentration.

[0116] The gaseous product stream 222 was analyzed by an online gas chromatography system (Agilent 7890 gas chromatograph) equipped with both FID and TCD detectors. The liquid product stream was analyzed according to the offline analytical test methods. In particular, the liquid product stream was analyzed by simulated distillation according to test method EN 15199-2 using the Agilent 7890 gas chromatograph and naphtha analysis techniques.

[0117] For the simulated distillation, the analysis was conducted for five distillation fractions: (1) light hydrocarbon gases having 1-4 carbon atoms; (2) a light naphtha fraction having a boiling point range of from 0° C. to 150° C.; (3) a jet fuel fraction having a boiling point range of from 150° C. to 300° C.; (4) a diesel fraction having boiling point temperatures of from 300° C. to 343° C.; and (5) a heavy compounds fraction having boiling point temperatures greater than 343° C. The light hydrocarbon gases were further classified into fuel gas (hydrogen and methane), C2-C4 paraffins, ethylene (C2=), propylene (C3=), and mixed butenes (C4=). Coke was quantified after passing an air stream through the MAT unit at high temperatures to burn the coke into a mixture of carbon monoxide, carbon dioxide, and water, as previously discussed, and then passing the combustion gases through a CO2 analyzer, which included a calibrated infrared analyzer.

[0118] For Examples 1-5, the co-cracking process of Example 1 was used to test feed blends with different ratios of used cooking oil and plastic derived oil. The ratio of the used cooking oil and plastic derived oil and the reaction products obtained for Examples 1-5 are provided in Table 4 and in FIG. 4. The plastic derived oil and used cooking oil were combined at the desired weight percentages and mixed thoroughly to produce the feed before introducing the feed to the reactor (MAT unit 200).Comparative Example 6: Plastic Derived Oil Only

[0119] For Comparative Example 6, the plastic derived oil, by itself (no used cooking oil), was contacted with the cracking catalyst in the MAT unit according to the ACE testing methods discussed above. The composition of the plastic derived oil is in Table 3, and the cracking catalyst was the same as the cracking catalyst used in Examples 1-5. The cracking catalyst was steam deactivated, as previously discussed, and then contacted with the plastic derived oil under the same reaction conditions provided herein for Examples 1-5. The results for Comparative Example 6 (CE-6) are provided in Table 4 and FIG. 4.Comparative Example 7: Used Cooking Oil Only

[0120] For Comparative Example 7 (CE-7), the used cooking oil, by itself (no plastic derived oil), was contacted with the cracking catalyst in the MAT unit according to the ACE testing methods discussed above. The composition of the used cooking oil is in Table 3, and the cracking catalyst was the same as the cracking catalyst used in Examples 1-5. The cracking catalyst was steam deactivated, as previously discussed, and then contacted with the used cooking oil under the same sets of reaction conditions provided herein for Examples 1-5. The results for Comparative Example 7 (CE-7) are provided in Table 4 and FIG. 4.Co-Cracking Testing Results

[0121] The results of the catalytic cracking test results for Examples 1-5 and Comparative Examples 6 and 7 are provided in Table 4 and in FIG. 4.TABLE 5ACE Testing of PDO and UCO Feed Blends of Examples 2-8Constituent12345CE-6CE-7Blend10%20%50%90%80%PDOUCOCompositionUCO +UCO +UCO +UCO +UCO +90%80%50%10%20%PDOPDOPDOPDOPDOFuel Gas (wt. %)0.860.831.520.90.890.520.87C2-C4 paraffin10.387.458.9710.967.8220.397.21(wt. %)Ethylene (wt. %)1.411.511.351.171.644.071.63Propylene (wt. %)11.4710.218.5810.6810.9112.2210.68Butenes (wt. %)13.210.989.9212.1211.7412.0911.38Light Naphtha37.335.9735.2429.234.9732.6331.59(wt. %)Jet Fuel (wt. %)18.8225.3221.621.4422.0813.3223.76Diesel (wt. %)1.741.693.252.81.331.33.05Heavy Compounds2.343.497.585.275.790.937.13(wt. %)Coke (wt. %)2.472.5525.462.822.542.7

[0122] Referring to FIG. 4 and Table 4, the blended plastic derived oil and used cooking oil streams generally had higher production of C2-C4 paraffins and light naphtha, compared to the individual used cooking oil stream. The blending of the plastic derived oil and used cooking oil allowed the plastic derived oil and used cooking oil to dilute each other and reduce the level of contaminants, as shown by the decreased production of heavy compounds and jet fuel as compared to the individual used cooking oil stream. The overall production of light naphtha increased with the percentage of plastic derived oil in the blend, with the blend having only 10% plastic derived oil being the only blend of plastic derived oil and used cooking oil to produce less light naphtha than the individual plastic derived oils and used cooking oil streams. Production of C2-C4 paraffins was greatest for the 90% plastic derived oil and 10% used cooking oil blend and the 10% plastic derived oil and 90% used cooking oil blend, indicating that the more homogeneous the blend, the greater the production of C2-C4 paraffins. Overall, the plastic derived oil and used cooking oil blends resulted in increased light naphtha production and reduction in the level of contaminants. Referring to FIG. 4 and Table 4, the plastic derived oil and used cooking oil blends were shown to be suitable for co-catalytic cracking to produce circular chemicals and low carbon fuels.

[0123] A first aspect of the present disclosure is directed to a process for producing circular chemicals and low-carbon fuels, the process comprising producing a plastic derived oil stream from solid waste plastic, contacting the plastic derived oil stream with an acid gas removal catalyst disposed in an acid gas removal unit, and passing the treated plastic derived oil stream and a used cooking oil stream to a fluidized catalytic cracking (FCC) system comprising an FCC reactor, and contacting the treated plastic derived oil stream and the used cooking oil stream with a cracking catalyst in the FCC reactor. Contacting the plastic derived oil stream with the acid gas removal catalyst may remove acid gases from the plastic derived oil stream to produce a treated plastic derived oil stream, where the treated plastic derived oil stream has concentrations of halogen compounds, sulfur compounds, or both that may be less than concentrations of the halogen compounds, sulfur compounds, or both in the plastic derived oil stream. Contacting the treated plastic derived oil stream and the used cooking oil stream with the cracking catalyst at a reaction temperature in the FCC reactor may cause at least a portion of hydrocarbons from the treated plastic derived oil stream and the used cooking oil stream to undergo catalytic cracking reactions to produce an FCC effluent comprising circular chemicals, low-carbon fuels, or both.

[0124] A second aspect of the present disclosure may include the first aspect, where a weight ratio of the used cooking oil stream to the treated plastic derived oil stream introduced to the FCC reactor may be from 1:9 to 9:1.

[0125] A third aspect of the present disclosure may include either one of the first or second aspects, where the used cooking oil stream may have one or more of the following characteristics: a density of from 0.90 g / cm3 to 0.95 g / cm3; an API gravity of from 20 degrees to 25 degrees; an initial boiling point temperature of greater than or equal to 500° C.; a final boiling point temperature less than or equal to 720° C.; or combinations thereof.

[0126] A fourth aspect of the present disclosure may include any one of the first through third aspects, where the plastic derived oil stream may have one or more of the following characteristics: a density of from 0.65 g / cm3 to 1.1 g / cm3; a chloride concentration of greater than or equal to 100 ppmw based on the total weight of the plastic derived oil stream; an oxygen content of from 100 ppmw to 10,000 ppmw based on the total weight of the plastic derived oil stream; an initial boiling point temperature of from 20° C. to 100° C.; a final boiling point temperature of from 300° C. to 600° C.; a 50% boiling point temperature of from 150° C. to 350° C.; or any combinations thereof.

[0127] A fifth aspect of the present disclosure may include any one of the first through fourth aspects, where the treated plastic derived oil stream may have a chloride concentration of less than 100 ppmw based on the total weight of the treated plastic derived oil stream.

[0128] A sixth aspect of the present disclosure may include any one of the first through fifth aspects, where the FCC effluent may comprise greater than or equal to 40 wt. % C2-C4 paraffins and light naphtha based on the total weight of the FCC effluent, the light naphtha comprising hydrocarbons having boiling point temperatures of from 0° C. to 150° C.

[0129] A seventh aspect of the present disclosure may include any one of the first through fifth aspects, where the FCC effluent may comprise greater than or equal to 29 wt. % light naphtha, the light naphtha comprising hydrocarbons having boiling point temperatures of from 0° C. to 150° C.; greater than or equal to 7 wt. % C2-C4 paraffins; or both.

[0130] An eighth aspect of the present disclosure may include any one of the first through seventh aspects, where the acid gas removal catalyst is a solid inorganic alkali metal salt.

[0131] A ninth aspect of the present disclosure may include any one of the first through eighth aspects, where the cracking catalyst may comprise 75 wt. % equilibrium catalyst and 25 wt. % cracking additive based on the total weight of the cracking catalyst.

[0132] A tenth aspect of the present disclosure may include any one of the first through ninth aspects, comprising contacting the plastic derived oil stream and used cooking oil stream with the cracking catalyst in the FCC reactor at a reaction temperature of from 500° C. to 650° C. and a catalyst-to-oil weight ratio of from 2 to 40, where the catalyst-to-oil weight ratio is the mass flow rate of the cracking catalyst through the FCC reactor divided by the total combined mass flow rate of the treated plastic derived oil stream and the used cooking oil stream to the FCC reactor.

[0133] An eleventh aspect of the present disclosure may include any one of the first through tenth aspects, comprising contacting the plastic derived oil stream and used cooking oil stream with the cracking catalyst in the FCC reactor at a pressure of 101 kPa to 303 kPa and a gas hourly space velocity of from 0.2 per hour (h−1) to 100 h−1.

[0134] A twelfth aspect of the present disclosure may include any one of the first through eleventh aspects, further comprising separating the used cracking catalyst from the FCC effluent in a fluid-solid separation unit downstream of the FCC reactor and regenerating the used cracking catalyst in a catalyst regenerator to produce a regenerated cracking catalyst.

[0135] A thirteenth aspect of the present disclosure may include the twelfth aspect, further comprising passing the regenerated cracking catalyst back to the FCC reactor as at least a portion of the cracking catalyst.

[0136] A fourteenth aspect of the present disclosure may include either one of the twelfth or thirteenth aspects, where regenerating the used cracking catalyst may comprise contacting the used cracking catalyst with a regeneration gas at a regeneration temperature of from 500° C. and 900° C., where the regeneration gas is an oxygen-containing gas.

[0137] A fifteenth aspect of the present disclosure may include any one of the first through fourteenth aspects, where producing the plastic derived oil stream from solid waste plastic may comprises melting and dehalogenating the solid waste plastic in a dehalogenation unit to produce a liquefied plastic stream; passing the liquefied plastic stream to a pyrolysis reactor; and subjecting the liquefied plastic stream to pyrolysis in the pyrolysis reactor to produce the plastic derived oil stream.

[0138] A sixteenth aspect of the present disclosure may include the fifteenth aspect, where the solid waste plastic may comprise mixed plastics of differing compositions.

[0139] A seventeenth aspect of the present disclosure may include either one of the fifteenth or sixteenth aspects, where melting and dehalogenating the solid waste plastic may comprise increasing a temperature of the solid waste plastic to a temperature of from 250° C. and 300° C. to melt the solid waste plastic and produce the liquefied plastic stream.

[0140] An eighteenth aspect of the present disclosure may include any one of the fifteenth through seventeenth aspects, where subjecting the liquefied plastic stream to pyrolysis in the pyrolysis reactor may comprise increasing a temperature of the liquefied plastic stream to a temperature of from 350° C. to 1000° C. in the pyrolysis reactor.

[0141] A nineteenth aspect of the present disclosure may be directed to a system for converting solid waste plastics and used cooking oil into circular chemicals and low carbon fuels. The system may comprise a plastic derived oil stream; an acid gas removal unit in fluid communication with the plastic derived oil stream, where the acid gas removal unit may comprise a reaction vessel and an acid gas removal catalyst disposed within the reaction vessel, where the acid gas removal unit may be configured to contact the plastic derived oil stream with the acid gas removal catalyst to remove halogen compounds, sulfur-containing compounds, or both from the plastic derived oil stream to produce a treated plastic derived oil stream; a fluid catalytic cracking (FCC) system disposed downstream of the acid gas removal unit and comprising an FCC reactor, where the FCC reactor may be in fluid communication with the acid gas removal unit to pass the treated plastic derived oil stream from the acid gas removal unit to the FCC reactor; and a used cooking oil stream in fluid communication with the FCC reactor to pass the used cooking oil stream to the FCC reactor. The FCC system may be configured to contact the treated plastic derived oil stream and the used cooking oil stream with a cracking catalyst under reaction conditions to produce an FCC effluent comprising circular chemicals and low carbon fuels.

[0142] A twentieth aspect of the present disclosure may include the nineteenth aspect, further comprising: an inlet stream comprising solid waste plastic; a dehalogenation unit in fluid communication with the inlet stream, where the dehalogenation unit may be configured to increase a temperature of the inlet stream to melt the solid waste plastic to produce a liquid plastic stream; and a pyrolysis reactor disposed downstream of the dehalogenation unit, where the pyrolysis reactor may be configured to pyrolyze the liquid plastic stream to produce the plastic derived oil stream.

[0143] A twenty-first aspect of the present disclosure may include the twentieth aspect, where the dehalogenation unit may be configured to increase the temperature of the inlet stream to a temperature from 250° C. and 300° C. to melt the solid waste plastic to produce the liquid plastic stream.

[0144] A twenty-second aspect of the present disclosure may include either one of the twentieth or twenty-first aspects, where the pyrolysis reactor may be in fluid communication with the dehalogenation unit to pass the liquid plastic stream directly from the dehalogenation unit to the pyrolysis reactor.

[0145] A twenty-third aspect of the present disclosure may include any one of the twentieth through twenty-second aspects, where the pyrolysis reactor may be operable to increase the temperature of the liquid plastic stream to a temperature of 350° C. to 1000° C. to produce the plastic derived oil stream.

[0146] A twenty-fourth aspect of the present disclosure may include any one of the twentieth through twenty-third aspects, where the acid gas removal unit may be in fluid communication with the pyrolysis reactor to pass the plastic derived oil stream directly from the pyrolysis reactor to the acid gas removal unit.

[0147] A twenty-fifth aspect of the present disclosure may include any one of the nineteenth through twenty-fourth aspects, where the acid gas removal catalyst may be a solid inorganic alkali metal salt.

[0148] A twenty-sixth aspect of the present disclosure may include any one of the nineteenth through twenty-fifth aspects, where the cracking catalyst may comprise 75 wt. % equilibrium catalyst and 25 wt. % cracking additive based on the total weight of the cracking catalyst.

[0149] A twenty-seventh aspect of the present disclosure may include any one of the nineteenth through twenty-sixth aspects, where the FCC system further may comprise a fluid-solid separation unit disposed at an outlet of the FCC reactor and a catalyst regenerator downstream of the fluid-solid separation unit, where: the fluid-solid separation unit may be configured to separate the FCC effluent from a used cracking catalyst; and the catalyst regenerator may be configured to regenerate the used cracking catalyst in a catalyst regenerator to produce a regenerated cracking catalyst.

[0150] A twenty-eighth aspect of the present disclosure may include the twenty-seventh aspect, where the fluid-solid separation unit is in fluid communication with the outlet of the FCC reactor.

[0151] A twenty-ninth aspect of the present disclosure may include either one of the twenty-seventh or twenty-eighth aspects, where the catalyst regenerator may be configured to contact the used cracking catalyst with a regeneration gas under reaction conditions to produce the regenerated cracking catalyst, where the regeneration gas is an oxygen-containing gas.

[0152] A thirtieth aspect of the present disclosure may include any one of the nineteenth through twenty-ninth aspects, further comprising a product separation system disposed downstream of the FCC system, where the product separation system may be configured to separate the FCC effluent to produce a plurality of product streams.

[0153] A thirty-first aspect of the present disclosure may include any one of the nineteenth through thirtieth aspects, where the used cooking oil stream may have one or more of the following characteristics: a density of from 0.90 g / cm3 to 0.95 g / cm3; an API gravity of from 20 degrees to 25 degrees; an initial boiling point temperature of greater than or equal to 500° C.; a final boiling point temperature less than or equal to 720° C.; or combinations thereof.

[0154] A thirty-second aspect of the present disclosure may include any one of the nineteenth through thirty-first aspects, where the plastic derived oil stream may have one or more of the following characteristics: a density of from 0.65 g / cm3 to 1.1 g / cm3; a chloride concentration of greater than or equal to 100 ppmw based on the total weight of the plastic derived oil; an oxygen content of from 100 ppmw to 10,000 ppmw based on the total weight of the plastic derived oil; an initial boiling point temperature of from 20° C. to 100° C.; a final boiling point temperature of from 300° C. to 600° C.; a 50% boiling point temperature of from 150° C. to 350° C.; or any combinations thereof.

[0155] It is noted that any two quantitative values assigned to a property may constitute a range of that property, and all combinations of ranges formed from all stated quantitative values of a given property are contemplated in this disclosure.

[0156] It is noted that one or more of the following claims utilize the term “where” as a transitional phrase. For the purposes of defining the present technology, it is noted that this term is introduced in the claims as an open-ended transitional phrase that is used to introduce a recitation of a series of characteristics of the structure and should be interpreted in like manner as the more commonly used open-ended preamble term “comprising.”

[0157] Having described the subject matter of the present disclosure in detail and by reference to specific aspects, it is noted that the various details of such aspects should not be taken to imply that these details are essential components of the aspects. Rather, the claims appended hereto should be taken as the sole representation of the breadth of the present disclosure and the corresponding scope of the various aspects described in this disclosure. Further, it will be apparent that modifications and variations are possible without departing from the scope of the appended claims.

Examples

examples

[0110]The various embodiments of systems and processes of the present disclosure will be further clarified by the following examples. The examples are illustrative in nature, and should not be understood to limit the subject matter of the present disclosure.

Catalyst Testing

[0111]In these examples, the feed compositions (plastic derived oil, used cooking oil, and combinations of plastic derived oil and used cooking oil) were catalytically cracked according to an Advanced Cracking Evaluation (ACE) test procedure. The ACE tests were conducted using a micro-activity cracking testing (MAT) unit. The MAT unit and ACE testing process is described more in detail in U.S. Pat. No. 6,069,012.

[0112]Referring to FIG. 3, the MAT unit 200 used in these examples is schematically depicted. The MAT unit 200 includes a fluidized reactor 210 configured to simulate reaction in an FCC reactor. Fluidization gas 212 is introduced to the bottom of the fluidized reactor 210 to maintain the catalyst 204 in a ...

examples 1-5

Co-Cracking of Plastic Derived Oil and Used Cooking Oil

[0113]In Examples 1-5, a used cooking oil was co-processed with plastic derived oil through fluidized catalytic cracking using a commercially available cracking catalyst (UMIX75 catalyst), which comprised 75 wt. % equilibrium catalyst and 25 wt. % cracking additive. The cracking additive was OLEFINSULTRA® cracking additive available from W.R. Grace and Company. The composition for the plastic derived oil stream (PDO) produced from solid waste plastic and the composition for the used cooking oil stream (UCO) for Example 1 are provided in Table 3. In Examples 1-5, the plastic derived oil and the used cooking oil were combined in various weight ratios, which are provided in Table 4.

TABLE 3Plastic Derived Oil and Used Cooking Oil CompositionsFractionPDOUCONaphtha (0-150° C.) (wt. %)17.10Jet Fuel (150-300° C.) (wt. %)41.80Diesel (300-343° C.) (wt. %)13.60Heavy Compounds (343+ ° C.) (wt. %)27.5100

[0114]The ACE testing for the co-crack...

