Direct conversion of plastic derived oil and light crude oil 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 from solid waste plastic, treating the plastic derived oil stream to produce a treated plastic derived oil stream having reduced concentrations of halogen compounds, sulfur compounds, or both, passing the treated plastic derived oil stream and a light crude oil stream to a cracking reactor, and contacting the treated plastic derived oil stream and the light crude oil stream with a cracking catalyst in the cracking reactor. Contacting of the treated plastic derived oil stream and the light crude oil stream with the cracking catalyst at a reaction temperature in the cracking reactor cracks at least a portion of hydrocarbons from the treated plastic derived oil stream and light crude oil stream to produce a cracking effluent comprising circular chemicals, low-carbon fuels, or both.

Description

BACKGROUNDField

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

[0002] Catalytic cracking, such as but not limited to Fluid Catalytic Cracking (FCC), has been a conventional process in refineries for transforming lower value feeds into gasoline and other greater value chemical products and intermediates. Conventional hydrocarbon feeds for catalytic cracking processes include hydrocracked bottoms, and heavy feed fractions such as vacuum gas oils and atmospheric residue; however, these hydrocarbon feeds are limited and are obtained through costly and energy intensive refining steps. Crude oil may also be a potential feedstock, but concentrations of metal, nitrogen, and sulfur in crude oils contribute to deactivation of cracking catalysts. Further, with increasing focus on reducing the environmental impact, research is ongoing for reducing the carbon footprint of and reducing greenhouse gas emissions from refinery processes.

[0003] 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.SUMMARY

[0004] Accordingly, an ongoing need exists for systems and processes that improve the carbon footprint of and reducing greenhouse emissions from refinery systems for producing greater value chemicals and intermediates from hydrocarbon sources. The present disclosure is directed to systems and processes for co-cracking plastic derived oils and light crude oil 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. Plastic derived oils have good properties and hydrocarbon constituents useful for application as fuel blending components or chemical feedstocks. The systems and processes disclosed herein include a cracking reactor system for co-cracking plastic derived oil and light crude oil to produce greater value chemical product and intermediates, 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 processes may also include producing the plastic derived oil through 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 a treated plastic derived oil. The treated plastic derived oil may then be combined with the light crude oil and co-processed in the cracking reactor using a cracking catalyst. Co-processing the plastic derived oil and the light crude oil in a cracking reaction system can reduce the carbon footprint of the refinery operation and can reduce greenhouse gas emissions from the refinery operation, among other features.

[0005] According to one or more aspects of the present disclosure, a process for producing circular chemicals and low-carbon fuels may comprise producing a plastic derived oil stream from solid waste plastic; treating the plastic derived oil stream to produce a treated plastic derived oil stream having 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 light crude oil stream to a cracking reactor; and contacting the treated plastic derived oil stream and the light crude oil stream with a cracking catalyst in the cracking reactor. Contacting of the treated plastic derived oil stream and the light crude oil stream with the cracking catalyst at a reaction temperature in the cracking reactor may cause at least a portion of hydrocarbons from the treated plastic derived oil stream and the light crude oil stream to undergo catalytic cracking reactions to produce a cracking effluent comprising circular chemicals, low-carbon fuels, or both.

[0006] According to one or more other aspects, a system for upgrading solid waste plastics and light crude oil into circular chemicals and low carbon fuels may comprise a plastic derived oil stream derived from solid waste plastic; 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 cracking reactor system disposed downstream of the acid gas removal unit and comprising a cracking reactor and a cracking catalyst disposed in the cracking reactor, where the cracking 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 cracking reactor; and a light crude oil stream in fluid communication with the cracking reactor to pass the light crude oil stream to the cracking reactor. The cracking reactor may be configured to contact the treated plastic derived oil stream and the light crude oil stream with the cracking catalyst under reaction conditions to produce a cracking effluent comprising circular chemicals, low carbon fuels, or both.

[0007] 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

[0008] 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:

[0009] FIG. 1 schematically depicts a generalized flow diagram of a system for co-processing plastic derived oils and light crude oil to produce greater value circular chemicals and intermediates, according to embodiments shown and described in this disclosure;

[0010] 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;

[0011] FIG. 3 schematically depicts a generalized flow diagram of another system for co-processing plastic derived oils and light crude oil to produce greater value circular chemicals and intermediates, according to embodiments shown and described in this disclosure;

[0012] FIG. 4 schematically depicts a test reactor system for converting hydrocarbon feeds having different ratios of plastic derived oil and light crude oil, according to embodiments shown and described in this disclosure; and

[0013] FIG. 5 graphically depicts compositions of the reaction effluents obtained from contacting feed streams with different ratios of plastic derived oil to light crude oil with a cracking catalyst, according to embodiments shown and described in this disclosure.

[0014] For the purpose of describing the simplified schematic illustrations and descriptions of FIGS. 1-4, 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.

[0015] 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.

[0016] 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.

[0017] 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. 1-4. 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.