BACKGROUNDField

[0001] The present disclosure generally relates to catalysts and processes for producing greater value hydrocarbon products or intermediates from waste products, more specifically, catalysts and processes for co-processing used cooking oil and plastic derived oils to produce greater value circular chemicals and low carbon fuels.Technical Background

[0002] The use of plastics in commercial and industrial applications has become prolific. The increasing use of plastics worldwide has increased the generation of waste plastic, which presents a sustainability opportunity. Plastic is a synthetic or semisynthetic organic polymer composed of mainly carbon and hydrogen. Further, plastics tend to be durable, with a slow rate of degradation, therefore, plastics stay in the environment for a long time and are not prone to rapid breakdown upon disposal. Pure plastics are generally insoluble in water and nontoxic. However, some additives used in plastic preparation are toxic and may leach into the environment. Examples of toxic additives include phthalates. Other typical additives include fillers, colorants, plasticizers, stabilizers, anti-oxidants, flame retardants, ultraviolet (UV) light absorbers, antistatic agents, blowing agents, lubricants, or combinations of these, which are used during preparation of the plastics to change its composition and properties. Development of processes for converting waste plastics into reusable materials, such as chemical products, intermediates, or low carbon footprint fuels is continuing. Plastics pyrolyze at high temperatures and polymers can be converted back to their original monomers or smaller polymers, as gas or liquid, and can be recovered.

[0003] Additionally, cooking oil is widely consumed; millions of tons of cooking oil is used annually, resulting in significant waste product, known as used cooking oil. Thermal degradation during cooking can create harmful chemicals, such as hydroperoxides and fatty acid oligomers, that are then present in used cooking oil. The fatty acid oligomers make the used cooking oil unusable for human consumption or agricultural purposes. As a result, most used cooking oil is discarded, either to landfills or to sewage systems. As the need for alternative fuel sources has grown, processes to convert used cooking oil to useable materials, such as but not limited to chemical products, intermediates, or low carbon footprint fuels have started to develop.SUMMARY

[0004] Used cooking oils and oils derived from waste plastics can contain compounds useful as fuel blending components or chemical feedstocks. However, pyrolysis of used cooking oil produces oils with poor combustion quality, decreased engine performance, and increased emissions. The techniques used to improve the quality of the oils produced from pyrolysis of used cooking oil are often costly and highly sophisticated. Similarly, the additives added to the plastics during production can present challenges in effectively utilizing any products from pyrolysis of solid waste plastics. Upon pyrolysis of the solid waste plastics, the additives end-up in the pyrolysis effluent and thus require further processing to generate useful products. Additionally, the oils produced from pyrolysis of plastic waste can present a challenge due to the presence of halogen-containing compounds, such as those resulting from the presence of polyvinyl chloride (PVC) or other halogen-containing plastics. PVC is one of the most abundant plastics used for consumable goods. Waste plastic can contain from 1 weight percent (wt. %) to 5 wt. % PVC or other halogen-containing plastics. However, recycling of used PVC and other halogen-containing plastics is very difficult due to the presence of chlorine or other halogens in the structure.

[0005] Plastic derived oils have good properties and hydrocarbon constituents useful for application as fuel blending components or chemical feedstocks. However, plastic derived oils can present a processing challenge due to the presence of halogen-containing compounds (such as chlorine-containing hydrocarbon compounds) and due to the wide boiling point temperature range of the plastic derived oils, such as C5 to C25 or greater (boiling point temperatures of from 30° C. to 400° C. or even greater than 400° C.). Plastic derived oils can also include compounds with different functional groups and families of organic compounds such as but not limited to oxygenates, aromatic compounds, olefins, alkanes, other hydrocarbon compounds, or combinations of these. The direct use of plastic waste derived oil in catalytic cracking to produce circular chemicals can lead to problems downstream because of the presence of halogen-containing compounds, such as but not limited to chlorine-containing hydrocarbon compounds.

[0006] Used cooking oil is a common and widely produced waste product. As such, there is a steadily increasing demand for technologies capable of converting used cooking oil into circular chemicals and low carbon fuels. However, producing high-quality oils from used cooking oil may require sophisticated processes, such as hydrothermal cracking and hydro-deoxygenation. Further, biomass oils, such as used cooking oil, have generally been considered unsuitable for co-processing in FCC units because biomass oils produce high coke yields. The coke formation on the surfaces of the catalyst reduces the catalytic cracking activity of the cracking catalysts, thereby reducing the efficiency and yield from the catalytic cracking process.

[0007] Accordingly, an ongoing need exists for processes for co-cracking plastic derived oils and used cooking oils to produce greater value chemical products and intermediates, such as but not limited to light olefins (C2-C4 olefins), light aromatic compounds (C6-C8 aromatic compounds), light naphtha, low carbon footprint fuel components, other circular chemicals, or combinations of these. The present disclosure satisfies these needs by presenting systems and processes for co-cracking plastic derived oil and used cooking oil to produce greater value chemicals and intermediates, such as circular chemicals and low carbon fuels. In particular, the systems and methods disclosed herein include a fluidized catalytic cracking system for co-cracking plastic derived oil and used cooking oil to produce circular chemicals and low carbon fuels, which can include but are not limited to light olefins, light aromatic compounds, low carbon footprint fuel blending components, or combinations of these. The systems and methods may also include dehalogenating solid waste plastic in a dehalogenation unit to produce a liquefied plastic stream, pyrolyzing the liquefied plastic waste in a pyrolysis reactor to produce a plastic derived oil stream, and contacting the plastic derived oil stream with an acid gas removal catalyst in an acid gas removal unit to produce treated plastic derived oil. The treated plastic derived oil may then be blended with the used cooking oil and co-cracked in the FCC reactor using a cracking catalyst. The method may further include regeneration of the used cracking catalyst in a catalyst regenerator.

[0008] According to one or more aspects of the present disclosure, a process for producing circular chemicals and low-carbon fuels comprises producing a plastic derived oil stream from solid waste plastic and contacting the plastic derived oil stream with an acid gas removal catalyst disposed in an acid gas removal unit. Contacting the plastic derived oil stream with the acid gas removal catalyst may remove acid gases from the plastic derived oil stream to produce a treated plastic derived oil stream, where the treated plastic derived oil stream may have concentrations of halogen compounds, sulfur compounds, or both that are less than concentrations of the halogen compounds, sulfur compounds, or both in the plastic derived oil stream. The process further includes passing the treated plastic derived oil stream and a used cooking oil stream to a fluidized catalytic cracking (FCC) system comprising an FCC reactor and contacting the treated plastic derived oil stream and the used cooking oil stream with a cracking catalyst in the FCC reactor. Contacting the treated plastic derived oil stream and the used cooking oil stream with the cracking catalyst at a reaction temperature in the FCC reactor causes at least a portion of hydrocarbons from the treated plastic derived oil stream and the used cooking oil stream to undergo catalytic cracking reactions to produce an FCC effluent comprising circular chemicals, low-carbon fuels, or both.

[0009] According to one or more other aspects, a system for converting solid waste plastics and used cooking oil into circular chemicals and low carbon fuels comprises a plastic derived oil stream; an acid gas removal unit in fluid communication with the plastic derived oil stream, where the acid gas removal unit may comprise a reaction vessel and an acid gas removal catalyst disposed within the reaction vessel, where the acid gas removal unit may be configured to contact the plastic derived oil stream with the acid gas removal catalyst to remove halogen compounds, sulfur-containing compounds, or both from the plastic derived oil stream to produce a treated plastic derived oil stream; a fluid catalytic cracking (FCC) system disposed downstream of the acid gas removal unit and comprising an FCC reactor, where the FCC reactor may be in fluid communication with the acid gas removal unit to pass the treated plastic derived oil stream from the acid gas removal unit to the FCC reactor; and a used cooking oil stream in fluid communication with the FCC reactor to pass the used cooking oil stream to the FCC reactor. The FCC system may be configured to contact the treated plastic derived oil stream and the used cooking oil stream with a cracking catalyst under reaction conditions to produce an FCC effluent comprising circular chemicals and low carbon fuels.

[0010] Additional features and advantages of the technology described in this disclosure will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from the description or recognized by practicing the technology as described in this disclosure, including the detailed description which follows, the claims, as well as the appended drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The following detailed description of specific embodiments of the present disclosure can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:

[0012] FIG. 1 schematically depicts a generalized flow diagram of a system for converting solid waste plastic and used cooking oil to greater value circular chemicals and intermediates, according to embodiments shown and described in this disclosure;

[0013] FIG. 2 schematically depicts a generalized flow diagram of a fluidized catalytic cracking (FCC) reactor of the system of FIG. 1, where the FCC reactor is a riser reactor, according to embodiments shown and described in this disclosure;

[0014] FIG. 3 schematically depicts a test reactor system for converting hydrocarbon feeds having different ratios of used cooking oil to plastic derived oil, according to embodiments shown and described in this disclosure; and

[0015] FIG. 4 graphically depicts compositions of the reaction effluents obtained from contacting blends with different plastic derived oil stream and used cooking oil percentages with a cracking catalyst, according to embodiments shown and described in this disclosure.

[0016] For the purpose of describing the simplified schematic illustrations and descriptions of FIGS. 1-3, some of the numerous valves, temperature sensors, electronic controllers, and the like that may be employed and well known to those of ordinary skill in the art of certain chemical processing operations are not included. Further, accompanying components that are often included in chemical processing operations, such as, for example, air supplies, heat exchangers, surge tanks, catalyst hoppers, or other related systems are not depicted. It would be known that these components are within the spirit and scope of the present embodiments disclosed. However, operational components, such as those described in the present disclosure, may be added to the embodiments described in this disclosure.

[0017] It should further be noted that arrows in the drawings refer to process streams. However, the arrows may equivalently refer to transfer lines that may serve to transfer process streams between two or more system components. Additionally, arrows that connect to system components define inlets or outlets in each given system component. The arrow direction corresponds generally with the major direction of movement of the materials of the stream contained within the physical transfer line signified by the arrow. Furthermore, arrows that do not connect two or more system components signify a product stream which exits the depicted system or a system inlet stream which enters the depicted system. Product streams may be further processed in accompanying chemical processing systems or may be commercialized as end products. System inlet streams may be streams transferred from accompanying chemical processing systems or may be non-processed feedstock streams. Some arrows may represent recycle streams, which are effluent streams of system components that are recycled back into the system. However, it should be understood that any represented recycle stream, in embodiments, may be replaced by a system inlet stream of the same material, and that a portion of a recycle stream may exit the system as a system product.

[0018] Additionally, arrows in the drawings may schematically depict process steps of transporting a stream from one system component to another system component. For example, an arrow from one system component pointing to another system component may represent “passing” a system component effluent to another system component, which may include the contents of a process stream “exiting” or being “removed” from one system component and “introducing” the contents of that product stream to another system component.

[0019] It should be understood that two or more process streams are “mixed” or “combined” when two or more lines intersect in the schematic flow diagrams of FIGS. 1-3. Mixing or combining may also include mixing by directly introducing both streams into a like reactor, separation device, or other system component. For example, it should be understood that when two streams are depicted as being combined directly prior to entering a separator or reactor, that in some embodiments the streams could equivalently be introduced into the separator or reactor and be mixed in the reactor.

[0020] Reference will now be made in greater detail to various embodiments of the present disclosure, some embodiments of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or similar parts.DETAILED DESCRIPTION

[0021] Embodiments of the present disclosure are directed to systems and processes for producing greater value circular chemicals and low carbon fuels through co-processing of plastic derived oils and used cooking oils. Referring now to FIG. 1, one embodiment of a system 100 for co-processing a plastic derived oil stream 102 and a used cooking oil stream 104 is schematically depicted. The system 100 includes a plastic derived oil stream 102 and an acid gas removal unit 110 in fluid communication with the plastic derived oil stream 102. The acid gas removal unit 110 includes a reaction vessel 111 and an acid gas removal catalyst 112 disposed within the reaction vessel 111. The acid gas removal unit 110 may be configured to contact the plastic derived oil stream 102 with the acid gas removal catalyst 112 to remove halogen compounds, sulfur-containing compounds, or both from the plastic derived oil stream 102 to produce a treated plastic derived oil stream 114. The system 100 further includes a fluidized catalytic cracking (FCC) system 120 disposed downstream of the acid gas removal unit 110 and having an FCC reactor 122 containing a cracking catalyst 124. The FCC reactor 122 may be in fluid communication with the acid gas removal unit 110 to pass the treated plastic derived oil 114 from the acid gas removal unit 110 to the FCC reactor 122. The system 100 further includes a used cooking oil stream 104 in fluid communication with the FCC reactor 122 to pass the used cooking oil stream 104 to the FCC reactor 122. FCC reactor 122 may be a fluidized bed reactor configured to contact the treated plastic derived oil stream 114 and the used cooking oil stream 104 with the cracking catalyst 124 under reaction conditions to produce an FCC effluent 132 comprising circular chemicals, low carbon fuels, or both. In embodiments, the system 100 may further include a dehalogenation unit 10 and a pyrolysis unit 20 upstream of the acid gas removal unit 110, where the dehalogenation unit 10 and pyrolysis unit 20 may be configured to convert solid waste plastic 12 through dehalogenation and pyrolysis to produce the plastic derived oil stream 102.

[0022] The present disclosure is also directed to processes for producing circular chemicals, low-carbon fuels, or both using the systems 100. The processes of the present disclosure include passing the plastic derived oil stream 102 to the acid gas removal unit 110 and contacting the plastic derived oil stream 102 with an acid gas removal catalyst 112 disposed in the acid gas removal unit 110. Contacting the plastic derived oil stream 102 with the acid gas removal catalyst 112 may remove acid gases from the plastic derived oil stream 102 to produce a treated plastic derived oil stream 114, where the treated plastic derived oil stream 114 has concentrations of halogen compounds, sulfur compounds, or both that are less than concentrations of the halogen compounds, sulfur compounds, or both in the plastic derived oil stream 102. The processes further include passing the treated plastic derived oil stream 114 and the used cooking oil stream 104 to the FCC system 120 comprising the FCC reactor 122, and contacting the treated plastic derived oil stream 114 and the used cooking oil stream 104 with the cracking catalyst in the FCC reactor 122. Contacting the treated plastic derived oil stream 114 and the used cooking oil stream 104 with the cracking catalyst at a reaction temperature in the FCC reactor 122 may cause at least a portion of hydrocarbons from the treated plastic derived oil stream 114 and the used cooking oil stream 104 to undergo catalytic cracking reactions to produce an FCC effluent 132 comprising circular chemicals, low-carbon fuels, or both. In embodiments, the processes may further include producing the plastic derived oil stream 102, such as by melting and dehalogenating solid waste plastic 12 in a dehalogenation unit 10 to produce a liquefied plastic stream 14 and subjecting the liquefied plastic stream 14 to pyrolysis in a pyrolysis reactor 20 to produce the plastic derived oil stream 102.

[0023] Co-cracking the plastic derived oil stream 102 and the used cooking oil stream 104 may produce a high yield of circular chemicals and low carbon fuels, such as a yield of greater than 50 wt. % of C2-C4 olefins and light naphtha, where the light naphtha includes the light aromatic compounds having from 6-9 carbon atoms. The plastic derived oil and used cooking oil dilute each other, resulting in lower containment levels, which may ease the integration of alternative feeds into new and existing FCC systems. Further, plastic derived oil and used cooking oil are renewable feeds that can aid in decarbonization of FCC facilities. Co-cracking plastic derived oil and used cooking oil in existing refining assets allows refiners to introduce renewable and circular carbon into their finished products, among other features.

[0024] As used in this disclosure, the term “catalyst” refers to any substance that increases the rate of a specific chemical reaction. Catalysts and catalyst components described in this disclosure can be utilized to promote various reactions, such as, but not limited to catalytic cracking, aromatic cracking, dehalogenation, acid gas removal, pyrolysis, other chemical reactions, or combinations of these.

[0025] As used in this disclosure, the term “used catalyst” refers to catalyst that has been contacted with reactants but has not been regenerated to restore at least a portion of the catalytic activity to the catalyst. The term “regenerated catalyst” refers to a catalyst that has been regenerated in a regenerator or through a regeneration process to increase the catalytic activity, the temperature, or both of the regenerated catalyst.

[0026] As used in this disclosure, the term “aromatic compounds” refers to compounds having one or more aromatic ring structures. The term “light aromatic compounds” refers to compounds having an aromatic ring, with or without substitution, and from six to eight carbon atoms. The term “BTEX” refers to any combination of one or a plurality of benzene, toluene, ethylbenzene, para-xylene, meta-xylene, and ortho-xylene.

[0027] As used in this disclosure, the term “xylenes,” when used without a designation of the isomer, such as the prefix para, meta, or ortho, refers to one or more of meta-xylene, ortho-xylene, para-xylene, and mixtures of these xylene isomers.

[0028] As used in this disclosure, the terms “butenes” and “mixed butenes” refers to 1-butene, cis-2-butene, trans-2-butene, isobutene, and combinations of these. As used in this disclosure, the term “normal butenes” refers to 1-butene, cis-2-butene, trans-2-butene, and any combination thereof, but not including isobutene.

[0029] As used in this disclosure, the terms “low carbon footprint fuels” or “low carbon footprint fuel components” refer to fuels and fuel components derived from non-fossil origin, in contrast to conventional fuels which are produced directly from petroleum extracted from subterranean sources. The “low carbon footprint fuels” or “low carbon footprint fuel components” are produced sustainably from municipal or organic waste, sustainable biomass, renewables, or circular CO2. Production and use of the low carbon footprint fuels and fuel components result in very little or no additional CO2 generated. Low carbon footprint fuels and fuel components can help to reduce greenhouse emissions and mitigate the effects of climate change.

[0030] As used in this disclosure, the term “circular chemicals” refers to chemicals that are derived from the process of recycling waste materials back to produce useful chemical products and intermediates.

[0031] As used in this disclosure, the terms “boiling point temperature”, or “boiling temperature”, or “boiling point” refer to the temperature at which a compound or composition boils at atmospheric pressure, unless otherwise stated.

[0032] As used in this disclosure, the term “initial boiling point” or “IBP” of a composition is defined in accordance with standard test method ASTM D2887.

[0033] As used in this disclosure, the term “final boiling point” or “FBP” of a composition is defined in accordance with standard test method ASTM D2887.

[0034] As used in this disclosure, the term “separation unit” refers to any separation device that at least partially separates one or more chemicals in a mixture from one another. For example, a separation unit may selectively separate different chemical species from one another, forming one or more chemical fractions. Examples of separation units include, without limitation, distillation columns, cryogenic distillation units, fractionators, flash drums, knock-out drums, knock-out pots, centrifuges, filtration devices, traps, scrubbers, expansion devices, membranes, solvent extraction devices, pressure swing adsorption units, high-pressure separators, low-pressure separators, fluid-solid separators, and the like. It should be understood that separation processes described in this disclosure may not completely separate all of one chemical consistent from all of another chemical constituent. It should be understood that the separation processes described in this disclosure “at least partially” separate different chemical components from one another, and that even if not explicitly stated, it should be understood that separation may include only partial separation. As used in this disclosure, one or more chemical constituents may be “separated” from a process stream to form a new process stream. Generally, a process stream may enter a separation unit and be divided or separated into two or more process streams of desired composition.

[0035] As used in this disclosure, the terms “upstream” and “downstream” refer to the relative positioning of unit operations with respect to the direction of flow of the process streams through the system. A first unit operation of a system is considered “upstream” of a second unit operation if process streams flowing through the system encounter the first unit operation before encountering the second unit operation. Likewise, a second unit operation is considered “downstream” of the first unit operation if the process streams flowing through the system encounter the first unit operation before encountering the second unit operation.

[0036] As used in this disclosure, passing a stream or effluent from one unit “directly” to another unit refers to passing the stream or effluent from the first unit to the second unit without passing the stream or effluent through an intervening reaction system or separation system that substantially changes the composition of the stream or effluent. Heat transfer devices, such as heat exchangers, preheaters, coolers, or other heat transfer equipment, and pressure devices, such as pumps, pressure regulators, compressors, or other pressure devices, are not considered to be intervening systems that change the composition of a stream or effluent, unless otherwise specifically stated in the present disclosure. Combining two streams or effluents together upstream of a process unit also is not considered to comprise an intervening system that changes the composition of one or both of the streams or effluents being combined. Simply dividing a stream into two streams having the same composition is also not considered to comprise an intervening system that changes the composition of the stream.

[0037] As used in this disclosure, the term “effluent” refers to a stream that is passed out of a reactor, a reaction zone, or a separator following a particular reaction or separation process. Generally, an effluent has a different composition than the stream that entered the separator, reactor, or reaction zone. It should be understood that when an effluent is passed to another system unit, only a portion of that effluent may be passed. For example, a slip stream (having the same composition) may carry some of the effluent away, meaning that only a portion of the effluent may enter the downstream system unit. The terms “reaction effluent” or “reactor effluent” are more particularly used to refer to streams that are passed out of a reactor or reaction zone.

[0038] It should further be understood that streams may be named for the components of the stream, and the component for which the stream is named may be the major component of the stream (such as comprising from 50 weight percent (wt. %), from 70 wt. %, from 90 wt. %, from 95 wt. %, from 99 wt. %, from 99.5 wt. %, or even from 99.9 wt. % of the contents of the stream to 100 wt. % of the contents of the stream, notwithstanding any inert gases or diluents added to the stream). It should also be understood that components of a stream are disclosed as passing from one system component to another when a stream comprising that component is disclosed as passing from that system component to another. For example, a disclosed “plastic derived oil stream” passing to a first system component or from a first system component to a second system component should be understood to equivalently disclose the “plastic derived oil” passing to the first system component or passing from a first system component to a second system component.

[0039] The demand for circular chemicals, which can be used for the production of chemical intermediates used in production of polymers and plastics as well as for fuel components, is steadily increasing. Circular chemicals can include monomers, such as ethylene, propylene, butenes, benzene, xylenes, and toluene, which can be produced from used cooking oil, plastic waste, plastic derived oil, or other organic waste materials. These monomers can then be used again for the production of polymers, such as polyethylene, polypropylene, or polyethylene terephthalate. They are called circular chemicals because they are derived from the process of recycling waste materials back to produce useful chemical products and intermediates. Converting plastic waste and used cooking oil can also produce low carbon footprint fuel components, such as gasoline, jet fuels, or diesel fuels, which can provide additional sources of fuel with reduced CO2 generation, compared to fuel components derived directly from fossil fuels extracted from subterranean sources.

[0040] As previously discussed, plastic derived oils have good properties and contain hydrocarbon constituents useful for application as chemical intermediates and fuel blending components. However, plastic derived oils can include halogen-containing compounds, such as but not limited to chloro-organic compounds, and other contaminants resulting from the types of solid waste plastic and additives included in the plastics, and the plastic derived oils can have a broad boiling point temperature range, such as from 30° C. to 400° C., or even greater than 400° C. Plastic derived oils can also include compounds with different functional groups and families of organic compounds, such as but not limited to oxygenates, aromatic compounds, olefins, alkanes, other hydrocarbon compounds, or combinations of these. The direct use of plastic waste derived oils in catalytic cracking to produce chemical products, intermediates, or fuel components can lead to problems downstream because of the presence of the halogen-containing compounds. In particular, halogen-containing compounds may poison or damage catalysts, form salts that foul refinery equipment, and contaminate refined products. Additionally, the breakdown of halogen-containing compounds may cause corrosion in refinery equipment.

[0041] Used cooking oil has a high conversion and has been shown to give high yields of light olefins, making it a potentially useful feed for refinery processes. However, cracking of used cooking oil generally produces low-quality oils and techniques to improve oil quality, such as hydrothermal cracking and hydro-deoxygenation, are costly and require a high degree of sophistication. Co-processing the used cooking oils in FCC systems may aid in reducing the complexity and cost required to produce high-quality oils from used cooking oil. However, used cooking oils have generally been considered unsuitable for co-processing in FCC systems because they produce high coke yields that can inhibit catalyst function.

[0042] Thus, an ongoing need exists for more efficient processes and catalysts for co-processing plastic derived oils and used cooking oils through fluidized catalytic cracking processes (FCC processes) to produce greater value chemicals and intermediates while also decontaminating the plastic derived oils, used cooking oils, and greater value chemicals and intermediates, such as removing halogen-containing compounds (dehalogenation). The present disclosure solves these problems in the art by providing processes and systems for co-cracking plastic derived oils and used cooking oils. In embodiments, the systems for co-processing the plastic derived oil and used cooling oil may include an acid gas removal unit, in which the plastic derived oil stream contacts an acid gas removal catalyst to produce a treated plastic derived oil stream. The system may also include an FCC system, and the treated plastic derived oil stream and a used cooking oil stream may both be passed to the FCC system. The treated plastic derived oil stream and used cooking oil stream contact a cracking catalyst in an FCC reactor of the FCC system to produce an FCC effluent. The FCC system may further include a fluid-solid separation unit configured to separate the FCC effluent from a used cracking catalyst. The FCC system may include a catalyst regenerator configured to regenerate the used cracking catalyst to produce a regenerated cracking catalyst, which may be passed back to the FCC reactor as the cracking catalyst. The system may also include a dehalogenation unit and a pyrolysis unit upstream of the acid gas removal unit, where the dehalogenation unit may be configured to melt a dehalogenated solid waste plastic to produce a liquid plastic stream, and the pyrolysis reactor may be configured to subject the liquid plastic stream to pyrolysis to produce the plastic derived oil stream.

[0043] The processes of the present disclosure may include simultaneously contacting a cracking catalyst with a plastic derived oil stream and used cooking oil stream to produce greater value chemical products and intermediates, such as but not limited circular chemicals, low-carbon footprint fuels, or combinations thereof. In embodiments, the process may include dehalogenating a solid waste plastic in a dehalogenation unit to produce a liquefied plastic stream, passing the liquefied plastic stream to a pyrolysis reactor, where the liquefied plastic stream may be pyrolyzed to produce plastic derived oil stream, and passing the plastic derived oil stream to an acid gas removal unit, where the plastic derived oil stream may contact an acid gas removal catalyst to produce a treated plastic derived oil stream. The processes of the present disclosure include passing the treated plastic derived oil stream and the used cooking oil stream to the FCC reactor of the FCC system. The processes may include contacting the treated plastic derived oil stream and the used cooking oil stream with a cracking catalyst in the FCC reactor to produce an FCC effluent comprising circular chemicals, low-carbon fuels, or both, which may include but are not limited to light olefins, light aromatic compounds, naphtha range hydrocarbons, or combinations thereof. In embodiments, the process may further include separating the FCC effluent from the used cracking catalyst, and regenerating the used cracking catalyst.

[0044] The processes of the present disclosure produce greater value chemicals and intermediates that are circular chemicals. The systems and processes of co-cracking of plastic derived oil and used cooking oil of the present disclosure may also enable the recycling of a broader range of types of solid waste plastic and used cooking oils. The used cooking oil and plastic derived oil may dilute each other, reducing the level of contaminants and, as a result, reducing downstream problems caused by halogen-containing compounds (such as organochlorides) or other contaminants. The reaction products can be considered to have a low carbon footprint. Low carbon footprint fuels and fuel components can help to reduce greenhouse emissions and mitigate the effects of climate change. The systems and processes of co-cracking of the present disclosure can be easily integrated into existing petroleum refineries and petrochemical installations, such as existing FCC reactor systems, among other features. Plastic derived oil and used cooking oil are renewable feeds and can aid in decarbonizing existing refinery facilities, among other features.

[0045] Referring again to FIG. 1, one embodiment of a system 100 for co-processing a plastic derived oil stream 102 and a used cooking oil stream 104 is schematically depicted. The system 100 may include a plastic derived oil stream 102, an acid gas removal unit 110, a used cooking oil stream 104, an FCC system 120 disposed downstream of the acid gas removal unit 110, and an effluent separation system 150 disposed downstream of the FCC system 120. The acid gas removal unit 110 may be configured to contact the plastic derived oil stream 102 with an acid gas removal catalyst 112 to remove halogen compounds, sulfur compounds, or both to produce a treated plastic derived oil stream 114. The FCC system 120 may be configured to contact the treated plastic derived oil stream 114 and the used cooking oil stream 104 with a cracking catalyst 124 in an FCC reactor 122 at reaction conditions, separate an FCC effluent 132 from the used cracking catalyst 134, and regenerate the used cracking catalyst 134 to produce a regenerated cracking catalyst 142. The effluent separation system 150 may be configured to separate the FCC effluent 132 to produce a plurality of product streams, such as but not limited to an ethylene stream, a propylene stream, a mixed butenes stream, a light aromatics stream, a light naphtha stream, a gasoline stream, a jet fuel stream, a diesel stream, a heavy compounds stream, or any combination of these streams. In embodiments, the system 100 may include a dehalogenation unit 10 upstream of the acid gas removal unit 110, where solid waste plastic 12 is melted and dehalogenated in the dehalogenation unit 10 to produce a liquid plastic stream 14. The system 100 may further include a pyrolysis reactor 20 upstream of the acid gas removal unit 110, where the liquid plastic stream 14 may be pyrolyzed in the pyrolysis reactor 20 to produce the plastic derived oil stream 102.

[0046] The FCC system 120 may include the FCC reactor 122, which may be the fluidized bed reactor. The FCC reactor 122 may be configured to contact the treated plastic derived oil stream 114 and the used cooking oil stream 104 with the cracking catalyst 124 at reaction conditions sufficient to convert at least a portion of hydrocarbons in the treated plastic derived oil stream 114 and the used cooking oil stream 104 to produce the FCC effluent 132. The FCC system 120 may further comprise the fluid-solid separation unit 130 disposed at an outlet end of the FCC reactor 122. The fluid-solid separation unit 130 may be configured to separate the FCC effluent 132 from the used cracking catalyst 134. Referring again to FIG. 1, the FCC system 120 may further include a catalyst regenerator 140 disposed downstream of the fluid-solid separation unit 130. The catalyst regenerator 140 may be configured to regenerate the used cracking catalyst 134 to produce a regenerated cracking catalyst 142, which may be passed back to the FCC reactor 122 as at least a portion of the cracking catalyst 124.

[0047] The plastic derived oil stream 102 may be a liquid stream comprising hydrocarbons and produced through melting, dehalogenation, and pyrolysis of solid waste plastic. As previously discussed, the plastic derived oil stream 102 may include hydrocarbons, such as but not limited to aromatic compounds, olefins, alkanes, other hydrocarbon compounds. Additionally, the plastic derived oil stream 102 may include other organic compounds, such as but not limited to oxygenates, halogen-containing compounds such as organic halide compounds, plastic additives, and other contaminants. The plastic derived oil stream 102 may comprise a concentration of halogen-containing compounds of from 10 part per million by weight (ppmw) to 1,000 ppmw. In embodiments, the plastic derived oil stream 102 may comprise a concentration of halogen-containing compounds of from 10 ppmw to 500 ppmw, from 10 ppmw to 400 ppmw, from 10 ppmw to 300 ppmw, from 50 ppmw to 500 ppmw, from 50 ppmw to 400 ppmw, from 50 ppmw to 300 ppmw, from 100 ppmw to 1,000 ppmw, from 100 ppmw to 500 ppmw, from 100 ppm to 400 ppmw, from 100 ppmw to 300 ppmw, from 150 ppmw to 500 ppmw, from 150 ppmw to 400 ppmw, or from 150 ppmw to 300 ppmw. In embodiments, the plastic derived oil stream 102 may have a concentration of halogen-containing compounds of greater than or equal to 100 ppmw, greater than or equal to 150 ppmw, greater than or equal to 200 ppmw, or even greater than or equal to 250 ppmw.

[0048] In embodiments, the plastic derived oil stream 102 may comprise light naphtha range hydrocarbons, jet fuel constituents, diesel range constituents, heavy compounds, or combinations of these. Light naphtha range hydrocarbons refer to hydrocarbons having atmospheric boiling point temperatures of from 0° C. to 150° C., jet fuel constituents include hydrocarbons having atmospheric boiling point temperatures of from 150° C. to 300° C., diesel range constituents include hydrocarbons having atmospheric boiling point temperatures of from 300° C. to 343° C., and the heavy compounds refer to hydrocarbons having atmospheric boiling point temperatures of greater than 343° C. In embodiments, the plastic derived oil stream 102 may comprise from 10 wt. % to 35 wt. % light naphtha range hydrocarbons, such as from 15 wt. % to 30 wt. %, from 15 wt. % to 25 wt. %, from 20 wt. % to 25 wt. %, about 23.8 wt. %, or about 17.1 wt. % of the light naphtha range hydrocarbons per unit weight of the plastic derived oil stream 102. In embodiments, the plastic derived oil stream 102 may comprise from 35 wt. % to 70 wt. % jet fuel constituents, such as from 35 wt. % to 60 wt. %, from 35 wt. % to 55 wt. %, from 35 wt. % to 50 wt. %, from 40 wt. % to 60 wt. %, from 40 wt. % to 55 wt. %, from 40 wt. % to 50 wt. %, about 49.7 wt. %, or about 41.8 wt. % of the jet fuel constituents per unit weight of the plastic derived oil stream 102. In embodiments, the plastic derived oil stream 102 may comprise from 5 wt. % to 25 wt. % of the diesel range constituents, such as from 5 wt. % to 20 wt. %, from 5 wt. % to 15 wt. %, from 10 wt. % to 25 wt. %, from 10 wt. % to 20 wt. %, from 10 wt. % to 15 wt. %, about 15.2 wt. % or about 13.6 wt. % of the diesel range constituents per unit weight of the plastic derived oil stream 102. In embodiments, the plastic derived oil stream 102 may comprise from 5 wt. % to 40 wt. % heavy compounds, such as from 5 wt. % to 35 wt. %, from 5 wt. % to 30 wt. %, from 10 wt. % to 40 wt. %, from 10 wt. % to 35 wt. %, from 20 wt. % to 40 wt. %, from 20 wt. % to 35 wt. %, from 20 wt. % to 30 wt. %, about 11.3 wt. %, or about 27.5 wt. % of the heavy compounds per unit weight of the plastic derived oil stream 102.

[0049] In embodiments, the plastic derived oil stream 102 may comprise naphtha range hydrocarbons, middle distillates, heavy compounds, or combinations of these. Naphtha range hydrocarbons refer to hydrocarbons having atmospheric boiling point temperatures of from 25° C. to 221° C., middle distillates include hydrocarbons having atmospheric boiling point temperatures of from 221° C. to 343° C., and the heavy compounds refer to hydrocarbons having atmospheric boiling point temperatures of greater than 343° C. In embodiments, the plastic derived oil stream 102 may comprise from 20 wt. % to 45 wt. % naphtha range hydrocarbons, such as from 20 wt. % to 40 wt. %, from 20 wt. % to 35 wt. %, from 20 wt. % to 30 wt. %, from 30 wt. % to 45 wt. %, from 30 wt. % to 40 wt. %, from 35 wt. % to 45 wt. %, from 35 wt. % to 40 wt. %, or about 38 wt. % naphtha range hydrocarbons based on the total weight of the plastic derived oil stream 102. In embodiments, the plastic derived oil stream 102 may comprise from 40 wt. % to 70 wt. % middle distillates, such as from 40 wt. % to 60 wt. %, from 40 wt. % to 55 wt. %, from 40 wt. % to 50 wt. %, from 45 wt. % to 70 wt. %, from 45 wt. % to 60 wt. %, from 45 wt. % to 55 wt. %, from 45 wt. % to 50 wt. %, or about 48 wt. % middle distillates based on the total weight of the plastic derived oil stream 102. In embodiments, the plastic derived oil stream 102 may comprise from 5 wt. % to 25 wt. % heavy compounds, such as from 5 wt. % to 20 wt. %, from 5 wt. % to 15 wt. %, from 10 wt. % to 25 wt. %, from 10 wt. % to 20 wt. %, from 10 wt. % to 15 wt. %, or about 14 wt. % heavy compounds based on the total weight of the plastic derived oil stream 102.

[0050] The plastic derived oil stream 102 may be characterized by a boiling point distribution determined according to standard test method ASTM D2887. In embodiments, the plastic derived oil stream 102 may have an initial boiling point (IBP) of from 20° C. to 100° C., such as from 20° C. to 60° C., from 20° C. to 50° C., from 25° C. to 100° C. from 25° C. to 60° C., from 25° C. to 50° C., or from 25° C. to 40° C. In embodiments, the plastic derived oil stream 102 may have a final boiling point (FBP) of from 300° C. to 600° C., such as from 300° C. to 500° C., from 300° C. to 450° C., from 350° C. to 600° C., from 350° C. to 500° C., from 350° C. to 450° C., or from 375° C. to 425° C. In embodiments, the plastic derived oil stream 102 may have a 50% boiling point temperature of from 150° C. to 350° C., such as from 150° C. to 300° C., from 150° C. to 275° C., from 200° C. to 350° C., from 200° C. to 300° C., from 200° C. to 275° C., from 225° C. to 350° C., from 225° C. to 300° C., or from 225° C. to 275° C., where the 50% boiling point temperature is determined according to ASTM D2887 and is generally the temperature at which 50% by weight of the constituents have transitioned from the liquid phase to the vapor phase.