[0018] 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

[0019] Embodiments of the present disclosure are directed to systems and processes for co-processing plastic derived oils and light crude oils to produce greater value chemical products and intermediates, such as circular chemicals and low carbon fuels. Referring now to FIG. 1, one embodiment of a system 100 for co-processing a plastic derived oil stream 102 and a light crude oil is schematically depicted. The system 100 may comprise a plastic derived oil stream 102 derived from solid waste plastic 12 and an acid gas removal unit 110 in fluid communication with the plastic derived oil stream 102, where the acid gas removal unit 110 may comprise 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 to produce a treated plastic derived oil stream 126. The system 100 further includes a cracking reactor system, such as but not limited to FCC system 130, disposed downstream of the acid gas removal unit 110 and comprising a cracking reactor (FCC reactor 132) and a cracking catalyst 134 disposed in the cracking reactor. The cracking reactor may be in fluid communication with the acid gas removal unit 110 to pass the treated plastic derived oil stream 126 from the acid gas removal unit 110 to the cracking reactor. The system 100 further includes a light crude oil stream 104 in fluid communication with the cracking reactor (FCC reactor 132) to pass the light crude oil stream 104 to the cracking reactor. The cracking reactor is configured to contact the treated plastic derived oil stream 126 and the light crude oil stream 104 with the cracking catalyst 134 under reaction conditions to produce a cracking effluent 142 comprising circular chemicals, low carbon fuels, or both.

[0020] The present disclosure is also directed to processes for producing circular chemicals and low-carbon fuels using the system 100. The processes may comprise producing the plastic derived oil stream 102 from solid waste plastic 12; treating the plastic derived oil stream 102 to produce a treated plastic derived oil stream 126 having 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; passing the treated plastic derived oil stream 126 and the light crude oil stream 104 to the cracking reactor; and contacting the treated plastic derived oil stream 126 and the light crude oil stream 104 with the cracking catalyst 134 in the cracking reactor, where the contacting of the treated plastic derived oil stream 126 and the light crude oil stream 104 with the cracking catalyst 134 at a reaction temperature in the cracking reactor causes at least a portion of hydrocarbons from the treated plastic derived oil stream 102 and the light crude oil stream 104 to undergo catalytic cracking reactions to produce the cracking effluent 142 comprising circular chemicals, low-carbon fuels, or both.

[0021] As used in this disclosure, the term “cracking” refers to chemical reactions that include breaking a molecule having carbon-carbon bonds into more than one molecule by the breaking of one or more of the carbon-carbon bonds and / or converting one or more cyclic moieties in a compound, such as one or more aromatic rings or cycloalkyl groups, to non-cyclic moieties. As used in the present disclosure, the term “catalytic cracking” refers to cracking conducted in the presence of a catalyst.

[0022] 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.

[0023] As used in this disclosure, the term “used catalyst” refers to catalyst that has been contacted with reactants but has not been regenerated in a regenerator or through a regeneration process 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.

[0024] As used in this disclosure, the term “crude oil” refers to a mixture of petroleum liquids and gases, including impurities, such as sulfur-containing compounds, nitrogen-containing compounds, and metal compounds, extracted directly from a subterranean formation or received from a desalting unit without having any fractions, such as naphtha, separated by distillation. A “topped crude oil” refers to a crude oil from which a portion of light hydrocarbons (hydrocarbons having a low boiling point temperature less than a threshold temperature) have been removed through a topping process.

[0025] 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.

[0026] 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.

[0027] As used in this disclosure, the term “light olefins” refers to olefins having from 2 to 4 carbon atoms, where the term “olefins” has its normal meaning as understood by a person of ordinary skill in art of chemistry.

[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 term “naphtha” refers to hydrocarbons having atmospheric boiling point temperatures of from 0° C. to 221° C.

[0030] As used in this disclosure, the term “light cycle oil” and the abbreviation “LCO” refer to hydrocarbons having atmospheric boiling point temperatures of from 221° C. to 343° C.

[0031] As used in this disclosure, the term “heavy cycle oil” and the abbreviation “HCO” refer to hydrocarbons having atmospheric boiling point temperatures of greater than 343° C.

[0032] 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.

[0033] 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.

[0034] 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.

[0035] As used in this disclosure, the term “initial boiling point” or “IBP” of a composition refers to the temperature at which the constituents of the composition having the lowest boiling point temperature begin to transition from the liquid phase to the vapor phase, as determined according to the standard test methods in ASTM D2887.

[0036] As used in this disclosure, the term “final boiling point” or “FBP” of a composition refers to the temperature at which the greatest boiling temperature constituents of the composition transition from the liquid phase to the vapor phase, as determined according to the standard test methods in ASTM D2887.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] As used in this disclosure, the term “reactor” refers to any vessel, container, conduit, or the like, in which a chemical reaction, such as catalytic cracking, occurs between one or more reactants optionally in the presence of one or more catalysts. A reactor can include one or a plurality of “reaction zones” disposed within the reactor. The term “reaction zone” refers to a region in a reactor where a particular reaction takes place.