[0051] In embodiments, the plastic derived oil stream 102 may have a density of from 0.65 g / cm3 to 1.1 g / cm3, such as from 0.65 g / cm3 to 1.0 g / cm3, from 0.65 g / cm3 to 0.9 g / cm3, from 0.65 g / cm3 to 0.8 g / cm3, from 0.7 g / cm3 to 1.1 g / cm3, from 0.7 g / cm3 to 1.0 g / cm3, from 0.7 g / cm3 to 0.9 g / cm3, from 0.7 g / cm3 to 0.8 g / cm3, from 0.75 g / cm3 to 1.1 g / cm3, from 0.75 g / cm3 to 1.0 g / cm3, from 0.75 g / cm3 to 0.9 g / cm3, or from 0.75 g / cm3 to 0.85 g / cm3, as determined by ASTM D4052. In embodiments, the plastic derived oil stream 102 may have less than or equal to 0.1 wt. % sulfur, as determined by ASTM D4294. In embodiments, the plastic derived oil stream 102 may have less than 0.01 wt. % Conradson carbon, as determined according to ASTM D4530. In embodiments, the plastic derived oil stream 102 may have an oxygen content of from 100 ppmw to 10,000 ppmw, such as from 100 ppmw to 7,000 ppmw, from 500 ppmw to 10,000 ppmw, from 500 ppmw to 7000 ppmw, from 1000 to 10,000 ppmw, from 1000 to 7000 ppmw, or from 5000 ppm to 10,000 ppmw. In embodiments, the plastic derived oil stream 102 may have a moisture content (concentration of water) of less than or equal to 5000 ppmw, less than or equal to 2000 ppmw, less than or equal to 1000 ppmw, less than or equal to 500 ppmw, or less than or equal to 400 ppmw, as determined according to ASTM D6304A. In embodiments, the plastic derived oil stream 102 may have the properties provided in Table 1.TABLE 1Properties of one embodiment of the plastic derived oil stream 102PropertyUnitsTest MethodValueDensityg / cm3ASTM D40520.792Total Oxygen ConcentrationppmwCombustion5540basedTotal Chloride ConcentrationppmwUOP 779342Total Sulfurwt. %ASTM D42940.064Total NitrogenppmwASTM D46291135Bromine Numberg(Br2) / ASTM D115943.3100 gSilicappmwUOP 4070.109SodiumppmwUOP 4070.174IronppmwUOP 4070.097WaterppmwASTM D6304A299Conradson Carbon Residuewt. %ASTM D4530<0.01Simulated Distillation TableRecovery (wt. %)UnitsTest MethodTemperatureSIMDIST - IBP° C.ASTM D288729.4SIMDIST - 5 wt. %° C.ASTM D288777.7SIMDIST - 10 wt. %° C.ASTM D2887107.1SIMDIST - 15 wt. %° C.ASTM D2887127.3SIMDIST - 20 wt. %° C.ASTM D2887139.9SIMDIST - 25 wt. %° C.ASTM D2887158.7SIMDIST - 30 wt. %° C.ASTM D2887173.6SIMDIST - 35 wt. %° C.ASTM D2887188.7SIMDIST - 40 wt. %° C.ASTM D2887207.9SIMDIST - 45 wt. %° C.ASTM D2887225.6SIMDIST - 50 wt. %° C.ASTM D2887240.0SIMDIST - 55 wt. %° C.ASTM D2887253.9SIMDIST - 60 wt. %° C.ASTM D2887266.2SIMDIST - 65 wt. %° C.ASTM D2887279.3SIMDIST - 70 wt. %° C.ASTM D2887293.8SIMDIST - 75 wt. %° C.ASTM D2887307.1SIMDIST - 80 wt. %° C.ASTM D2887320.2SIMDIST - 85 wt. %° C.ASTM D2887333.7SIMDIST - 90 wt. %° C.ASTM D2887347.8SIMDIST - 95 wt. %° C.ASTM D2887364.7SIMDIST - FBP° C.ASTM D2887405.3

[0052] The plastic derived oil stream 102 may be produced from solid waste plastic through melting and dehalogenation followed by pyrolysis. Referring to FIG. 1, the systems 100 disclosed herein may further include the dehalogenation unit 10 and the pyrolysis reactor 20, both of which may be disposed upstream of the acid gas removal unit 110. The dehalogenation unit 10 may be operable to melt and dehalogenate the solid waste plastic 12 to produce a liquefied plastic stream 14. The liquefied plastic stream 14 may be passed to the pyrolysis reactor 20 downstream of the dehalogenation unit 10. The pyrolysis reactor 20 may be configured to subject the liquefied plastic stream 14 to pyrolysis to produce the plastic derived oil stream 102. The processes disclosed herein may include producing the plastic derived oil stream 102 from a solid waste plastic 12 by liquefying and dehalogenating the solid waste plastic 12 in the dehalogenation unit 10 to produce a liquefied plastic stream 14, passing the liquefied plastic stream 14 to the pyrolysis reactor 20, and subjecting the liquefied plastic stream 14 to pyrolysis to in the pyrolysis reactor 20 produce the plastic derived oil stream 102.

[0053] The solid waste plastic 12, which is supplied to the dehalogenation unit 10, may comprise a plastic feedstock including mixed solid waste plastic of differing compositions. The solid waste plastic 12 may be a mixture of plastics from various polymer families. In embodiments, the solid waste plastic 12 may comprise plastics representative of one or more of the polymer families, such as but not limited to olefins, carbonates, aromatic polymers, sulfones, fluorinated hydrocarbon polymers, chlorinated hydrocarbon polymers, acrylonitriles, or combinations of these families of polymers. In embodiments, the mixed waste plastics 12 may include polyethylene (PE), polypropylene (PP), diphenylcarbonate, polystyrene (PS), polyether sulfone, polyfluoroethylene (PTFE), polyvinyl chloride (PVC), polyacrylonitrile (PAN), other polymers, or combinations of these. In embodiments, solid waste plastic 12 may be a mixture of high density polyethylene (HDPE, for example, a density of about 0.93 to 0.97 grams per cubic centimeter (g / cm3)), low density polyethylene (LDPE, for example, about 0.910 g / cm3 to 0.940 g / cm3), polypropylene (PP), linear low density polyethylene (LLDPE), polystyrene (PS), polyvinyl chloride (PVC), polyethylene terephthalate (PET), or combinations of these polymers. In embodiments, the solid waste plastic 12 may include one or more chlorinated hydrocarbons, such as PVC. The plastics of the solid waste plastic 12 may be natural, synthetic, or semi-synthetic polymers. Utilization of the solid waste plastic 12 comprising a mixture of different types of plastics and polymers may allow for recycling of solid plastics without necessitating fine sorting of the plastics into different types.

[0054] The solid waste plastic 12 may be provided in a variety of different forms. In embodiments, the solid waste plastic 12 may be in the form of a powder in smaller scale operations. In embodiments, the solid waste plastic 12 may be in the form of pellets, such as pellets with a particle size of from 1 to 5 millimeter (mm) for larger scale operations. In embodiments, the solid waste plastic 12 may be provided as chopped or ground waste plastics. In embodiments, the system 100 may include a plastic grinding unit (not shown) upstream of the dehalogenation unit 10, where the plastic grinding unit may be operable to grind plastic articles into smaller pieces to produce the solid waste plastic 12. In embodiments, the solid waste plastic 12 may comprise waste plastic, manufacturing off-spec product, new plastic products, unused plastic products, or combinations of these.

[0055] The dehalogenation unit 10 may be in fluid communication with the solid waste plastic 12 to pass the solid waste plastic 12 to the dehalogenation unit 10. The dehalogenation unit 10 may be operable to increase the temperature of the solid waste plastic 12 to a temperature between 250° C. and 350° C., such as from 250° C. to 300° C., to melt the plastics and generate the liquefied plastic stream 14. When the solid waste plastic 12 include halogenated plastics, such as but not limited to PVC, melting the plastics may release some hydrogen halides, such as HCl. The dehalogenation unit 10 may also be operable to scrub HCl and other halogen halides released during melting of the solid waste plastic 12. Removal of some of the chlorine, fluorine, or other halides from the solid waste plastic 12 may reduce the concentration of halides in the liquefied plastic stream 14. As a result, the liquefied plastic stream 14 may have a reduced concentration of chlorine compounds and other halogen-containing compounds compared to the solid waste plastic 12. Reducing the concentration of organic halide compounds in the liquefied plastic stream 14 may reduce corrosion problems in the downstream pyrolysis reactor 20. However, the liquefied plastic stream 14 may still contain halogen-containing organic compounds and other contaminants. Thus, dehalogenation in the dehalogenation unit 10 removes only a portion of the halogen-containing compounds from the liquefied plastic stream 14.

[0056] In embodiments, the dehalogenation unit 10 may be operable to increase the temperature of the solid waste plastic 12 to a temperature of from 250° C. to 350° C. to melt the solid waste plastic 12 and remove at least a portion of the chlorine and other halogens from the resulting liquefied plastic stream 14. In embodiments, the dehalogenation unit 10 may be operable to increase the temperature of the solid waste plastic 12 to a temperature of from 250° C. to 300° C., from 275° C. to 350° C., from 275° C. to 325° C., or from 300° C. to 350° C. The temperature of the dehalogenation unit 10 may be controlled to remove HCl without cracking a substantial number of C—H or C—C bonds.

[0057] In embodiments, the HCl and other hydrogen halides released from the liquefied plastic stream 14 may be passed out of the dehalogenation unit 10 as a halogen-rich stream (not shown). The halogen-rich stream may include hydrogen halides, such as HCl, as well as hydrogen and light hydrocarbon gases, such as but not limited to mono aromatics, hydrogen, methane, and C2-C5 gases. In embodiments, the halogen-rich stream may be scrubbed with water or a sodium hydroxide solution in a downstream acid gas scrubbing unit (not shown) to remove the halogen compounds from the halogen-rich stream. In embodiments, the hydrogen halide compounds may be scrubbed within the dehalogenation unit 10, such as by contacting the released gases with adsorbents, such as but not limited to Al2O3, zeolites, or other chemical removers. In embodiments, the dehalogenation unit 10 may include a melting reactor and an acid gas scrubber downstream of the melting reactor. In embodiments, a single unit forming the dehalogenation unit 10 may achieve both melting of the solid waste plastic and scrubbing to remove hydrogen halides. Organic halide compounds not released during dehalogenation in the dehalogenation unit 10 may be passed onward in the liquefied plastic stream 14 to the pyrolysis reactor 20.

[0058] Referring again to FIG. 1, the pyrolysis reactor 20 may be disposed downstream of the dehalogenation unit 10 and in fluid communication with the liquefied plastic stream 14 discharged from the dehalogenation unit 10. In embodiments, the liquefied plastic stream 14 may be passed directly from the dehalogenation unit 10 to the pyrolysis reactor 20. The pyrolysis reactor 20 may be operable to increase the temperature of the liquefied plastic stream 14 to a temperature of from 300° C. to 1000° C., such as from 350° C. to 1000° C., in an anaerobic environment (no oxygen present), to convert the liquefied plastic stream 14 to the plastic derived oil stream 102. In particular, the pyrolysis of the liquefied plastic stream 14 in the pyrolysis reactor 20 may cause at least a portion of the long chain polymers in the liquefied plastic stream 14 to break apart into smaller fragments comprising organic compounds having smaller average molecular weights compared to the long chain polymers in the liquefied plastic stream 14.

[0059] The specific reactor used as the pyrolysis reactor 20 can be of different types and are not limited for the purposes of the present disclosure. Typical reactor types that can be used to serve the function of the pyrolysis reactor 20 can include but are not limited to tank reactors, rotary kilns, packed catalyst bed reactors, bubbling bed reactors, or other types of reactors. In embodiments, the pyrolysis of the liquefied plastic stream 14 in the pyrolysis reactor 20 may be performed in the presence or absence of a pyrolysis catalyst at a temperature of from 300° C. to 1000° C. or from 350° C. to 1000° C. In embodiments, the pyrolysis reactor 20 may operate at a low severity at a temperature less than or equal to 450° C. or at a high severity at a temperature greater than 450° C. In embodiments, the pyrolysis reactor 20 may be operated at a temperature of from 400° C. to 600° C., from 400° C. to 500° C., from 400° C. to 450° C., from 450° C. to 500° C., or from 425° C. to 475° C. In embodiments, the pyrolysis reactor 20 may be operated at a pressure in the range of 1 bar to 100 bars (100 kilopascals (kPa) to 10,000 kPa), from 1 bar to 50 bars (100 kPa to 5000 kPa), from 1 bar to 25 bars (1 kPa to 2500 kPa), or from 1 bar to 10 bars (1 kPa to 1000 kPa). Further, in various embodiments, the residence time of the liquefied plastic stream 14 in the pyrolysis reactor 20 may be from 1 second to 3600 seconds, from 60 seconds to 1800 seconds, or from 60 seconds to 900 seconds. The plastic derived oil stream 102 may be passed out of the pyrolysis reactor 20.

[0060] The used cooking oil stream 104 may include hydrocarbons, such as but not limited to aromatic compounds, olefins, alkanes, other hydrocarbon compounds. Additionally, the used cooking oil stream 104 may include other organic compounds, such as but not limited to oxygenates, halogen-containing compounds such as organic halide compounds, and other contaminants.

[0061] In embodiments, the used cooking oil stream 104 may comprise primarily heavy compounds, which refer to hydrocarbons having atmospheric boiling point temperatures of greater than 343° C. In embodiments, the used cooking oil stream 104 may comprise greater than or equal to 80 wt. % heavy compounds, such as greater than or equal to 85 wt. %, greater than or equal to 90 wt. %, greater than or equal to 95 wt. %, greater than or equal to 98 wt. %, greater than or equal to 99 wt. %, or even 100 wt. % heavy compounds per unit weight of the used cooking oil stream 104.

[0062] In embodiments, the used cooking oil stream 104 may comprise less than or equal to 15 wt. % light naphtha range hydrocarbons, less than or equal to 10 wt. % light naphtha range hydrocarbons, less than or equal to 5 wt. %, or even less than or equal to 1 wt. % light naphtha range hydrocarbons per unit weight of the used cooking oil stream 104. In embodiments, the used cooking oil stream 104 may comprise less than or equal to 15 wt. % jet fuel constituents, such as less than or equal to 10 wt. %, less than or equal to 5 wt. %, or even less than or equal to 1 wt. % jet fuel constituents per unit weight of the used cooking oil stream 104. In embodiments, the used cooking oil stream 104 may compromise less than or equal to 20 wt. % the diesel range constituents, such as less than or equal to 15 wt. % less than or equal to 10 wt. %, less than or equal to 5 wt. %, or even less than or equal to 1 wt. % of the diesel range constituents per unit weight of the used cooking oil stream 104.

[0063] The used cooking oil stream 104 may be characterized by a boiling point distribution determined using standard test method ASTM D2887. The used cooking oil stream 104 may have a narrow boiling point distribution of from 450° C. to 750° C., such as from 500° C. to 700° C., or from 500° C. to 650° C. In embodiments, the used cooking oil stream 104 may have an initial boiling point (IBP) of greater than or equal to 450° C., such as from 450° C. to 600° C., from 450° C. to 580° C., from 450° C. to 550° C., from 500° C. to 600° C., from 500° C. to 580° C., from 500° C. to 560° C., from 500° C. to 550° C., from 510° C. to 600° C., from 510° C. to 580° C., from 510° C. to 560° C., or from 510° C. to 550° C. In embodiments, the used cooking oil stream 104 may have a final boiling point (FBP) of less than or equal to 750° C., such as from 600° C. to 750° C., such as from 600° C. to 720° C., from 600° C. to 700° C., from 600° C. to 675° C., from 620° C. to 750° C., from 620° C. to 720° C., from 620° C. to 700° C., or from 620° C. to 675° C. In embodiments, the used cooking oil stream 104 may have a 50% boiling point temperature of from 580° C. to 620° C., such as from 550° C. to 610° C., from 590° C. to 620° C., from 590° C. to 610° C., from 600° C. to 620° C., from 600° C. to 615° C., or from 600° C. to 610° C., where the 50% boiling point temperature is defined according to test method ASTM D2887.

[0064] The used cooking oil stream 104 may have a density of from 0.8 g / cm3 to 1.1 g / cm3, such as from 0.8 g / cm3 to 1.05 g / cm3, from 0.8 g / cm3 to 1 g / cm3, from 0.8 g / cm3 to 0.95 g / cm3, from 0.85 g / cm3 to 1.1 g / cm3, from 0.85 g / cm3 to 1.05 g / cm3, from 0.85 g / cm3 to 1 g / cm3, from 0.85 g / cm3 to 0.95 g / cm3, from 0.9 g / cm3 to 1.1 g / cm3, from 0.9 g / cm3 to 1.05 g / cm3, from 0.9 g / cm3 to 1 g / cm3, from 0.9 g / cm3 to 0.95 g / cm3, or from 0.92 g / cm3 to 0.93 g / cm3, as determined by ASTM D4052. The used cooking oil stream 104 may have an API gravity of from 15 degrees to 30 degrees, such as from 15 degrees to 27 degrees, from 15 degrees to 25 degrees, from 18 degrees to 30 degrees, from 18 degrees to 27 degrees, from 18 degrees to 25 degrees, from 20 degrees to 30 degrees, from 20 degrees to 27 degrees, from 20 degrees to 25 degrees, or from 21 degrees to 23 degrees, as determined according to ASTM 287. The used cooking oil stream 104 may have less than or equal to 1.00 wt. % free fatty acid (FFA), as determined by ASTM 5555-95.

[0065] In embodiments, the used cooking oil stream 104 may have a chlorine content of from 0 (zero) ppmw to 20 ppmw, such as from 2 ppmw to 20 ppmw, from 2 ppmw to 10 ppmw, from 2 ppmw to 8 ppmw, from 5 ppmw to 20 ppmw, from 5 ppmw to 15 ppmw, from 5 ppmw to 10 ppmw, or from 12 ppm to 20 ppm, as determined by standard test method UOP 407. In embodiments, the used cooking oil stream 104 may have a sulfur content from 0 ppmw to 20 ppmw, such as from 0 ppmw to 10 ppmw, from 0 ppmw to 8 ppmw, from 1 ppmw to 20 ppmw, from 1 ppmw to 10 ppmw, from 5 ppmw to 20 ppmw, from 5 ppmw to 15 ppmw, or from 5 ppmw to 10 ppmw, as determined by ASTM D4294. In embodiments, the used cooking oil stream 104 may have a phosphorus content of from 0 ppmw to 10 ppmw, such as from 0 ppmw to 5 ppmw, from 0 ppmw to 2 ppmw, from 0.1 ppmw to 10 ppmw, such as from 0.1 ppmw to 5 ppmw, from 0.1 ppmw to 2 ppmw, from 0.1 ppmw to 1.5 ppmw, from 0.5 ppmw to 10 ppmw, from 0.5 ppmw to 5 ppmw, from 0.5 ppmw to 2 ppmw, or from 0.5 ppmw to 1.5 ppmw, as determined by UOP 407.