[0041] As used in this disclosure, the term “high-severity conditions” refers to operating conditions of a fluid catalytic cracking system that include temperatures greater than or equal to 580° C., such as from 580° C. to 800° C., a catalyst to oil ratio greater than or equal to 1:1, or from 1:1 to 60:1, and a residence time of less than or equal to 60 seconds, or from 0.1 seconds to 60 seconds, each of which conditions may be more severe than typical operating conditions of fluid catalytic cracking systems.

[0042] As used in this disclosure, the terms “catalyst-to-oil ratio” and “CTO weight ratio” refer to the weight ratio of a catalyst to hydrocarbons in a reactor, such as in the cracking reaction zone of the FCC reactor 132 of the present disclosure. The catalyst-to-oil ratio of the present disclosure is calculated by dividing the mass flow rate of the cracking catalyst introduced to the FCC reactor 132 by the mass flow rate of the hydrocarbons introduced to the FCC reactor 132, such as the hydrocarbons being introduced through the plastic derived oil stream 102 and the light crude oil stream 104.

[0043] As used in this disclosure, the term “contact time” refers to the amount of time that reactants, such as the hydrocarbons of the crude oil feed, are in contact with the FCC catalyst composition, at reaction conditions, such as at the reaction temperature.

[0044] 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.

[0045] 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 purposely 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.

[0046] As previously discussed, catalytic cracking, such as fluidized catalytic cracking, is a widely utilized refinery operation for converting lower-value hydrocarbon feedstocks, such as crude oil, vacuum gas oils, atmospheric residues, and other heavy oils, to greater value chemical products and intermediates, such as but not limited to light olefins, light aromatic compounds, and naphtha. Global focus has shifted towards efforts to reduce the environmental impact of human activities. As such, a greater need exists for systems and methods for improving the carbon footprint of and reducing greenhouse gas emissions from refinery operations.

[0047] Similarly, 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 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 can also produce low carbon footprint fuel components, such as naphtha, light cycle oil (LCO), and heavy cycle oil (HCO), which can provide additional sources of fuel with reduced CO2 generation, compared to fuel components derived directly from processing fossil fuels extracted from subterranean sources.

[0048] Plastic derived oils have good properties and contain hydrocarbon constituents useful for application as chemical intermediates and fuel blending components. 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.

[0049] Accordingly, an ongoing need exists for systems and processes for improving the carbon footprint of and reducing greenhouse emissions from refinery systems for producing greater value chemicals and intermediates from hydrocarbon sources. The present disclosure is directed to systems and processes for co-cracking plastic derived oils and light crude oil 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 systems and processes of the present disclosure include a cracking reactor system for co-cracking plastic derived oil and light crude oil to produce greater value chemical product and intermediates, 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 processes may also include producing the plastic derived oil through 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 a treated plastic derived oil having reduced concentrations of halogen-containing compounds compared to the plastic derived oil. The treated plastic derived oil may then be combined with the light crude oil and co-processed in the cracking reactor using a cracking catalyst.

[0050] Co-processing plastic derived oil with light crude oil introduces an alternative and low carbon feed (the plastic derived oil) into a refinery system to produce circular chemicals and low carbon fuels. Co-processing the plastic derived oil and the light crude oil in a cracking reactor system, such as but not limited to an FCC system or fixed bed cracking reactor system, can reduce the carbon footprint of the refinery operation and can reduce greenhouse gas emissions from the refinery operation. Co-feeding the plastic derived oil with the light crude oil to the catalytic cracking system can increase the conversion of the light crude oil in the catalytic cracking system as well as increase the yield of desired products, such as circular chemicals, low carbon fuel components, or both. The introduction of the plastic derived oil to the catalytic cracking process can help in decarbonization of the catalytic cracking process for direct conversion of light crude oil. The plastic derived oil may include oxygenates and may, therefore, help improve the heat balance of the catalytic cracking process, since catalytic cracking of oxygenates is exothermic. Thus, introduction of the plastic derived oil may reduce the requirement for outside fuel sources to provide heat to the catalytic cracking reactor system, thus reducing the emission of greenhouse gases from the catalytic cracking system. The systems and processes of the present disclosure produce greater value chemicals and intermediates that include circular chemicals and low carbon fuels. The systems and processes of co-processing of the plastic derived oil and light crude oil may also enable the recycling of a broader range of types of solid waste plastic, among other features.

[0051] Referring again to FIG. 1, one embodiment of a system 100 for co-processing a plastic derived oil stream 102 and a light crude oil is schematically depicted. The system 100 may include a plastic derived oil stream 102, an acid gas removal unit 110, a plastic derived oil (PDO) separation system 120, a light crude oil stream 104, a cracking reactor disposed downstream of the acid gas removal unit 110, and a cracking effluent separation system 160 disposed downstream of the cracking reactor. 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 an acid gas removal effluent 114. The PDO separation system 120 may be disposed downstream of the acid gas removal unit 110 and may be configured to separate non-condensable gases 124 from the acid gas removal effluent 114 to produce a treated plastic derived oil 126.

[0052] In embodiments, the cracking reactor may be an FCC system 130, as shown in FIG. 1. The FCC system 130 may be configured to contact the treated plastic derived oil stream 126 and the light crude oil stream 104 with a cracking catalyst 134 in an FCC reactor 132 at reaction conditions, separate a cracking effluent 142 from the used cracking catalyst 144, and regenerate the used cracking catalyst 144 to produce a regenerated cracking catalyst 152. The cracking effluent separation system 160 may be configured to separate the cracking effluent 142 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 naphtha stream, an LCO stream, an HCO stream, other product 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 and downstream of the dehalogenation unit 10, where the liquid plastic stream 14 may be pyrolyzed in the pyrolysis reactor 20 to produce the plastic derived oil stream 102.

[0053] Referring again to FIG. 1, the FCC system 130 may include the FCC reactor 132, which may be the fluidized bed reactor. The FCC reactor 132 may be configured to contact the treated plastic derived oil stream 126 and the light crude oil stream 104 with the cracking catalyst 134 at reaction conditions sufficient to convert at least a portion of hydrocarbons in the treated plastic derived oil stream 126 and the light crude oil stream 104 to produce the cracking effluent 142. The FCC system 130 may further comprise the fluid-solid separation unit 140 disposed at an outlet end of the FCC reactor 132. The fluid-solid separation unit 140 may be configured to separate the cracking effluent 142 from the used cracking catalyst 144. The FCC system 130 may further include a catalyst regenerator 150 disposed downstream of the fluid-solid separation unit 140. The catalyst regenerator 150 may be configured to regenerate the used cracking catalyst 144 to produce a regenerated cracking catalyst 152, which may be passed back to the FCC reactor 132 as at least a portion of the cracking catalyst 134.

[0054] 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.

[0055] 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. 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. 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. 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. 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.

[0056] The plastic derived oil stream 102 may be characterized by a boiling point distribution determined according to standard test method ASTM D2887. 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. 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. 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.

[0057] 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 OxygenppmwCombustion based5540ConcentrationTotal ChlorideppmwUOP 779342ConcentrationTotal Sulfurwt. %ASTM D42940.064Total NitrogenppmwASTM D46291135Bromine Numberg(Br2) / 100 gASTM D115943.3SilicappmwUOP 4070.109SodiumppmwUOP 4070.174IronppmwUOP 4070.097WaterppmwASTM D6304A299Conradson Carbonwt. %ASTM D4530<0.01ResidueSimulated 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

[0058] 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.

[0059] 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. 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.

[0060] The solid waste plastic 12 may be provided in a variety of different forms. The solid waste plastic 12 may be in the form of a powder in smaller scale operations. For larger scale operations, 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). 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.

[0061] 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.

[0062] 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.

[0063] 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 16. The halogen-rich stream 16 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 16 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 16. 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 to the pyrolysis reactor 20 in the liquefied plastic stream 14.

[0064] 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.

[0065] 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). 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.

[0066] Referring again to FIG. 1, the plastic derived oil stream 102 is passed to the acid gas removal unit 110. The acid gas removal unit 110 comprises a reaction vessel 111 and an acid gas removal catalyst 112 disposed within the reaction vessel 111. 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 acid gas removal effluent 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 also passed out of the acid gas removal unit 110 along with the other gaseous hydrocarbons.

[0067] 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 reaction vessel 111 used for the acid gas removal unit 110.

[0068] Referring again to FIG. 1, the PDO separation system 120 may be disposed downstream of the acid gas removal unit 110. The acid gas removal effluent 114 may be passed directly from the acid gas removal unit 110 to the PDO separation system 120. The PDO separation system 120 may be configured to remove the non-condensable gases from the acid gas removal effluent 114 to produce a treated plastic derived oil 126. The PDO separation system 120 may include one or more condensing units 122 configured to condense the condensable hydrocarbons from the acid gas removal effluent 114 to produce the treated plastic derived oil 126. The condensing units 122 of the PDO separation system 120 may operate at a temperature of less than 25° C., such as at a temperature of from 0° C. to 25° C. The non-condensable gases may be removed from the PDO separation system 120 in a non-condensable gas stream 124. The non-condensable gas stream 124 may include gases having boiling point temperatures less than 0° C. (zero ° C.), such as but not limited to C1-C4 hydrocarbons and lesser amounts of H2, CO, CO2, H2S, NH3, or other light gases depending on the composition of the solid plastic waste used to make the plastic derived oil stream 102. In embodiments, the PDO separation system 120 may be configured to remove an aqueous stream (not shown) from the acid gas removal effluent 114, where the aqueous stream includes any water produced from treatment of the plastic derived oil stream 102 in the acid gas removal unit 110.

[0069] The treated plastic derived oil stream 126 may have a concentration of halogen-containing compounds less than the plastic derived oil stream 102 upstream of the acid gas removal unit 110. The treated plastic derived oil stream 126 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 126 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 126. In embodiments, the treated plastic derived oil stream 126 may comprise less than 500 ppmw of sulfur-containing compounds. It will be appreciated that in embodiments, the treated plastic derived oil stream 126 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 126.