[0066] In embodiments, the used cooking oil stream 104 may have a total metal content less than 10 ppmw, such as from 0 ppmw to 10 ppmw, from 0 ppmw to 5 ppmw, from 1 ppmw to 10 ppmw, from 1 ppmw to 5 ppmw, from 2 ppmw to 10 ppmw, or from 2 ppmw to 5 ppmw, as determined by UOP 407. In embodiments, the used cooking oil stream 104 may include calcium, iron, potassium, sodium, silicon, tin, zinc, other metals, or combinations of metals. For example, the used cooking oil stream 104 may have a calcium content of from 0 ppmw to 1 ppmw, such as from 0.1 ppmw to 1 ppmw, from 0.1 ppmw to 0.5 ppmw, from 0.1 ppmw to 0.25 ppmw, from 0.25 ppmw to 0.5 ppmw, from 0.25 ppmw to 0.75 ppmw, from 0.25 ppmw to 0.5 ppmw, from 0.5 ppmw to 0.75 ppmw, from 0.75 ppmw to 1 ppmw, or from 0.5 ppmw to 1 ppmw, as determined by UOP 407. In embodiments, the used cooking oil stream 104 may have an iron content of less than or equal to 0.1 ppmw, less than or equal to 0.05 ppmw, or less than or equal to 0.02 ppmw, as determined UOP 407. In embodiments, the used cooking oil stream 104 may have a potassium content of from 0 ppmw to 0.2 ppmw, such as from 0.01 ppmw to 0.2 ppmw, from 0.01 ppmw to 0.1 ppmw, from 0.05 ppmw to 0.15 ppmw, from 0.05 ppmw to 0.2 ppmw, or from 0.1 ppmw to 0.2 ppmw, as determined by UOP 407. In embodiments, the used cooking oil stream 104 may have a sodium content of from 0.5 ppmw to 1.5 ppmw, such as from 0.5 ppmw to 0.75 ppmw, from 0.5 ppmw to 1 ppmw, from 0.75 ppmw to 1.25 ppmw, from 0.75 ppmw to 1 ppmw, from 1 ppmw to 1.25 ppmw, from 1 ppmw to 1.25 ppmw, from 1 ppmw to 1.5 ppmw, or from 1.25 ppmw to 1.5 ppmw, as determined by UOP 407. In embodiments, the used cooking oil stream 104 may have a silicon content of from 1.5 ppmw to 3 ppmw, such as from 1.5 ppmw to 2 ppmw, from 1.5 ppmw to 2.5 ppmw, from 2 ppmw to 2.5 ppmw, from 2 ppmw to 3 ppmw, or from 2.5 ppmw to 3 ppmw, as determined by UOP 407. In embodiments, the used cooking oil stream 104 may have a tin content of less than or equal to 0.2 ppmw, less than or equal to 0.15 ppmw, less than or equal to 0.1 ppmw, or less than or equal to 0.05 ppmw, as determined by UOP 407. In embodiments, the used cooking oil stream 104 may have a zinc content of from 0.01 ppmw to 0.3 ppmw, such as from 0.01 ppmw to 0.1 ppmw, from 0.05 ppmw to 0.15 ppmw, from 0.05 ppmw to 0.2 ppmw, from 0.1 ppmw to 0.2 ppmw, from 0.15 ppmw to 0.3 ppmw, or from 0.2 ppmw to 0.3 ppmw, as determined by UOP 407. The composition of an exemplary used cooling oil suitable for the used cooking oil stream 104 of the present disclosure is provided in Table 2.TABLE 2Properties of an exemplary used cooking oilsuitable for the used cooking oil stream 104PropertyTest MethodValueDensity (g / cm3)ASTM D40520.925API Gravity (degrees)ASTM 28722.01Free Fatty Acid (FFA) (wt. %)ASTM 5555-950.73Chlorine (ppmw)UOP 4078.00Sulfur (ppmw)ASTM D42947.91Phosphorus (ppmw)UOP 4070.78Total Metals (ppmw)UOP 4073.81Calcium (ppmw)UOP 4070.50Iron (ppmw)UOP 4070.02Potassium (ppmw)UOP 4070.10Sodium (ppmw)UOP 4071.06Silicon(ppmw)UOP 4072.13Tin (ppmw)UOP 4070.06Zinc (ppmw)UOP 4070.17SIMDIST - IBP (° C.)ASTM D2887519SIMDIST - 25 wt. % (° C.)ASTM D2887599SIMDIST - 50 wt. % (° C.)ASTM D2887607SIMDIST - 75 wt. % (° C.)ASTM D2887615SIMDIST - IBP (° C.)ASTM D2887632

[0067] Referring again to FIG. 1, the plastic derived oil stream 102 is passed to the acid gas removal unit 110. An acid gas removal catalyst 112 is disposed within the acid gas removal unit 110. The acid gas removal catalyst 112 may be a catalyst operable to remove residual HCl and sulfur-containing compounds such as H2S from the plastic derived oil stream 102 to produce the treated plastic derived oil stream 114. The acid gas removal catalyst 112 may be a solid inorganic alkali metal salt. Examples of the solid inorganic alkali metal salt may include but are not limited to sodium bicarbonate, sodium carbonate, sodium hydroxide, lime, or any combinations thereof, such as a mixture of sodium bicarbonate and lime. The reaction of HCl and H2S generates metal chlorides, metal sulfates, and water. The metal chlorides and metal sulfates are solids and stay in the acid gas removal unit 110, while the water goes out as steam with other gaseous hydrocarbons. Other acidic gases such as CO and CO2 are expelled along with the other gaseous hydrocarbons.

[0068] In various embodiments, acid gas removal unit 110 may operate as a fluidized bed, a fixed bed, a moving bed, or a packed bed reactor system. As such, the acid gas removal catalyst 112 may be provided as pellets or a powder, depending on the type of reactor used for the acid gas removal unit 110.

[0069] As previously indicated, the acid gas removal catalyst 112 within the acid gas removal unit 110 removes residual HCl and sulfur-containing compounds from the plastic derived oil stream 102 to generate the treated plastic derived oil stream 114. The treated plastic derived oil stream 114 may have a concentration of halogen-containing compounds less than the plastic derived oil stream 102 upstream of the acid gas removal unit 110. In embodiments, the treated plastic derived oil stream 114 may have a concentration of halogen-containing compounds of less than 100 ppmw, such as less than 50 ppmw, less than 20 ppmw, less than 10 ppmw. In embodiments, the treated plastic derived oil stream 114 may have a concentration of halogen-containing compounds of from 1 ppmw to 100 ppmw, from 1 ppmw to 80 ppmw, from 1 ppmw to 50 mm, from 1 ppmw to 20 ppmw, from 1 ppmw to 10 ppmw, from 5 ppmw to 100 ppmw, from 5 ppmw to 80 ppmw, from 5 ppmw to 50 ppmw, from 5 ppmw to 20 ppmw, from 5 ppmw to 10 ppmw, from 10 ppmw to 100 ppmw, from 10 ppmw to 80 ppmw, from 10 ppmw to 50 mm, from 10 ppmw to 20 ppmw, from 20 ppmw to 100 ppmw, from 20 ppmw to 80 ppmw, from 20 ppmw to 50 mm, from 50 ppmw to 100 ppmw, or from 50 ppmw to 80 ppmw per unit weight of the treated plastic derived oil stream 114. In embodiments, the treated plastic derived oil stream 114 may comprise less than 500 ppmw of sulfur-containing compounds. It will be appreciated that in embodiments, the treated plastic derived oil stream 114 may comprises less than 100 ppmw total halogen-containing compounds and less than 500 ppmw of sulfur-containing compounds, per unit weight of the treated plastic derived oil stream 114.

[0070] Referring again to FIG. 1, the used cooking oil stream 104 and the treated plastic derived oil stream 114 may be passed to the FCC system 120, such as to the FCC reactor 122. The used cooking oil stream 104 and the treated plastic derived oil stream 114 may be separately introduced to the FCC system, such as to the FCC reactor 122, or combined upstream of the FCC reactor 122. For example, the treated plastic derived oil stream 114 and used cooking oil stream 104 may be combined in a mixing tank or other mixing unit prior to entering the FCC reactor 122. In embodiments, the FCC reactor 122 of the FCC system 120 may be downstream of the pyrolysis reactor 20 and in fluid communication with the pyrolysis reactor 20 to pass the treated plastic derived oil stream 114 from the pyrolysis reactor 20 directly to the FCC reactor 122.

[0071] The hydrocarbons introduced to the FCC reactor 122 comprise a mixture of the treated plastic derived oil stream 114 and the used cooking oil stream 104. The hydrocarbons introduced to the FCC reactor 122 may comprise from 10 wt. % to 90 wt. % of the treated plastic derived oil stream 114 based on the total weight of the hydrocarbons introduced to the FCC reactor 122. In embodiments, the hydrocarbons introduced to the FCC reactor 122 may include from 10 wt. % to 80 wt. %, from 10 wt. % to 50 wt. %, from 20 wt. % to 90 wt. %, from 20 wt. % to 80 wt. %, from 20 wt. % to 50 wt. %, from 50 wt. % to 90 wt. %, from 50 wt. % to 80 wt. %, or from 80 wt. % to 90 wt. % of the treated plastic derived oil stream 114 based on the total weight of the hydrocarbons introduced to the FCC reactor 122.

[0072] The hydrocarbons introduced to the FCC reactor 122 may comprise from 10 wt. % to 90 wt. % of the used cooking oil stream 104 based on the total weight of the hydrocarbons introduced to the FCC reactor 122. In embodiments, the hydrocarbons introduced to the FCC reactor 122 may include from 10 wt. % to 80 wt. %, from 10 wt. % to 50 wt. %, from 20 wt. % to 90 wt. %, from 20 wt. % to 80 wt. %, from 20 wt. % to 50 wt. %, from 50 wt. % to 90 wt. %, from 50 wt. % to 80 wt. %, or from 80 wt. % to 90 wt. % of the used cooking oil stream 104 based on the total weight of the hydrocarbons introduced to the FCC reactor 122. A mass flow ratio of the treated plastic derived oil stream 114 to the used cooking oil stream 104 may be from 1:9 to 9:1.

[0073] Referring again to FIG. 1, the treated plastic derived oil stream 114 and the used cooking oil stream 104 may be passed to the FCC system 120, such as to the FCC reactor 122 of the FCC system 120. The FCC reactor 122 may comprise a cracking catalyst 124. Contact of the treated plastic derived oil stream 114 and the used cooking oil stream 104 with the cracking catalyst 124 may cause at least a portion of the hydrocarbons from the treated plastic derived oil stream 114 and the used cooking oil stream 104 to under catalytic cracking to produce lighter hydrocarbons and hydrocarbon gases. Contact of the treated plastic derived oil stream 114 and the used cooking oil stream 104 with the cracking catalyst 124 may produce an FCC effluent 122 that includes a greater concentration of greater-value chemicals and intermediates, such as but not limited to light olefins, light aromatic compounds, light naphtha, gasoline constituents, jet fuel constituents, diesel constituents, or combinations of these greater value chemicals and intermediates, compared to the combined treated plastic derived oil stream 114 and used cooking oil stream 104.

[0074] The FCC reactor 122 may be a fluidized bed reactor. The FCC reactor 122 may include one or a plurality of fluidized bed reactors. When the FCC reactor 122 comprises a plurality of reactors, the plurality of reactors may be parallel, such as for purposes of increasing capacity of the FCC system 120 for upgrading the treated plastic derived oil stream 114 and used cooking oil stream 104. In embodiments, the FCC reactor 122 is a fluidized bed reactor in which treated plastic derived oil stream 114, used cooking oil stream 104, and the cracking catalyst 114 are combined together at one end of the reactor and flow co-currently through the fluidized bed reactor to an outlet of the FCC reactor 122. The FCC reactor 122 may be a riser reactor or a downer reactor. In embodiments, the FCC reactor 122 may be a riser reactor.

[0075] The cracking catalyst 124 utilized in the FCC reactor 122 may be any conventional cracking catalyst known to those skilled in the art for catalyzing cracking reactions of hydrocarbons. The cracking catalyst 124 is different from the acid gas removal catalyst 112. In embodiments, the cracking catalyst 124 may comprise a commercial catalyst for FCC applications. In embodiments, the cracking catalyst 124 may comprise one or more commercial catalysts for FCC applications. Alternatively, or additionally, the cracking catalyst 124 may comprise other suitable solid acid catalysts. In embodiments, the cracking catalyst 124 may comprise one or more binders, cracking promoters, matrix materials, or other constituents to modify the physical or chemical properties such as catalyst attrition index and catalyst density. In embodiments, the cracking catalyst 124 may be an equilibrium catalyst (ECAT) and may include a cracking additive to increase the yield of light olefins. Other cracking catalysts may also be suitable for the cracking catalyst 124 in the FCC reactor 122. In embodiments, the cracking catalyst 124 may comprise an equilibrium catalyst and a cracking additive, where the equilibrium catalyst may comprise a Y-type zeolite or a USY zeolite, and the cracking additive may include an mordenite framework inverted (MFI) zeolite, such as but not limited to a ZSM-5 zeolite.

[0076] In embodiments, the cracking catalyst 124 may comprise from 65 wt. % to 85 wt. % ECAT, per unit weight of the cracking catalyst. For example, the cracking catalyst 124 may comprise ECAT in amounts from 65 wt. % to 85 wt. %, from 65 wt. % to 80 wt. %, 70 wt. % to 85 wt. %, from 70 wt. % to 80 wt. %, or any combination of these ranges per unit weight of cracking catalyst. Further, in embodiments, the cracking catalyst 124 may comprise a cracking additive in amounts from 15 wt. % to 35 wt. %, from 20 wt. % to 35 wt. %, from 15 wt. % to 30 wt. %, from 20 wt. % to 30 wt. %, or any combination of these ranges per unit weight of cracking catalyst. In embodiments, the cracking catalyst 124 may comprise from 20 wt. % to 30 wt. % light olefin additives, per unit weight of the cracking catalyst 124.

[0077] In embodiments, the cracking catalyst 124 may be a simple mixture or blend of ECAT particles and cracking additive particles. In embodiments, the ECAT and cracking additives of the cracking catalyst, in the form of a powder or slurry, may be combined with other materials, such as but not limited to binder materials, matrix materials, or other materials, and formed into composite particles of the cracking catalyst 124. The combined materials may be extruded to produce the cracking catalyst 124 in the form of composite particles comprising the various constituents of the cracking catalyst 124. In embodiments, cracking catalyst 124 may be prepared through a spray drying process, which may include forming a slurry comprising the ECAT, cracking additives, the binder materials, and the matrix materials and then spray drying the slurry to produce the composite particles of the cracking catalyst 124. In embodiments, the cracking catalyst 124 may be prepared through extrusion and pelletizing or other process for forming composite catalyst particles.

[0078] The binder materials may comprise silica, alumina, silica-alumina, or any combinations of these. The alumina may comprise an acid peptized alumina. The silica-alumina may comprise an amorphous silica-alumina. In embodiments, the cracking catalyst 124 may comprise from 10 wt. % to 20 wt. % of the binder, per unit weight of the cracking catalyst. For example, the cracking catalyst 124 may comprise the binder in amounts of from 10 wt. % to 18 wt. %, from 10 wt. % to 16 wt. %, from 10 wt. % to 14 wt. %, from 12 wt. % to 20 wt. %, from 14 wt. % to 20 wt. %, from 16 wt. % to 20 wt. %, or any combination of these ranges, per unit weight of the cracking catalyst. In embodiments, the cracking catalyst 124 may comprise from 10 wt. % to 20 wt. % of the acid peptized alumina binder, per unit weight of the cracking catalyst 124.

[0079] Matrix materials may include clays, such as but not limited to kaolin, montmorilonite, halloysite, bentonite, or combinations of these. In embodiments, the cracking catalyst 124 may comprise from 20 wt. % to 60 wt. % of the matrix material, per unit weight of the cracking catalyst. For example, the cracking catalyst may comprise the matrix material in amounts of from 20 wt. % to 55 wt. %, from 20 wt. % to 50 wt. %, from 20 wt. % to 45 wt. %, from 20 wt. % to 40 wt. %, from 20 wt. % to 35 wt. %, from 25 wt. % to 60 wt. %, from 30 wt. % to 60 wt. %, from 35 wt. % to 60 wt. %, from 40 wt. % to 60 wt. %, from 45 wt. % to 60 wt. %, or any combination of these ranges, per unit weight of the cracking catalyst. In embodiments, the cracking catalyst 124 may comprise from 20 wt. % to 60 wt. % kaolin clay per unit weight of the cracking catalyst 124.

[0080] The FCC reactor 122 may be configured to contact the treated plastic derived oil stream 114 and used cooking oil stream 104 with the cracking catalyst 124 at a reaction temperature of from 500 degrees Celsius (C) to 650° C., such as from 500° C. to 600° C., from 550° C. to 650° C., from 550° C. to 600° C., or from 600° C. to 650° C. The FCC reactor 122 may be configured to contact the treated plastic derived oil stream 114 and used cooking oil stream 104 with the cracking catalyst 124 at a pressure of from 101 kilopascals (kPa) to 303 kPa, such as from 125 kPa to 303 kPa, from 150 kPa to 303 kPa, from 200 kPa to 303 kPa, from 250 kPa to 303 kPa, from 101 kPa to 250 kPa, from 101 kPa to 200 kPa, from 101 kPa to 150 kPa, at atmospheric pressure (˜101 kPa), or any combination of these ranges. In embodiments, the FCC reactor 122 may be configured to contact the treated plastic derived oil stream 114 and used cooking oil stream 104 with the cracking catalyst 124 at a gas hourly space velocity (GHSV) of from 0.2 per hour (h−1) to 100 h−1, such as from 1 h−1 to 100 h−1, from 5 h−1 to 100 h−1, from 10 h−1 to 100 h−1, from 25 h−1 to 100 h−1, from 50 h−1 to 100 h−1, from 0.2 h−1 to 80 h−1, from 0.2 h−1 to 50 h−1, from 0.2 h−1 to 25 h−1, from 0.2 h−1 to 10 h−1, or any combinations of these ranges. In embodiments, the FCC reactor 122 may be operable to contact the treated plastic derived oil stream 114 and used cooking oil stream 104 with the cracking catalyst 124 at a catalyst-to-oil weight ratio of greater than or equal to 2, such as from 2 to 40, from 2 to 35, from 2 to 30, from 2 to 25, from 2 to 20, from 2 to 15, from 2 to 12, from 2 to 10, from 2 to 8, from 4 to 10, from 4 to 40, from 8 to 40, from 15 to 40, from 20 to 40, from 30 to 40, or any combination of these ranges. The catalyst-to-oil weight ratio in the FCC reactor 122 is equal to an average ratio of a mass flow rate of the cracking catalyst 124 through the FCC reactor 122 divided by a mass flow rate of the hydrocarbons (treated plastic derived oil stream 114+used cooking oil stream 104) in the FCC reactor 122 during steady state operation of the FCC system 120.

[0081] In embodiments, the FCC effluent 132 may be separated from the used cracking catalyst 134 at or proximate to an outlet end of the FCC reactor 122. Referring again to FIG. 1, in embodiments, the reaction mixture, which may include the FCC effluent 132 and the used cracking catalyst 134, may be passed out of the FCC reactor 122 to the fluid-solid separation unit 130. As previously discussed, the fluid-solid separation unit 130 may be disposed at the outlet end of the FCC reactor 122. The fluid-solid separation unit 130 may be configured to separate the FCC effluent 132 from the solid particles of the used cracking catalyst 134. The FCC effluent 132 is in a fluid phase (generally a vapor phase at the reaction conditions of the FCC reactor). In FIG. 1, the fluid-solid separation unit 130 is depicted as a vessel disposed at the outlet end of the FCC reactor 122, where the vessel reduces the fluid velocity of the FCC effluent 132 to allow the solid particles of the used cracking catalyst 134 to separate and settle out from the fluid phase of the FCC effluent 132. The used cracking catalyst 134 may settle in the bottom of the fluid-solid separation unit 130, and the FCC effluent 132 may pass out of a top portion of the fluid-solid separation unit 130. In embodiments, the fluid-solid separation unit 130 may further include one or more downstream cyclones, filters, or other unit operation (not shown) that may be configured to remove catalyst fines from the FCC effluent 132. Other types of fluid-solid separation devices are contemplated for the fluid-solid separation unit 130. The used cracking catalyst 134 may be passed from the fluid-solid separation unit 130 to the catalyst regenerator 140.

[0082] Referring again to FIG. 1, as previously discussed, the FCC system 120 includes the catalyst regenerator 140. The used cracking catalyst 134 may be passed from the fluid-solid separation unit 130 to the catalyst regenerator 140 and regenerated to produce a regenerated cracking catalyst 142. The regenerated cracking catalyst 142 may be passed back to the FCC reactor 122 as at least a portion of or all of the cracking catalyst 124. The catalyst regenerator 140 may be disposed downstream of the solid-fluid separation unit 130 and in fluid communication with an outlet of the solid-fluid separation unit 130 to pass the used cracking catalyst 134 from the solid-fluid separation unit 130 directly to the catalyst regenerator 140.