[0070] The light crude oil stream 104 is a light crude oil, such as an Arab light (AL) crude oil. In embodiments, the light crude oil stream 104 may comprise, consist of, or consist essentially of a whole crude oil or a crude oil that has undergone at least some processing, such as desalting, solids separation, scrubbing, or combinations of these, but has not been subjected to separation through distillation. For instance, the light crude oil stream 104 can be a de-salted light crude oil that has been subjected to a de-salting process. In embodiments, the light crude oil stream 104 can include a light crude oil that has not undergone pretreatment, separation (such as distillation), or other operation that changes the hydrocarbon composition of the light crude oil prior to introducing the light crude oil stream 104 to the cracking reactor. As used herein, the “hydrocarbon composition” of the light crude oil refers to the composition of the hydrocarbon constituents of the light crude oil and does not include entrained non-hydrocarbon solids, salts, water, or other non-hydrocarbon constituents.

[0071] In embodiments, the light crude oil stream 104 comprises, consists of, or consists essentially of a light crude oil, such as AL crude oil from Saudi Arabia. The light crude oil stream 104 may have an API gravity of from 30 degrees to 35 degrees, such as from 30 degrees to 34 degrees, from 30 degrees to 33 degrees, from 31 degrees to 35 degrees, from 31 degrees to 34 degrees, or from 31 degrees to 33 degrees, as determined according to the standard test method in ASTM D287. The light crude oil stream 104 may have a density of from 0.85 g / cm3 to 0.87 g / cm3, from 0.85 g / cm3 to 0.86 g / cm3, or from 0.86 g / cm3 to 0.87 g / cm3, as measured at 15 degrees Celsius according to the standard test method in ASTM 287.

[0072] The light crude oil stream 104 may have a nitrogen content of less than or equal to 1600 parts per million by weight (ppmw), such as less than or equal to 1000 ppmw, from 500 ppmw to 1600 ppmw, or from 500 ppmw to 1000 ppmw, per unit weight of the light crude oil stream 104. The nitrogen content of the light crude oil stream may be determined according to the standard test method in ASTM 4629. The light crude oil stream 104 may have a sulfur content of less than or equal to 2.4 weight percent (wt. %), such as from 1.9 wt. % to 2.4 wt. %, per unit weight of the light crude oil stream 104, as determined according to the standard test method in ASTM 5453. Any nitrogen and / or sulfur in the light crude oil stream 104 may react with hydrogen introduced to the cracking reactor, such as the FCC reactor 132 of FCC system 130 in FIG. 1, which may reduce the amount of hydrogen available to react with the hydrocarbons during the catalytic cracking reactions. Therefore, the light crude oil stream 104 has low concentrations of nitrogen and sulfur.

[0073] The light crude oil stream 104 may include low concentrations (less than 30 ppmw) of heavy metals, such as but not limited to vanadium, nickel, or iron. The presence of vanadium may destroy the zeolitic structures of the zeolites in the cracking catalyst, thereby reducing catalyst activity and selectivity towards the greater value chemicals and intermediates. Vanadium may also increase hydrogen and coke production. The light crude oil stream 104 may have a vanadium content of less than 30 ppmw, less than 25 ppmw, or even less than 20 ppmw, per unit weight of the light crude oil stream 104. The presence of nickel in the light crude oil stream 104 may promote dehydrogenation reactions and increase hydrogen and coke production. The light crude oil stream 104 may have a nickel content of less than 15 ppmw, or less than or equal to 10 ppmw, per unit weight of the light crude oil stream 104. The presence of iron in the light crude oil stream 104 may neutralize acid sites in the catalyst and may destroy the zeolitic structures of the zeolites in the cracking catalyst. Iron may also make the cracking catalyst more sensitive to high temperature spots in the FCC system 130, such as the higher temperatures experienced during regeneration. The light crude oil stream 104 may have less than 5 ppmw iron, such as less than 2 ppmw iron, per unit weight of the light crude oil stream 104. The content of the various metals in the light crude oil stream 104 may be determined according to the international standard test method in IP 501 from the Energy Institute.

[0074] The light crude oil stream 104 may be characterized by a distillation profile determined according to the standard test method in ASTM D7169. The light crude oil stream 104 may have an initial boiling point temperature (IBP) of from 20° C. to 40° C., such as from 20° C. to 30° C., from 20° C. to 25° C., from 25° C. to 40° C., from 25° C. to 30° C., or from 30° C. to 40° C., as determined according to ASTM D7169. The light crude oil stream 104 may have an end boiling point temperature (EBP) of less than 720° C., such as from 500° C. to 720° C., from 550° C. to 720° C., or from 600° C. to 720° C., as determined according to ASTM D7169. The light crude oil stream 104 may have a 5 wt. % boiling point temperature of less than or equal to 80° C., such as from 20° C. to 80° C., from 20° C. to 70° C., from 20° C. to 50° C., from 30° C. to 80° C., from 30° C. to 70° C., or from 30° C. to 50° C., as determined according to standard test method ASTM D7169. The light crude oil stream 104 may have a 50 wt. % boiling point temperature of from 290° C. to 350° C., such as from 290° C. to 330° C., or from 290° C. to 310° C., as determined according to standard test method ASTM D7169. The light crude oil stream 104 may have a 90 wt. % boiling point temperature of from 550° C. to 700° C., such as from 550° C. to 650° C., from 550° C. to 600° C., or from 600° C. to 700° C., as determined according to standard test method ASTM D7169. Properties for an AL crude oil that may be suitable for the light crude oil stream 104 are provided in Table 2.

[0075] The distribution of different hydrocarbons-such as paraffin compounds, naphthenes, aromatic compounds, and polyaromatic compounds (including heavy polynuclear aromatic compounds)—can influence the conversion and yield obtained from fluidized catalytic cracking of the light crude oil stream 104. For instance, paraffin compounds are generally the most reactive in FCC systems and contribute to high conversion. Naphthenes are the next most reactive group of hydrocarbons in the light crude oil stream 104, followed by aromatic compounds and then polyaromatic compounds. The heavy polynuclear aromatic compounds are the least reactive and do not contribute much to the overall conversion and yields of the greater value products and intermediates by the FCC system.

[0076] The light crude oil stream 104 can have a concentration of paraffin compounds of less than 50 wt. %, such as less than or equal to 40 wt. %, or even less than or equal to 35 wt. % per unit weight of the light crude oil stream 104, as determined according to ASTM D5443. The light crude oil stream 104 can have a concentration of paraffin compounds of from 5 wt. % to less than 50 wt. %, from 5 wt. % to 40 wt. %, from 5 wt. % to 35 wt. %, from 10 wt. % to less than 50 wt. %, from 10 wt. % to 40 wt. %, from 10 wt. % to 35 wt. %, from 20 wt. % to 50 wt. %, from 20 wt. % to 40 wt. %, or even from 20 wt. % to 35 wt. % per unit weight of the light crude oil stream 104.

[0077] The light crude oil stream 104 can have a concentration of naphthenes of from 1 wt. % to 50 wt. %, from 1 wt. % to 30 wt. %, from 1 wt. % to 25 wt. %, from 1 wt. % to 20 wt. %, from 1 wt. % to 15 wt. %, from 5 wt. % to 50 wt. %, from 5 wt. % to 30 wt. %, from 5 wt. % to 25 wt. %, from 5 wt. % to 20 wt. %, from 5 wt. % to 15 wt. %, from 10 wt. % to 50 wt. %, from 10 wt. % to 30 wt. %, from 10 wt. % to 25 wt. %, from 10 wt. % to 20 wt. %, from 15 wt. % to 50 wt. %, from 15 wt. % to 30 wt. %, from 10 wt. % to 25 wt. %, from 15 wt. % to 20 wt. %, from 20 wt. % to 50 wt. %, from 25 wt. % to 50 wt. %, from 25 wt. % to 30 wt. %, or even from 30 wt. % to 50 wt. % per unit weight of the light crude oil stream 104, as determined according to ASTM D5443.

[0078] The light crude oil stream 104 can have a concentration of aromatic compounds of greater than or equal to 20 wt. %, greater than or equal to 30 wt. %, or even greater than or equal to 40 wt. % per unit weight of the light crude oil stream 104, as determined according to ASTM D5443. The concentration of aromatic compounds in this paragraph includes polyaromatic compounds and polynuclear aromatic compounds. In embodiments, the light crude oil stream 104 can have a concentration of aromatic compounds of from 20 wt. % to 90 wt. %, from 20 wt. % to 80 wt. %, from 20 wt. % to 70 wt. %, from 20 wt. % to 60 wt. %, from 20 wt. % to 50 wt. %, from 30 wt. % to 90 wt. %, from 30 wt. % to 80 wt. %, from 30 wt. % to 70 wt. %, from 30 wt. % to 60 wt. %, from 30 wt. % to 50 wt. %, from 35 wt. % to 80 wt. %, or even from 35 wt. % to 50 wt. % per unit weight of the light crude oil stream 104.TABLE 2AL CrudeAnalysisUnitsOilTest MethodAmerican Petroleumdegree32.8ASTM D287Institute (API) gravityDensitygrams per cubic0.860ASTM D287centimeter(g / cm3)Sulfur Contentwt. %2.088ASTM D4294Nitrogen Contentparts per1523ASTM D4629million byweight (ppmw)Paraffinswt. %31ASTM D5443Naphtheneswt. %11.1ASTM D5443Aromaticswt. %44.9ASTM D5443Polyaromaticswt. %12.9ASTM D5443Sodium (Na) Contentppmw<1IP 501Vanadium (V) Contentppmw17IP 501Nickel (Ni) Contentppmw5IP 501Iron (Fe) Contentppmw2IP 5015% Boiling Point (BP)° C.37ASTM D716910% BP° C.87ASTM D716920% BP° C.126ASTM D716930% BP° C.183ASTM D716940% BP° C.238ASTM D716950% BP° C.293ASTM D716960% BP° C.347ASTM D716970% BP° C.407ASTM D716980% BP° C.473ASTM D716990% BP° C.557ASTM D7169End Boiling Point° C.719ASTM D7169(EBP)