[0083] During the reactions in the FCC reactor 122, coke may deposit on the used cracking catalyst 134 as a result of the cracking reactions. The coke may block reactive sites on the cracking catalyst and reduce the catalytic activity of the cracking catalyst for catalyzing the cracking reactions. The catalyst regenerator 140 may be configured to heat the used cracking catalyst 134 to a temperature sufficient to remove coke from the cracking catalyst 134 to produce the regenerated cracking catalyst 142. In embodiments, the catalyst regenerator 140 may be configured to contact the used cracking catalyst 134 with the regeneration gas 144 at the regeneration temperature, which may be sufficient to combust coke deposits on the used cracking catalyst 134, increase the temperature of the regenerated cracking catalyst 142, or combinations thereof.

[0084] The regeneration temperature in the catalyst regenerator 140 may be sufficient to combust the coke deposits, increase the temperature of the catalyst particles, or both to produce the regenerated cracking catalyst 142. The regeneration gas 144 may be an oxygen-containing gas, such as but not limited to air. In embodiments, the regeneration gas 144 may include a fuel gas in addition to the oxygen-containing gas. The fuel gas may be added to increase the heat produced in the catalyst regenerator 140, which can increase combustion of coke deposits, further increase the temperature of the cracking catalyst, or both. In embodiments, the regeneration temperature in the catalyst regenerator 140 may be greater than the operating temperature of the FCC reactor 122. In embodiments, the regeneration temperature in the catalyst regenerator 140 may be from 500° C. to 900° C., such as from 500° C. to 800° C., from 500° C. to 750° C., from 550° C. to 900° C., from 550° C. to 800° C., or from 550° C. to 750° C.

[0085] Combustion gases produced through combustion of the coke deposits, and optionally any supplemental fuels added to the catalyst regenerator 140, may be passed out of the catalyst regenerator 140 in a flue gas 146. The flue gas 146 may exit from a top portion of the catalyst regenerator 140. The flue gas 146 may be passed to one or more downstream treatment systems for properly handling of the combustion gases to reduce environmental impact, such as through acid gas removal systems, scrubbing, carbon capture, and the like.

[0086] The removal of coke deposits from the used cracking catalyst 134 produces the regenerated cracking catalyst 142. Referring again to FIG. 1, the catalyst regenerator 140 may be in fluid communication with the inlet end of the FCC reactor 122 to pass the regenerated cracking catalyst 142 back to the FCC reactor 122 as a portion of or all of the cracking catalyst 124. The system 100 may further include a regenerated cracking catalyst transfer line 148 fluidly coupling the catalyst regenerator 140 and the inlet of the FCC reactor 122. The regenerated cracking catalyst transfer line 148 may be operable to pass the regenerated cracking catalyst 142 from the catalyst regenerator 140 to the FCC reactor 122. In embodiments, the system 100 may further include a catalyst valve 149 disposed in the regenerated cracking catalyst transfer line 148 and operable to control a mass flow rate of the regenerated cracking catalyst 142 from the catalyst regenerator 140 to the FCC reactor 122.

[0087] The FCC effluent 132 may comprise fuel gases, light olefins, C2-C4 alkanes, light aromatic compounds, light naphtha, jet fuel constituents, diesel constituents, heavy compounds, or any combination of these constituents. The FCC effluent 132 may comprise a greater concentration of light olefins, light aromatic compounds, light naphtha range hydrocarbons, or combinations of these constituents compared to the treated plastic derived oil stream 114 and used cooking oil stream 104. The FCC effluent 132 may have reduced concentrations of jet fuel constituents, diesel constituents, and heavy compounds compared to the treated plastic derived oil stream 114 and may have reduced concentrations of heavy compounds compared to the used cooking oil stream 104.

[0088] In embodiments, a yield of light olefins, such as but not limited to ethylene, propylene, mixed butenes, and combinations thereof, in the FCC effluent 132 may be from 10 wt. % to 30 wt. %, from 10 wt. % to 20 wt. %, from 10 wt. % to 26 wt. %, from 10 wt. % to 23 wt. %, from 19 wt. % to 26 wt. %, or from 20 wt. % to 30 wt. % based on the mass flow rate of the treated plastic derived oil stream 114 and used cooking oil stream 104 introduced to the FCC reactor 122. In embodiments, the FCC effluent 132 may comprise from 10 wt. % to 30 wt. %, from 10 wt. % to 20 wt. %, from 10 wt. % to 26 wt. %, from 10 wt. % to 23 wt. %, from 19 wt. % to 26 wt. %, or from 20 wt. % to 30 wt. % light olefins per unit weight of the FCC effluent 132.

[0089] In embodiments, a yield of light naphtha in the FCC effluent 132 may be greater than or equal to 25 wt. %, such as greater than or equal to 28 wt. %, greater than or equal to 29 wt. %, greater than or equal to 30 wt. %, from 25 wt. % to 45 wt. %, from 25 wt. % to 40 wt. %, from 25 wt. % to 38 wt. %, from 28 wt. % to 45 wt. %, from 28 wt. % to 40 wt. %, from 28 wt. % to 38 wt. %, from 29 wt. % to 45 wt. %, from 29 wt. % to 40 wt. %, or from 29 wt. % to 38 wt. % based on the mass flow rate of the treated plastic derived oil stream 114 and used cooking oil stream 104 introduced to the FCC reactor 122. In embodiments, the FCC effluent 132 may comprise greater than or equal to 25 wt. %, such as greater than or equal to 29 wt. %, greater than or equal to 29 wt. %, greater than or equal to 30 wt. %, from 25 wt. % to 45 wt. %, from 25 wt. % to 40 wt. %, from 25 wt. % to 38 wt. %, from 28 wt. % to 45 wt. %, from 28 wt. % to 40 wt. %, from 28 wt. % to 38 wt. %, from 29 wt. % to 45 wt. %, from 29 wt. % to 40 wt. %, or from 29 wt. % to 38 wt. % light naphtha per unit weight of the FCC effluent 132.

[0090] In embodiments, a yield of light naphtha and C2-C4 paraffins in the FCC effluent may be from 35 wt. % to 55 wt. %, from 40 wt. % to 50 wt. %, from 42 wt. % to 47 wt. %, or from 40 wt. % to 48 wt. % based on the mass flow rate of the treated plastic derived oil stream 114 and used cooking oil stream 104 introduced to the FCC reactor 122. In embodiments, the FCC effluent 132 may comprise from 35 wt. % to 55 wt. %, from 40 wt. % to 50 wt. %, from 42 wt. % to 47 wt. %, or from 40 wt. % to 48 wt. % of the light naphtha and C2-C4 paraffins per unit weight of the FCC effluent 132.

[0091] In embodiments, a yield of C2-C4 paraffins in the FCC effluent 132 may be from 5 wt. % to 15 wt. %, from 5 wt. % to 10 wt. %, from 5 wt. % to 8 wt. %, from 7 wt. % to 12 wt. %, or from 10 wt. % to 15 wt. % based on the mass flow rate of the treated plastic derived oil stream 114 and used cooking oil stream 104 introduced to the FCC reactor 122. In embodiments, the FCC effluent 132 may comprise from 5 wt. % to 15 wt. %, from 5 wt. % to 10 wt. %, from 5 wt. % to 8 wt. %, from 7 wt. % to 12 wt. %, or from 10 wt. % to 15 wt. % the C2-C4 paraffins per unit weight of the FCC effluent 132.

[0092] In embodiments, a yield of jet fuel constituents in the FCC effluent 132 may be less than or equal to 40 wt. %, such as from 10 wt. % to 40 wt. %, from 10 wt. % to 35 wt. %, from 10 wt. % to 30 wt. %, from 10 wt. % to 26 wt. %, from 15 wt. % to 40 wt. %, from 15 wt. % to 35 wt. %, from 15 wt. % to 30 wt. %, from 15 wt. % to 26 wt. %, from 18 wt. % to 40 wt. %, from 18 wt. % to 35 wt. %, from 18 wt. % to 30 wt. %, from 18 wt. % to 26 wt. %, or from 20 wt. % to 30 wt. %, based on the mass flow rate of the treated plastic derived oil stream 114 and used cooking oil stream 104 introduced to the FCC reactor 122. In embodiments, the FCC effluent 122 may comprise less than or equal to 40 wt. %, such as from 10 wt. % to 40 wt. %, from 10 wt. % to 35 wt. %, from 10 wt. % to 30 wt. %, from 10 wt. % to 26 wt. %, from 15 wt. % to 40 wt. %, from 15 wt. % to 35 wt. %, from 15 wt. % to 30 wt. %, from 15 wt. % to 26 wt. %, from 18 wt. % to 40 wt. %, from 18 wt. % to 35 wt. %, from 18 wt. % to 30 wt. %, from 18 wt. % to 26 wt. %, or from 20 wt. % to 30 wt. % jet fuel constituents per unit weight of the FCC effluent 132.

[0093] In embodiments, a yield of constituents having boiling point temperature greater than 300° C. may be less than or equal to 20 wt. %, such as less than or equal to 15 wt. %, from 1 wt. % to 20 wt. %, from 1 wt. % to 15 wt. %, from 1 wt. % to 14 wt. %, from 1 wt. % to 13 wt. %, from 1 wt. % to 12 wt. %, from 1 wt. % to 10 wt. %, from 5 wt. % to 20 wt. %, from 5 wt. % to 15 wt. %, from 5 wt. % to 14 wt. %, from 5 wt. % to 13 wt. %, from 5 wt. % to 12 wt. %, from 5 wt. % to 10 wt. %, from 7 wt. % to 20 wt. %, from 7 wt. % to 15 wt. %, from 7 wt. % to 14 wt. %, from 7 wt. % to 13 wt. %, from 7 wt. % to 12 wt. %, or from 7 wt. % to 10 wt. % based on the mass flow rate of the treated plastic derived oil stream 114 and used cooking oil stream 104 introduced to the FCC reactor 112. In embodiments, the FCC effluent 132 may comprise less than or equal to 20 wt. %, such as less than or equal to 15 wt. %, from 1 wt. % to 20 wt. %, from 1 wt. % to 15 wt. %, from 1 wt. % to 14 wt. %, from 1 wt. % to 13 wt. %, from 1 wt. % to 12 wt. %, from 1 wt. % to 10 wt. %, from 5 wt. % to 20 wt. %, from 5 wt. % to 15 wt. %, from 5 wt. % to 14 wt. %, from 5 wt. % to 13 wt. %, from 5 wt. % to 12 wt. %, from 5 wt. % to 10 wt. %, from 7 wt. % to 20 wt. %, from 7 wt. % to 15 wt. %, from 7 wt. % to 14 wt. %, from 7 wt. % to 13 wt. %, from 7 wt. % to 12 wt. %, or from 7 wt. % to 10 wt. % constituents having boiling point temperature greater than 300° C. per unit weight of the FCC effluent 132.

[0094] Referring again to FIG. 1, the FCC effluent 132 may be passed to the FCC effluent separation system 150. In embodiments, the FCC effluent 132 may be passed directly from the fluid-solid separation unit 130 to the FCC effluent separation system 150. The FCC effluent 132 may be separated in the FCC effluent separation system 150 to produce at least one product stream. The effluent separation system 150 may be disposed downstream of the FCC reactor 122, such as downstream of the fluid-solid separation unit 130. The FCC effluent separation system 150 can include one or a plurality of separation units, which, collectively, operate to separate the FCC effluent 132 into the plurality of product streams. In embodiments, the FCC effluent separation system 150 may include one or more fractionation units. Other types of separation units are contemplated, such as but not limited to extraction units, distillation units, crystallization units, or other separation unit operations. The FCC effluent separation system 150 may be in fluid communication with the fluid-solid separation unit 130 to pass the FCC effluent 132 directly to the FCC effluent separation system 150.

[0095] The plurality of product streams can include one or more of a light olefin stream 152, a light naphtha stream 154, a jet fuel stream 156, a diesel stream 158, a heavy bottom stream 160, or any combination of these streams. The light olefin stream 152 can include one or more olefin streams comprising olefin compounds having from 2-4 carbon atoms. The light olefin streams 152 may include an ethylene stream, a propylene stream, a mixed butenes stream, or combinations of these. The light naphtha stream 154 may comprise constituents having boiling point temperatures of from 0° C. to 150° C. The light naphtha stream 154 may contain light aromatic compounds (aromatic compounds having from 6-8 carbon atoms) and gasoline components. The light naphtha stream 154 may include aromatic compounds having from 6 to 8 carbon atoms, such as benzene, toluene, xylenes, and / or ethylbenzene, which may be used as chemical intermediates for producing circular polymer materials (polymers made from recovered hydrocarbons instead of hydrocarbons produced from subterranean sources and therefore having a lower environmental footprint). In embodiments, the plurality of product streams may include the jet fuel stream 156, which may include constituents having boiling point temperatures of from 150° C. to 300° C. In embodiments, the plurality of product streams may include the diesel stream 158, which may include constituents having boiling point temperatures of from 300° C. to 343° C. The heavy bottom stream 160 may comprise heavy compounds, such as hydrocarbon compounds having boiling point temperatures greater than 343° C. In embodiments, the effluent separation system 150 further may be operable to produce a light gas stream (not shown) comprising light gases such as but not limited to hydrogen, methane, or both produced in the FCC reactor 122. In embodiments, the FCC effluent separation system 150 may be further operable to produce a light paraffin stream (not shown) comprising saturated hydrocarbons having from 2 to 4 carbon atoms (ethane, propane, butane, isobutane, or combinations thereof). Other product streams may be produced by the effluent separation system 150.

[0096] Referring now to FIG. 2, one embodiment of a fluidized bed reactor 300 that comprises a riser reactor (upflow reactor) is schematically depicted. FIG. 2 also schematically depicts one embodiment of a catalyst regenerator 400 for the fluidized bed reactor 300. In a riser reactor, the catalyst and reactants flow co-currently in an upward direction through the reaction zone. Although described in the context of riser reactors, it is understood that, in embodiments, the FCC reactor 122 may be a downer (downflow) fluidized bed reactor. In a downer or downflow fluidized bed reactor, the catalyst and reactants flow co-currently in the downward direction. Upward and downward are relative to the direction of the force of gravity.

[0097] The fluidized bed reactor 300 can include a riser 302, a reaction zone 304 downstream of the riser 302, and a separation zone 306 downstream of the reaction zone 304. The separation zone 306 in FIG. 2 corresponds to the fluid-solid separation unit 130 in FIG. 1. In operation of the fluidized bed reactor 300 of FIG. 2, the hydrocarbon feed 310 is introduced to the riser 302. For the FCC reactor 122, the hydrocarbon feed 310 is the combination of the treated plastic derived oil stream 114 and the used cooking oil stream 104. In embodiments, the hydrocarbon feed 310 may be combined with steam (not shown) upstream of the riser 302. The hydrocarbon feed 310 may be combined with an effective quantity of heated catalyst 320 in the riser 302. For the FCC reactor 122, the catalyst 320 may be the cracking catalyst 124.

[0098] The hydrocarbon feed 310 and the catalyst 320 (with optional steam) are contacted in the riser 302 and passed upward through the riser 302 into the reaction zone 304. In the riser 302 and the reaction zone 304, the hydrocarbons from the hydrocarbon feed 310 are contacted with the catalyst 320 at reaction conditions, which may cause at least a portion of the hydrocarbons to undergo one or more chemical reactions to produce a reaction mixture comprising a reactor effluent and the used catalyst. The reaction mixture comprising the used catalyst and reactor effluent may then be passed to the separation zone 306 downstream of the reaction zone 304. In the separation zone 306, the reaction mixture is separated to produce the reactor effluent 312 and the used catalyst 322. The separation zone 306 may include one or a plurality of solid-fluid separation devices, which may have any suitable configuration known in the art. Referring again to FIG. 1, the separation zone for the FCC reactor 122 may comprise the fluid-solid separation unit 130.

[0099] During the reaction, the catalyst 320 can become coked resulting in used catalyst 322, and the coke deposits can reduce access to the active catalytic sites on the used catalyst 322. The used catalyst 322 may also have a reduced temperature compared to the catalyst 320 introduced to the riser 302. The used catalyst 322 may be passed from the separation zone 306 to the catalyst regenerator 400.

[0100] Referring to FIG. 2, one embodiment of a catalyst regenerator 400 for a fluidized bed reactor 300 is schematically depicted. The catalyst regenerator 400 may be a riser catalyst regenerator comprising a riser 410 and a separation zone 420 disposed at the outlet end of the riser 410. During operation of the catalyst regenerator 400, the used catalyst 322 may be passed to the inlet 411 of the riser 410. A regeneration gas 412 may also be introduced to the inlet 411 of the riser 410. In embodiments, the regeneration gas 412 may be an oxygen-containing gas, such as air, compressed oxygen, or other oxygen-containing gas. In embodiments, the regeneration gas 412 may also include a fuel gas in addition to the oxygen-containing gas. The regeneration gas 412 and used catalyst 322 may be contacted at regeneration conditions, which may cause reaction between the used catalyst 322 and the regeneration gas 412. In embodiments, the regeneration gas 412 is the oxygen-containing gas and the reaction may include combustion of coke deposits, fuel gas, or both, which may cause removal of at least a portion of the coke deposits from the used catalyst, increase the temperature of the used catalyst, or both to produce the regenerated catalyst 422. The regenerated catalyst 422 may have reduced coke deposits, greater temperature, or both compared to the used catalyst 322.

[0101] The regenerated catalyst 422 may be separated from combustion gases in the catalyst separation zone 420, which is disposed at the outlet end of the riser 410. The combustion gases may be removed from the catalyst regenerator 400 as a flue gas 424. The flue gas 424 may include unreacted regeneration gases 412 as well as combustion gases, which may be the reaction products produced through combustion of coke deposits and / or fuel gas in the riser 410. The regenerated catalyst 422 may be passed back to the fluidized bed reactor 300 as at least a portion of the catalyst 320. Although depicted in FIG. 2 as a riser-type catalyst regenerator, is it understood that other configurations for the catalyst regenerator 400 may be employed, such as but not limited to downer catalyst regenerators, fixed bed catalyst regenerators, or other type of catalyst regenerator.

[0102] Referring again to FIG. 1, the system 100 can be used in processes for producing circular chemicals and low carbon fuels from plastic derived oil 102 and used cooking oil 104. The processes include passing a plastic derived oil stream 102 to an acid gas removal unit 110, where the plastic derived oil stream 102 contacts an acid gas removal catalyst 112, which may be a solid alkali metal salt. Contacting the plastic derived oil stream 102 with the acid gas removal catalyst 112 removes acid gases from the plastic derived oil stream 102 to produce a treated plastic oil stream 114. The acid gas removal unit 110 may have any of the features, configurations, catalysts, or operating conditions described in the present disclosure for the acid gas removal unit 110. The plastic derived oil stream 102 may have any of the compositions, properties, or other features previously discussed for the plastic derived oil stream 102.

[0103] The processes include contacting the treated plastic derived oil stream 114 and the used cooking oil stream 104 with the cracking catalyst 124 in the FCC reactor 122 at reaction conditions. Contact of the treated plastic derived oil stream 114 and the used cooking oil stream 104 with the cracking catalyst 124 at reaction conditions produces the FCC effluent 122 comprising the circular chemicals (olefins, light aromatic compounds or both), low-carbon fuels (light naphtha, jet fuel, diesel), or combinations thereof. The FCC system 120 may have any of the features, configurations, catalysts, or operating conditions described in the present disclosure for the FCC system 120. The used cooking oil stream 104 may have any of the compositions, properties, or other features previously discussed in the present disclosure for the used cooking oil stream 104. Additionally, the cracking catalyst 124 may contact heavy hydrocarbon molecules in the treated plastic derived oil stream 114 and the used cooking oil stream 104 and crack at least a portion of the heavy hydrocarbon molecules, which may produce greater value circular chemicals and low-carbon fuels, such as but not limited to the light olefins, light naphtha, and jet fuel constituents. Further, the processes disclosed herein may include combining the treated plastic derived oil stream 114 and the used cooking oil stream 104 prior to entering the FCC reactor 122 or at the inlet end of the FCC reactor 122.