[0079] The light crude oil stream 104 and the treated plastic derived oil stream 126 may be passed to the cracking reactor. The cracking reactor may be any type of reactor capable of contacting the light crude oil stream 104 and the treated plastic derived oil stream 126 with the cracking catalyst at the desired reaction conditions. The cracking reactor may be a fluidized bed reactor, a fixed bed reactor, a moving bed reactor, other type of reactor, or combinations thereof. In embodiments, the cracking reactor may be a fluidized bed reactor, such as the FCC reactor 132 of the FCC system 130 shown in FIG. 1. The subject matter of the present disclosure will be described in the context of the FCC system 130 depicted in FIG. 1. However, it is understood that the cracking reactor may be any other type of suitable reactor, such as the fixed bed reactor shown in FIG. 2, a moving bed reactor, or other type of reactor capable of contacting the hydrocarbon feeds with the cracking catalyst at the reaction conditions.

[0080] Referring again to FIG. 1, the light crude oil stream 104 and the treated plastic derived oil stream 126 may be passed to the FCC reactor 132 of the FCC system 130. The light crude oil stream 104 and the treated plastic derived oil stream 126 may be separately introduced to the FCC reactor 132 or combined upstream of the FCC reactor 132. For example, the treated plastic derived oil stream 126 and the light crude oil stream 104 may be combined in a mixing tank or other mixing unit prior to entering the FCC reactor 132. In embodiments, the FCC reactor 132 of the FCC system 130 may be downstream of the PDO separation system 120 and in fluid communication with the PDO separation system 120 to pass the treated plastic derived oil stream 126 from the PDO separation system 120 directly to the FCC reactor 132.

[0081] The hydrocarbons introduced to the FCC reactor 132 comprise a mixture of the treated plastic derived oil stream 126 and the light crude oil stream 104. A weight ratio of the treated plastic derived oil stream 126 to the light crude oil stream 104 may be from 0.1 to 1. The weight ratio of the treated plastic derived oil stream 126 and the light crude oil stream 104 is equal to the mass flow rate of the treated plastic derived oil stream 126 to the FCC reactor 132 divided by the mass flow rate of the light crude oil stream 104 to the FCC reactor 132. In embodiments, the weight ratio of the treated plastic derived oil stream 126 to the light crude oil stream 104 may be from 0.1 to 0.8, from 0.1 to 0.6, from 0.1 to 0.5, from 0.1 to 0.4, from 0.2 to 1, from 0.2 to 0.8, from 0.2 to 0.6, from 0.2 to 0.5, from 0.2 to 0.4, from 0.3 to 1, from 0.3 to 0.8, from 0.3 to 0.6, from 0.3 to 0.5, from 0.5 to 1, from 0.5 to 0.8, or from 0.6 to 1.

[0082] Referring again to FIG. 1, the FCC reactor 132 may comprise the cracking catalyst 134. Contact of the treated plastic derived oil stream 126 and the light crude oil stream 104 with the cracking catalyst 134 may cause at least a portion of the hydrocarbons from the treated plastic derived oil stream 126 and the light crude oil stream 104 to undergo catalytic cracking reactions to produce lighter hydrocarbons and hydrocarbon gases. Contact of the treated plastic derived oil stream 126 and the light crude oil stream 104 with the cracking catalyst 134 produces the cracking effluent 142 that includes a greater concentration of greater-value chemicals and intermediates, such as but not limited to light olefins, light aromatic compounds, naphtha, gasoline constituents, jet fuel constituents, diesel constituents, LCO, HCO, or any combinations of these greater value chemicals and intermediates, compared to the combined treated plastic derived oil stream 126 and the light crude oil stream 104. At least a portion of the greater-value chemicals and intermediates in the cracking effluent 142 may be considered circular chemicals, low carbon fuels, or both, which may be the greater-value chemicals and intermediates attributable to the introduction of the treated plastic derived oil stream 126 to the FCC reactor 132.

[0083] The FCC reactor 132 is a fluidized bed reactor. The FCC system 130 may include one or a plurality of the FCC reactors 132. When the FCC system 130 comprises a plurality of the FCC reactors 132, the plurality of FCC reactors 132 may be in parallel, such as for purposes of increasing a capacity of the FCC system 130 for upgrading the treated plastic derived oil stream 126 and light crude oil stream 104. In embodiments, the FCC reactor 132 is a fluidized bed reactor in which treated plastic derived oil stream 126, the light crude oil stream 104, and the cracking catalyst 134 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 132. The FCC reactor 132 may be a riser reactor or a downer reactor. In embodiments, the FCC reactor 132 may be a riser reactor.