[0104] The processes may include separating the FCC effluent 132 from the used cracking catalyst 134 downstream of the FCC reactor 122. Separating the FCC effluent 132 from the used cracking catalyst 134 may be accomplished by the fluid-solid separation unit 130 disposed at the outlet end of the FCC reactor 122. The processes may include passing the contents of the FCC reactor 122 to the fluid-solid separation unit 130 that separates the contents of the FCC reactor 122 into the FCC effluent 132 from the used cracking catalyst 134. The FCC effluent 132 may comprise light olefins, light naphtha, jet fuel constituents, diesel constituents, or combinations of these constituents. The FCC effluent 132 may have a greater concentration of light olefins, such as but not limited to ethylene, propylene, mixed butenes, or combinations thereof; light naphtha; or combinations thereof compared the treated plastic derived oil stream 114 and the used cooking oil stream 104.

[0105] The processes of the present disclosure may include passing the used cracking catalyst 134 to the catalyst regenerator 140, and regenerating the used cracking catalyst 134 in the catalyst regenerator 140 to produce the regenerated cracking catalyst 142. The regenerated cracking catalyst 142 may have a reduced concentration of halogens compared to the used cracking catalyst 134 prior to regeneration. The regenerated cracking catalyst 142 may also have reduced coke deposits, greater temperature, or both compared to the used cracking catalyst 134 prior to regeneration. In embodiments, regenerating the used cracking catalyst 134 may include contacting the used cracking catalyst 134 with the regeneration gas 144 at a regeneration temperature sufficient to remove coke deposits from the cracking catalyst, increase the temperature of the cracking catalyst, or both. In embodiments, the regeneration gas 144 may be an oxygen-containing gas, such as but not limited to air. In embodiments, regenerating the used cracking catalyst 134 may include contacting the used cracking catalyst 134 with the regeneration gas 144 in the catalyst regenerator 140 at the regeneration temperature that is greater than the operating temperature of the FCC reactor 122, such as at a regeneration temperature of from 500° C. to 800° C., from 500° C. to 750° C., from 500° C. to 700° C., from 550° C. to 800° C., from 550° C. to 750° C., from 550° C. to 700° C., from 600° C. to 800° C., from 600° C. to 750° C., from 600° C. to 700° C., or from 650° C. to 800° C. In embodiments, the regeneration gas 144 for the catalyst regenerator 140 may also include a fuel gas or a fuel oil. Combustion of the fuel gas and / or fuel oil in the catalyst regenerator 140 may increase the heat generated in the catalyst regenerator 140, thereby increasing the regeneration temperature in the catalyst regenerator 140.

[0106] The processes may further include passing a flue gas 146 out of the catalyst regenerator 140, wherein the flue gas 146 may comprise halogen compounds, such as but not limited to Cl2 or HCl. The flue gas 146 may also include unreacted regeneration gases and combustion gases produced from combustion of the coke deposits and any fuel gases added to the catalyst regenerator 140. The processes may include passing the flue gas 146 to a downstream treatment system for properly handling the hydrogen halides in the flue gas 146. The catalyst regenerator 140 may have any of the other features, configuration, or operating conditions described herein for the catalyst regenerator 140.

[0107] Referring again to FIG. 1, the processes disclosed herein may include combining the treated plastic derived oil stream 114 and the used cooking oil stream 104 and the cracking catalyst 124, such as the regenerated cracking catalyst 134, at the inlet end of the FCC reactor 122, where the treated plastic derived oil stream 114, the used cooking oil stream 104, and the cracking catalyst 124 may be contacted and may travel together through the FCC reactor 122. In embodiments, the processes may include contacting the treated plastic derived oil stream 114, the used cooking oil stream 104, and the cracking catalyst 124 in the FCC reactor 122 at a reaction temperature of from 500° C. to 700° C., such as from 500° C. to 650° C., from 500° C. to 600° C., from 550° C. to 650° C., from 550° C. to 600° C., or from 600° C. to 650° C. The processes may include contacting the treated plastic derived oil stream 114, the used cooking oil stream 104, and the cracking catalyst 124 may be contacted in the FCC reactor 122 at a pressure of from 100 kPa to 1000 kPa, from 101 kPa to 303 kPa, or at about atmospheric pressure (i.e., about 101.3 kPa). The processes may include contacting the treated plastic derived oil stream 114, the used cooking oil stream 104, and the cracking catalyst 124 in the FCC reactor 122 at a GHSV of from 0.2 h−1 to 100 h−1. The treated plastic derived oil stream 114, the used cooking oil stream 104, and the cracking catalyst 124 may be introduced to the FCC reactor 122 at a catalyst-to-oil weight ratio of greater than or equal to 2. The catalyst-to-oil weight ratio in the FCC reactor 122 is equal to a mass flow rate of the cracking catalyst 124 divided by a mass flow rate of the treated plastic derived oil stream 114 and used cooking oil stream 104 in the FCC reactor 122 during steady state operation. In embodiments, the catalyst-to-oil weight ratio in the FCC reactor 122 may be from 2 to 40, from 2 to 35, from 2 to 30, from 2 to 25, from 2 to 20, from 2 to 15, from 2 to 12, from 2 to 10, from 2 to 8, from 4 to 10, from 4 to 40, from 8 to 40, from 15 to 40, from 20 to 40, from 30 to 40, or any combination of these ranges. In embodiments, the FCC effluent 132 may comprise less than 100 ppmw halogen-containing compounds based on the total weight of the FCC effluent 132, such as less than 50 ppmw, less than 40 ppmw, less than 30 ppmw, less than 20 ppmw, or less than 10 ppmw of the halogen-containing compounds based on the total weight of the FCC effluent 132.

[0108] The processes of the present disclosure may further include separating the FCC effluent 132 in the effluent separation system 150 to produce a plurality of product streams, such as but not limited to an ethylene stream, a propylene stream, a mixed butenes stream, a light naphtha stream, a jet fuel stream, a diesel stream, or combinations of these product streams. In embodiments, the product streams may include one or more light olefin streams 152, a light naphtha stream 154, a jet fuel stream 156, a diesel stream 158, a heavy bottom stream 160, or any combinations of these product streams.

[0109] The processes may include providing the plastic derived oil stream 102 comprising hydrocarbons and from 10 parts per million by weight (ppmw) to 500 ppmw of halogen-containing compounds based on the total weight of the treated plastic derived oil stream 102. In embodiments, the processes may include producing the plastic derived oil stream 102 from solid waste plastic. Producing the plastic derived oil stream 102 may include passing solid waste plastic 12 to a dehalogenation unit 10, which melts the solid waste plastic 12 and removes some halogen compounds from the solid waste plastic 12 to produce the liquefied plastic stream 14. The processes may further include passing the liquefied plastic stream 14 to the pyrolysis unit 20 and subjecting the liquefied plastic stream 14 to pyrolysis in the pyrolysis unit 20 to produce the plastic derived oil stream 102.Examples

[0110] The various embodiments of systems and processes of the present disclosure will be further clarified by the following examples. The examples are illustrative in nature, and should not be understood to limit the subject matter of the present disclosure.Catalyst Testing

[0111] In these examples, the feed compositions (plastic derived oil, used cooking oil, and combinations of plastic derived oil and used cooking oil) were catalytically cracked according to an Advanced Cracking Evaluation (ACE) test procedure. The ACE tests were conducted using a micro-activity cracking testing (MAT) unit. The MAT unit and ACE testing process is described more in detail in U.S. Pat. No. 6,069,012.

[0112] Referring to FIG. 3, the MAT unit 200 used in these examples is schematically depicted. The MAT unit 200 includes a fluidized reactor 210 configured to simulate reaction in an FCC reactor. Fluidization gas 212 is introduced to the bottom of the fluidized reactor 210 to maintain the catalyst 204 in a fluidized state. The catalyst 204 is loaded into the fluidized reactor 210 from the catalyst hopper 206. The feed 202 is introduced to the top of the fluidized reactor 210 and flows downward into the catalyst 204 fluidized within the fluidized reactor 210. After contacting the feed 202 with the catalyst 204 in the reactor, the reaction effluent 216 is passed out of the fluidized reactor 210 to the product liquid receivers 220, which separate the liquid products from the gaseous products. The gaseous product stream 222 is passed to a product gas receiver 230. The composition of the gaseous product stream 222 is analyzed using a micro gas chromatograph 240 having a GC control unit 242. The catalyst 204 is regenerated by introducing a regeneration gas 214 into the bottom of the fluidized reactor 210. The flue gas is treated in a catalytic converter 260 and passed through a flow meter 262 and CO2 analyzer 264 for quantifying the amount of coke produced during the reactions. The MAT unit 200 can include an ACE control system 270 for controlling operation of the MAT unit 200.Examples 1-5: Co-Cracking of Plastic Derived Oil and Used Cooking Oil

[0113] In Examples 1-5, a used cooking oil was co-processed with plastic derived oil through fluidized catalytic cracking using a commercially available cracking catalyst (UMIX75 catalyst), which comprised 75 wt. % equilibrium catalyst and 25 wt. % cracking additive. The cracking additive was OLEFINSULTRA® cracking additive available from W.R. Grace and Company. The composition for the plastic derived oil stream (PDO) produced from solid waste plastic and the composition for the used cooking oil stream (UCO) for Example 1 are provided in Table 3. In Examples 1-5, the plastic derived oil and the used cooking oil were combined in various weight ratios, which are provided in Table 4.TABLE 3Plastic Derived Oil and Used Cooking Oil CompositionsFractionPDOUCONaphtha (0-150° C.) (wt. %)17.10Jet Fuel (150-300° C.) (wt. %)41.80Diesel (300-343° C.) (wt. %)13.60Heavy Compounds (343+ ° C.) (wt. %)27.5100

[0114] The ACE testing for the co-cracking was performed using steam-deactivated UMIX75 catalyst. The UMIX75 catalyst was first deactivated under hydrothermal conditions (100% steam, 810° C., 6 hours) before being used for catalyst evaluations. The ACE testing was performed with an effective catalyst-to-oil weight ratio of 8 and an injection time of 75 seconds. The ACE testing of the combined feed comprising a mixture of plastic derived oil and used cooking oil in the MAT unit was conducted at a reaction temperature of 550° C.

[0115] Prior to each experiment, the steam-deactivated catalyst was loaded into the reactor and heated to the desired reaction temperature. N2 gas was fed through the feed injector from the bottom to keep the catalyst particles fluidized. Once the catalyst bed temperature reached between 248° C.-552° C., the reaction was started by injecting the feed. For each evaluation, the feed was injected for a predetermined time (time-on-stream (TOS)) of 75 seconds. The desired catalyst-to-feed ratio of 8 was maintained by controlling the feed pump for the feed. The gaseous product was routed to the liquid receiver (220 in FIG. 3), where C5+ hydrocarbons were condensed. The remaining product gases were routed to the gas receiver (230 in FIG. 3) in the product gas stream 222. The used catalyst in the reactor was then stripped with a stripping gas (N2) to removing any residual liquid or gaseous products, reactants, or both from the catalyst. The stripping gases and residual products were also passed to the gas receiver (230 in FIG. 3). After catalyst stripping was completed, the reactor was heated to 700° C., and air injected to regenerate the used catalyst to produce regenerated catalyst. During regeneration, the released gas was routed to a CO2 analyzer (catalytic converter 260, flow meter 262 and CO2 analyzer 264 in FIG. 3). Coke yield was calculated from the flue gas flow rate and CO2 concentration.

[0116] The gaseous product stream 222 was analyzed by an online gas chromatography system (Agilent 7890 gas chromatograph) equipped with both FID and TCD detectors. The liquid product stream was analyzed according to the offline analytical test methods. In particular, the liquid product stream was analyzed by simulated distillation according to test method EN 15199-2 using the Agilent 7890 gas chromatograph and naphtha analysis techniques.

[0117] For the simulated distillation, the analysis was conducted for five distillation fractions: (1) light hydrocarbon gases having 1-4 carbon atoms; (2) a light naphtha fraction having a boiling point range of from 0° C. to 150° C.; (3) a jet fuel fraction having a boiling point range of from 150° C. to 300° C.; (4) a diesel fraction having boiling point temperatures of from 300° C. to 343° C.; and (5) a heavy compounds fraction having boiling point temperatures greater than 343° C. The light hydrocarbon gases were further classified into fuel gas (hydrogen and methane), C2-C4 paraffins, ethylene (C2=), propylene (C3=), and mixed butenes (C4=). Coke was quantified after passing an air stream through the MAT unit at high temperatures to burn the coke into a mixture of carbon monoxide, carbon dioxide, and water, as previously discussed, and then passing the combustion gases through a CO2 analyzer, which included a calibrated infrared analyzer.

[0118] For Examples 1-5, the co-cracking process of Example 1 was used to test feed blends with different ratios of used cooking oil and plastic derived oil. The ratio of the used cooking oil and plastic derived oil and the reaction products obtained for Examples 1-5 are provided in Table 4 and in FIG. 4. The plastic derived oil and used cooking oil were combined at the desired weight percentages and mixed thoroughly to produce the feed before introducing the feed to the reactor (MAT unit 200).Comparative Example 6: Plastic Derived Oil Only

[0119] For Comparative Example 6, the plastic derived oil, by itself (no used cooking oil), was contacted with the cracking catalyst in the MAT unit according to the ACE testing methods discussed above. The composition of the plastic derived oil is in Table 3, and the cracking catalyst was the same as the cracking catalyst used in Examples 1-5. The cracking catalyst was steam deactivated, as previously discussed, and then contacted with the plastic derived oil under the same reaction conditions provided herein for Examples 1-5. The results for Comparative Example 6 (CE-6) are provided in Table 4 and FIG. 4.Comparative Example 7: Used Cooking Oil Only

[0120] For Comparative Example 7 (CE-7), the used cooking oil, by itself (no plastic derived oil), was contacted with the cracking catalyst in the MAT unit according to the ACE testing methods discussed above. The composition of the used cooking oil is in Table 3, and the cracking catalyst was the same as the cracking catalyst used in Examples 1-5. The cracking catalyst was steam deactivated, as previously discussed, and then contacted with the used cooking oil under the same sets of reaction conditions provided herein for Examples 1-5. The results for Comparative Example 7 (CE-7) are provided in Table 4 and FIG. 4.Co-Cracking Testing Results

[0121] The results of the catalytic cracking test results for Examples 1-5 and Comparative Examples 6 and 7 are provided in Table 4 and in FIG. 4.TABLE 5ACE Testing of PDO and UCO Feed Blends of Examples 2-8Constituent12345CE-6CE-7Blend10%20%50%90%80%PDOUCOCompositionUCO +UCO +UCO +UCO +UCO +90%80%50%10%20%PDOPDOPDOPDOPDOFuel Gas (wt. %)0.860.831.520.90.890.520.87C2-C4 paraffin10.387.458.9710.967.8220.397.21(wt. %)Ethylene (wt. %)1.411.511.351.171.644.071.63Propylene (wt. %)11.4710.218.5810.6810.9112.2210.68Butenes (wt. %)13.210.989.9212.1211.7412.0911.38Light Naphtha37.335.9735.2429.234.9732.6331.59(wt. %)Jet Fuel (wt. %)18.8225.3221.621.4422.0813.3223.76Diesel (wt. %)1.741.693.252.81.331.33.05Heavy Compounds2.343.497.585.275.790.937.13(wt. %)Coke (wt. %)2.472.5525.462.822.542.7

[0122] Referring to FIG. 4 and Table 4, the blended plastic derived oil and used cooking oil streams generally had higher production of C2-C4 paraffins and light naphtha, compared to the individual used cooking oil stream. The blending of the plastic derived oil and used cooking oil allowed the plastic derived oil and used cooking oil to dilute each other and reduce the level of contaminants, as shown by the decreased production of heavy compounds and jet fuel as compared to the individual used cooking oil stream. The overall production of light naphtha increased with the percentage of plastic derived oil in the blend, with the blend having only 10% plastic derived oil being the only blend of plastic derived oil and used cooking oil to produce less light naphtha than the individual plastic derived oils and used cooking oil streams. Production of C2-C4 paraffins was greatest for the 90% plastic derived oil and 10% used cooking oil blend and the 10% plastic derived oil and 90% used cooking oil blend, indicating that the more homogeneous the blend, the greater the production of C2-C4 paraffins. Overall, the plastic derived oil and used cooking oil blends resulted in increased light naphtha production and reduction in the level of contaminants. Referring to FIG. 4 and Table 4, the plastic derived oil and used cooking oil blends were shown to be suitable for co-catalytic cracking to produce circular chemicals and low carbon fuels.

[0123] A first aspect of the present disclosure is directed to a process for producing circular chemicals and low-carbon fuels, the process comprising producing a plastic derived oil stream from solid waste plastic, contacting the plastic derived oil stream with an acid gas removal catalyst disposed in an acid gas removal unit, and passing the treated plastic derived oil stream and a used cooking oil stream to a fluidized catalytic cracking (FCC) system comprising an FCC reactor, and contacting the treated plastic derived oil stream and the used cooking oil stream with a cracking catalyst in the FCC reactor. Contacting the plastic derived oil stream with the acid gas removal catalyst may remove acid gases from the plastic derived oil stream to produce a treated plastic derived oil stream, where the treated plastic derived oil stream has concentrations of halogen compounds, sulfur compounds, or both that may be less than concentrations of the halogen compounds, sulfur compounds, or both in the plastic derived oil stream. Contacting the treated plastic derived oil stream and the used cooking oil stream with the cracking catalyst at a reaction temperature in the FCC reactor may cause at least a portion of hydrocarbons from the treated plastic derived oil stream and the used cooking oil stream to undergo catalytic cracking reactions to produce an FCC effluent comprising circular chemicals, low-carbon fuels, or both.

[0124] A second aspect of the present disclosure may include the first aspect, where a weight ratio of the used cooking oil stream to the treated plastic derived oil stream introduced to the FCC reactor may be from 1:9 to 9:1.

[0125] A third aspect of the present disclosure may include either one of the first or second aspects, where the used cooking oil stream may have one or more of the following characteristics: a density of from 0.90 g / cm3 to 0.95 g / cm3; an API gravity of from 20 degrees to 25 degrees; an initial boiling point temperature of greater than or equal to 500° C.; a final boiling point temperature less than or equal to 720° C.; or combinations thereof.

[0126] A fourth aspect of the present disclosure may include any one of the first through third aspects, where the plastic derived oil stream may have one or more of the following characteristics: a density of from 0.65 g / cm3 to 1.1 g / cm3; a chloride concentration of greater than or equal to 100 ppmw based on the total weight of the plastic derived oil stream; an oxygen content of from 100 ppmw to 10,000 ppmw based on the total weight of the plastic derived oil stream; an initial boiling point temperature of from 20° C. to 100° C.; a final boiling point temperature of from 300° C. to 600° C.; a 50% boiling point temperature of from 150° C. to 350° C.; or any combinations thereof.

[0127] A fifth aspect of the present disclosure may include any one of the first through fourth aspects, where the treated plastic derived oil stream may have a chloride concentration of less than 100 ppmw based on the total weight of the treated plastic derived oil stream.

[0128] A sixth aspect of the present disclosure may include any one of the first through fifth aspects, where the FCC effluent may comprise greater than or equal to 40 wt. % C2-C4 paraffins and light naphtha based on the total weight of the FCC effluent, the light naphtha comprising hydrocarbons having boiling point temperatures of from 0° C. to 150° C.

[0129] A seventh aspect of the present disclosure may include any one of the first through fifth aspects, where the FCC effluent may comprise greater than or equal to 29 wt. % light naphtha, the light naphtha comprising hydrocarbons having boiling point temperatures of from 0° C. to 150° C.; greater than or equal to 7 wt. % C2-C4 paraffins; or both.

[0130] An eighth aspect of the present disclosure may include any one of the first through seventh aspects, where the acid gas removal catalyst is a solid inorganic alkali metal salt.

[0131] A ninth aspect of the present disclosure may include any one of the first through eighth aspects, where the cracking catalyst may comprise 75 wt. % equilibrium catalyst and 25 wt. % cracking additive based on the total weight of the cracking catalyst.

[0132] A tenth aspect of the present disclosure may include any one of the first through ninth aspects, comprising contacting the plastic derived oil stream and used cooking oil stream with the cracking catalyst in the FCC reactor at a reaction temperature of from 500° C. to 650° C. and a catalyst-to-oil weight ratio of from 2 to 40, where the catalyst-to-oil weight ratio is the mass flow rate of the cracking catalyst through the FCC reactor divided by the total combined mass flow rate of the treated plastic derived oil stream and the used cooking oil stream to the FCC reactor.

[0133] An eleventh aspect of the present disclosure may include any one of the first through tenth aspects, comprising contacting the plastic derived oil stream and used cooking oil stream with the cracking catalyst in the FCC reactor at a pressure of 101 kPa to 303 kPa and a gas hourly space velocity of from 0.2 per hour (h−1) to 100 h−1.

[0134] A twelfth aspect of the present disclosure may include any one of the first through eleventh aspects, further comprising separating the used cracking catalyst from the FCC effluent in a fluid-solid separation unit downstream of the FCC reactor and regenerating the used cracking catalyst in a catalyst regenerator to produce a regenerated cracking catalyst.

[0135] A thirteenth aspect of the present disclosure may include the twelfth aspect, further comprising passing the regenerated cracking catalyst back to the FCC reactor as at least a portion of the cracking catalyst.

[0136] A fourteenth aspect of the present disclosure may include either one of the twelfth or thirteenth aspects, where regenerating the used cracking catalyst may comprise contacting the used cracking catalyst with a regeneration gas at a regeneration temperature of from 500° C. and 900° C., where the regeneration gas is an oxygen-containing gas.

[0137] A fifteenth aspect of the present disclosure may include any one of the first through fourteenth aspects, where producing the plastic derived oil stream from solid waste plastic may comprises melting and dehalogenating the solid waste plastic in a dehalogenation unit to produce a liquefied plastic stream; passing the liquefied plastic stream to a pyrolysis reactor; and subjecting the liquefied plastic stream to pyrolysis in the pyrolysis reactor to produce the plastic derived oil stream.

[0138] A sixteenth aspect of the present disclosure may include the fifteenth aspect, where the solid waste plastic may comprise mixed plastics of differing compositions.

[0139] A seventeenth aspect of the present disclosure may include either one of the fifteenth or sixteenth aspects, where melting and dehalogenating the solid waste plastic may comprise increasing a temperature of the solid waste plastic to a temperature of from 250° C. and 300° C. to melt the solid waste plastic and produce the liquefied plastic stream.

[0140] An eighteenth aspect of the present disclosure may include any one of the fifteenth through seventeenth aspects, where subjecting the liquefied plastic stream to pyrolysis in the pyrolysis reactor may comprise increasing a temperature of the liquefied plastic stream to a temperature of from 350° C. to 1000° C. in the pyrolysis reactor.

[0141] A nineteenth aspect of the present disclosure may be directed to a system for converting solid waste plastics and used cooking oil into circular chemicals and low carbon fuels. The system may comprise a plastic derived oil stream; an acid gas removal unit in fluid communication with the plastic derived oil stream, where the acid gas removal unit may comprise a reaction vessel and an acid gas removal catalyst disposed within the reaction vessel, where the acid gas removal unit may be configured to contact the plastic derived oil stream with the acid gas removal catalyst to remove halogen compounds, sulfur-containing compounds, or both from the plastic derived oil stream to produce a treated plastic derived oil stream; a fluid catalytic cracking (FCC) system disposed downstream of the acid gas removal unit and comprising an FCC reactor, where the FCC reactor may be in fluid communication with the acid gas removal unit to pass the treated plastic derived oil stream from the acid gas removal unit to the FCC reactor; and a used cooking oil stream in fluid communication with the FCC reactor to pass the used cooking oil stream to the FCC reactor. The FCC system may be configured to contact the treated plastic derived oil stream and the used cooking oil stream with a cracking catalyst under reaction conditions to produce an FCC effluent comprising circular chemicals and low carbon fuels.

[0142] A twentieth aspect of the present disclosure may include the nineteenth aspect, further comprising: an inlet stream comprising solid waste plastic; a dehalogenation unit in fluid communication with the inlet stream, where the dehalogenation unit may be configured to increase a temperature of the inlet stream to melt the solid waste plastic to produce a liquid plastic stream; and a pyrolysis reactor disposed downstream of the dehalogenation unit, where the pyrolysis reactor may be configured to pyrolyze the liquid plastic stream to produce the plastic derived oil stream.

[0143] A twenty-first aspect of the present disclosure may include the twentieth aspect, where the dehalogenation unit may be configured to increase the temperature of the inlet stream to a temperature from 250° C. and 300° C. to melt the solid waste plastic to produce the liquid plastic stream.

[0144] A twenty-second aspect of the present disclosure may include either one of the twentieth or twenty-first aspects, where the pyrolysis reactor may be in fluid communication with the dehalogenation unit to pass the liquid plastic stream directly from the dehalogenation unit to the pyrolysis reactor.

[0145] A twenty-third aspect of the present disclosure may include any one of the twentieth through twenty-second aspects, where the pyrolysis reactor may be operable to increase the temperature of the liquid plastic stream to a temperature of 350° C. to 1000° C. to produce the plastic derived oil stream.

[0146] A twenty-fourth aspect of the present disclosure may include any one of the twentieth through twenty-third aspects, where the acid gas removal unit may be in fluid communication with the pyrolysis reactor to pass the plastic derived oil stream directly from the pyrolysis reactor to the acid gas removal unit.

[0147] A twenty-fifth aspect of the present disclosure may include any one of the nineteenth through twenty-fourth aspects, where the acid gas removal catalyst may be a solid inorganic alkali metal salt.

[0148] A twenty-sixth aspect of the present disclosure may include any one of the nineteenth through twenty-fifth aspects, where the cracking catalyst may comprise 75 wt. % equilibrium catalyst and 25 wt. % cracking additive based on the total weight of the cracking catalyst.

[0149] A twenty-seventh aspect of the present disclosure may include any one of the nineteenth through twenty-sixth aspects, where the FCC system further may comprise a fluid-solid separation unit disposed at an outlet of the FCC reactor and a catalyst regenerator downstream of the fluid-solid separation unit, where: the fluid-solid separation unit may be configured to separate the FCC effluent from a used cracking catalyst; and the catalyst regenerator may be configured to regenerate the used cracking catalyst in a catalyst regenerator to produce a regenerated cracking catalyst.

[0150] A twenty-eighth aspect of the present disclosure may include the twenty-seventh aspect, where the fluid-solid separation unit is in fluid communication with the outlet of the FCC reactor.

[0151] A twenty-ninth aspect of the present disclosure may include either one of the twenty-seventh or twenty-eighth aspects, where the catalyst regenerator may be configured to contact the used cracking catalyst with a regeneration gas under reaction conditions to produce the regenerated cracking catalyst, where the regeneration gas is an oxygen-containing gas.

[0152] A thirtieth aspect of the present disclosure may include any one of the nineteenth through twenty-ninth aspects, further comprising a product separation system disposed downstream of the FCC system, where the product separation system may be configured to separate the FCC effluent to produce a plurality of product streams.

[0153] A thirty-first aspect of the present disclosure may include any one of the nineteenth through thirtieth aspects, where the used cooking oil stream may have one or more of the following characteristics: a density of from 0.90 g / cm3 to 0.95 g / cm3; an API gravity of from 20 degrees to 25 degrees; an initial boiling point temperature of greater than or equal to 500° C.; a final boiling point temperature less than or equal to 720° C.; or combinations thereof.

[0154] A thirty-second aspect of the present disclosure may include any one of the nineteenth through thirty-first aspects, where the plastic derived oil stream may have one or more of the following characteristics: a density of from 0.65 g / cm3 to 1.1 g / cm3; a chloride concentration of greater than or equal to 100 ppmw based on the total weight of the plastic derived oil; an oxygen content of from 100 ppmw to 10,000 ppmw based on the total weight of the plastic derived oil; an initial boiling point temperature of from 20° C. to 100° C.; a final boiling point temperature of from 300° C. to 600° C.; a 50% boiling point temperature of from 150° C. to 350° C.; or any combinations thereof.

[0155] It is noted that any two quantitative values assigned to a property may constitute a range of that property, and all combinations of ranges formed from all stated quantitative values of a given property are contemplated in this disclosure.

[0156] It is noted that one or more of the following claims utilize the term “where” as a transitional phrase. For the purposes of defining the present technology, it is noted that this term is introduced in the claims as an open-ended transitional phrase that is used to introduce a recitation of a series of characteristics of the structure and should be interpreted in like manner as the more commonly used open-ended preamble term “comprising.”

[0157] Having described the subject matter of the present disclosure in detail and by reference to specific aspects, it is noted that the various details of such aspects should not be taken to imply that these details are essential components of the aspects. Rather, the claims appended hereto should be taken as the sole representation of the breadth of the present disclosure and the corresponding scope of the various aspects described in this disclosure. Further, it will be apparent that modifications and variations are possible without departing from the scope of the appended claims.

Examples

examples

[0110]The various embodiments of systems and processes of the present disclosure will be further clarified by the following examples. The examples are illustrative in nature, and should not be understood to limit the subject matter of the present disclosure.

Catalyst Testing

[0111]In these examples, the feed compositions (plastic derived oil, used cooking oil, and combinations of plastic derived oil and used cooking oil) were catalytically cracked according to an Advanced Cracking Evaluation (ACE) test procedure. The ACE tests were conducted using a micro-activity cracking testing (MAT) unit. The MAT unit and ACE testing process is described more in detail in U.S. Pat. No. 6,069,012.

[0112]Referring to FIG. 3, the MAT unit 200 used in these examples is schematically depicted. The MAT unit 200 includes a fluidized reactor 210 configured to simulate reaction in an FCC reactor. Fluidization gas 212 is introduced to the bottom of the fluidized reactor 210 to maintain the catalyst 204 in a ...

examples 1-5

Co-Cracking of Plastic Derived Oil and Used Cooking Oil

[0113]In Examples 1-5, a used cooking oil was co-processed with plastic derived oil through fluidized catalytic cracking using a commercially available cracking catalyst (UMIX75 catalyst), which comprised 75 wt. % equilibrium catalyst and 25 wt. % cracking additive. The cracking additive was OLEFINSULTRA® cracking additive available from W.R. Grace and Company. The composition for the plastic derived oil stream (PDO) produced from solid waste plastic and the composition for the used cooking oil stream (UCO) for Example 1 are provided in Table 3. In Examples 1-5, the plastic derived oil and the used cooking oil were combined in various weight ratios, which are provided in Table 4.

TABLE 3Plastic Derived Oil and Used Cooking Oil CompositionsFractionPDOUCONaphtha (0-150° C.) (wt. %)17.10Jet Fuel (150-300° C.) (wt. %)41.80Diesel (300-343° C.) (wt. %)13.60Heavy Compounds (343+ ° C.) (wt. %)27.5100

[0114]The ACE testing for the co-crack...

Claims

1. A process for producing circular chemicals and low-carbon fuels, the process comprising:producing a plastic derived oil stream from solid waste plastic;contacting the plastic derived oil stream with an acid gas removal catalyst disposed in an acid gas removal unit, where contacting the plastic derived oil stream with the acid gas removal catalyst removes acid gases from the plastic derived oil stream to produce a treated plastic derived oil stream, where the treated plastic derived oil stream has concentrations of halogen compounds, sulfur compounds, or both that are less than concentrations of the halogen compounds, sulfur compounds, or both in the plastic derived oil stream;passing the treated plastic derived oil stream and a used cooking oil stream to a fluidized catalytic cracking (FCC) system comprising an FCC reactor; andcontacting the treated plastic derived oil stream and the used cooking oil stream with a cracking catalyst in the FCC reactor, where contacting the treated plastic derived oil stream and the used cooking oil stream with the cracking catalyst at a reaction temperature in the FCC reactor causes at least a portion of hydrocarbons from the treated plastic derived oil stream and the used cooking oil stream to undergo catalytic cracking reactions to produce an FCC effluent comprising circular chemicals, low-carbon fuels, or both.

2. The process of claim 1, where a weight ratio of the used cooking oil stream to the treated plastic derived oil stream introduced to the FCC reactor is from 1:9 to 9:1.

3. The process of claim 1, where the used cooking oil stream has one or more of the following characteristics:a density of from 0.90 g / cm3 to 0.95 g / cm3;an API gravity of from 20 degrees to 25 degrees;an initial boiling point temperature of greater than or equal to 500° C.;a final boiling point temperature less than or equal to 720° C.;or combinations thereof.

4. The process of claim 1, where the plastic derived oil stream has one or more of the following characteristics:a density of from 0.65 g / cm3 to 1.1 g / cm3;a chloride concentration of greater than or equal to 100 ppmw based on the total weight of the plastic derived oil stream;an oxygen content of from 100 ppmw to 10,000 ppmw based on the total weight of the plastic derived oil stream;an initial boiling point temperature of from 20° C. to 100° C.;a final boiling point temperature of from 300° C. to 600° C.;a 50% boiling point temperature of from 150° C. to 350° C.;or any combinations thereof.

5. The process of claim 1, where the treated plastic derived oil stream has a chloride concentration of less than 100 ppmw based on the total weight of the treated plastic derived oil stream.

6. The process of claim 1, where the acid gas removal catalyst is a solid inorganic alkali metal salt.

7. The process of claim 1, where the cracking catalyst comprises 75 wt. % equilibrium catalyst and 25 wt. % cracking additive based on the total weight of the cracking catalyst.

8. The process of claim 1, further comprising contacting the plastic derived oil stream and used cooking oil stream with the cracking catalyst in the FCC reactor at a reaction temperature of from 500° C. to 650° C. and a catalyst-to-oil weight ratio of from 2 to 40, where the catalyst-to-oil weight ratio is the mass flow rate of the cracking catalyst through the FCC reactor divided by the total combined mass flow rate of the treated plastic derived oil stream and the used cooking oil stream to the FCC reactor.

9. The process of claim 1, further comprising contacting the plastic derived oil stream and used cooking oil stream with the cracking catalyst in the FCC reactor at a pressure of 101 kPa to 303 kPa and a gas hourly space velocity of from 0.2 per hour (h−1) to 100 h−1.

10. The process of claim 1, further comprising separating the used cracking catalyst from the FCC effluent in a fluid-solid separation unit downstream of the FCC reactor, regenerating the used cracking catalyst in a catalyst regenerator to produce a regenerated cracking catalyst, and passing the regenerated cracking catalyst back to the FCC reactor as at least a portion of the cracking catalyst.

11. The process of claim 10, wherein regenerating the used cracking catalyst comprises contacting the used cracking catalyst with a regeneration gas at a regeneration temperature of from 500° C. and 900° C., where the regeneration gas is an oxygen-containing gas.

12. The process of claim 1, where producing the plastic derived oil stream from solid waste plastic comprises:melting and dehalogenating the solid waste plastic in a dehalogenation unit to produce a liquefied plastic stream;passing the liquefied plastic stream to a pyrolysis reactor; andsubjecting the liquefied plastic stream to pyrolysis in the pyrolysis reactor to produce the plastic derived oil stream.

13. The process of claim 12, where the solid waste plastic comprises mixed plastics of differing compositions.

14. The process of claim 12, where melting and dehalogenating the solid waste plastic comprises increasing a temperature of the solid waste plastic to a temperature of from 250° C. and 300° C. to melt the solid waste plastic and produce the liquefied plastic stream.

15. The process of claim 12, where subjecting the liquefied plastic stream to pyrolysis in the pyrolysis reactor comprises increasing a temperature of the liquefied plastic stream to a temperature of from 350° C. to 1000° C. in the pyrolysis reactor.

16. A system for converting solid waste plastics and used cooking oil into circular chemicals and low carbon fuels, the system comprising:a plastic derived oil stream;an acid gas removal unit in fluid communication with the plastic derived oil stream, where the acid gas removal unit comprises a reaction vessel and an acid gas removal catalyst disposed within the reaction vessel, where the acid gas removal unit is configured to contact the plastic derived oil stream with the acid gas removal catalyst to remove halogen compounds, sulfur-containing compounds, or both from the plastic derived oil stream to produce a treated plastic derived oil stream;a fluid catalytic cracking (FCC) system disposed downstream of the acid gas removal unit and comprising an FCC reactor, where the FCC reactor is in fluid communication with the acid gas removal unit to pass the treated plastic derived oil stream from the acid gas removal unit to the FCC reactor; anda used cooking oil stream in fluid communication with the FCC reactor to pass the used cooking oil stream to the FCC reactor;where the FCC system is configured to contact the treated plastic derived oil stream and the used cooking oil stream with a cracking catalyst under reaction conditions to produce an FCC effluent comprising circular chemicals and low carbon fuels.

17. The system of claim 16, further comprising:an inlet stream comprising solid waste plastic;a dehalogenation unit in fluid communication with the inlet stream, where the dehalogenation unit is configured to increase a temperature of the inlet stream to melt the solid waste plastic to produce a liquid plastic stream; anda pyrolysis reactor disposed downstream of the dehalogenation unit, the pyrolysis reactor configured to pyrolyze the liquid plastic stream to produce the plastic derived oil stream.

18. The system of claim 16, where the acid gas removal catalyst is a solid inorganic alkali metal salt and the cracking catalyst comprises 75 wt. % equilibrium catalyst and 25 wt. % cracking additive based on the total weight of the cracking catalyst.

19. The system of claim 16, where the FCC system further comprises a fluid-solid separation unit disposed at an outlet of the FCC reactor and a catalyst regenerator downstream of the fluid-solid separation unit, where:the fluid-solid separation unit is configured to separate the FCC effluent from a used cracking catalyst; andthe catalyst regenerator is configured to regenerate the used cracking catalyst in a catalyst regenerator to produce a regenerated cracking catalyst.

20. The system of claim 16, where:the used cooking oil stream has one or more of the following characteristics:a density of from 0.90 g / cm3 to 0.95 g / cm3;an API gravity of from 20 degrees to 25 degrees;an initial boiling point temperature of greater than or equal to 500° C.;a final boiling point temperature less than or equal to 720° C.;or combinations thereof; andthe plastic derived oil stream has one or more of the following characteristics:a density of from 0.65 g / cm3 to 1.1 g / cm3;a chloride concentration of greater than or equal to 100 ppmw based on the total weight of the plastic derived oil;an oxygen content of from 100 ppmw to 10,000 ppmw based on the total weight of the plastic derived oil;an initial boiling point temperature of from 20° C. to 100° C.;a final boiling point temperature of from 300° C. to 600° C.;a 50% boiling point temperature of from 150° C. to 350° C.;or any combinations thereof.

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