[0084] The cracking catalyst 134 may be any conventional cracking catalyst known to those skilled in the art for catalyzing cracking reactions of hydrocarbons. The cracking catalyst 134 is different from the acid gas removal catalyst 112. In embodiments, the cracking catalyst 134 may comprise a commercial catalyst for FCC applications. In embodiments, the cracking catalyst 134 may comprise one or more commercial catalysts for FCC applications. Alternatively, or additionally, the cracking catalyst 134 may comprise other suitable solid acid catalysts. In embodiments, the cracking catalyst 134 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 134 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 134 in the FCC reactor 132. In embodiments, the cracking catalyst 134 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 a Mordenite framework inverted (MFI) zeolite, such as but not limited to a ZSM-5 zeolite.

[0085] In embodiments, the cracking catalyst 134 may comprise from 65 wt. % to 85 wt. % ECAT, per unit weight of the cracking catalyst. For example, the cracking catalyst 134 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 134 may comprise a cracking additive in amounts from 5 wt. % to 40 wt. %, 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 134 may comprise from 20 wt. % to 30 wt. % light olefin cracking additive, per unit weight of the cracking catalyst 134.

[0086] In embodiments, the cracking catalyst 134 may comprise a ZSM-5 zeolite and a Y-type zeolite. The cracking catalyst 134 can also include an alumina binder, a matrix material comprising Kaolin clay, and colloidal silica. As used in the present disclosure, “ZSM-5” refers to zeolites having an MFI framework type according to the IUPAC zeolite nomenclature and consisting of silica and alumina. ZSM-5 refers to “Zeolite Socony Mobil-5” and is a pentasil family zeolite that can be represented by the chemical formula NanAlnSi96-nO192·16H2O, where 0<n<27. The molar ratio of silica to alumina in the ZSM-5 may be at least 5, at least 10, at least 25, at least 30 or even at least 50. In embodiments, the molar ratio of silica to alumina in the ZSM-5 may be from 5 to 80, from 10 to 70, from 25 to 60 or any range or subrange between these values. The ZSM-5 zeolite may have a specific surface area from 200 meters squared per gram (m2 / g) to 800 m2 / g, such as from 200 m2 / g to 400 m2 / g, from 200 m2 / g to 600 m2 / g, from 300 m2 / g to 400 m2 / g, from 300 m2 / g to 600 m2 / g, from 300 m2 / g to 800 m2 / g, from 400 m2 / g to 600 m2 / g, or from 400 m2 / g to 800 m2 / g. The specific surface area refers to the BET surface area as determined using the Brunauer-Emmett-Teller (BET) method of surface area analysis based on gas adsorption and analysis of gas adsorption isotherms. The ZSM-5 zeolite, can have a total pore volume per unit weight of the ZSM-5 zeolite of from 0.010 milliliters per gram (mL / g) to 0.500 mL / g, such as from 0.050 mL / g to 0.500 mL / g, from 0.010 mL / g to 0.300 mL / g, or from 0.050 mL / g to 0.300 mL / g. The total pore volume can be determined through nitrogen physisorption and analysis of nitrogen physisorption isotherms, which is a well-known method.

[0087] In embodiments, one or more of the zeolite components of the cracking catalyst 134 can include one or more phosphorous-containing compounds, such as phosphorous pentoxide (P2O5). Without being bound by any particular theory, it is believed that phosphorus-containing compounds may stabilize the zeolite framework structure by preventing the segregation of the framework alumina, which can improve the hydrothermal stability of the zeolite component. This may reduce the dealumination of the zeolite component that occurs during steaming, which can lead to a reduction in acidity and catalytic activity of the zeolite component. In embodiments, one or more of the zeolite components of the cracking catalyst 134 may include one or more phosphorous-containing compounds in an amount of from 1 wt. % to 20 wt. % based on the total weight of each zeolitic component. In embodiments, the phosphorous-containing compounds can be impregnated onto the ZSM-5 zeolite so that the ZSM-5 zeolite is impregnated with from 1 wt. % to 20 wt. % phosphorous-containing compounds, such as phosphorous pentoxide, based on the total weight of the ZSM-5 zeolite.

[0088] The cracking catalyst 134 can include up to 40 wt. % of the ZSM-5 zeolite based on the total weight the cracking catalyst 134. In embodiments, the cracking catalyst 134 can include from 1 wt. % to 40 wt. %, from 1 wt. % to 30 wt. %, from 1 wt. % to 25 wt. %, from 1 wt. % to 20 wt. %, 5 wt. % to 40 wt. %, from 5 wt. % to 30 wt. %, from 5 wt. % to 25 wt. %, from 5 wt. % to 20 wt. %, 10 wt. % to 40 wt. %, from 10 wt. % to 30 wt. %, from 10 wt. % to 25 wt. %, from 10 wt. % to 20 wt. %, from 15 wt. % to 40 wt. %, from 15 wt. % to 30 wt. %, or from 15 wt. % to 25 wt. % of the ZSM-5 zeolite based on the total weight of the cracking catalyst 134.

[0089] The cracking catalyst 134 may further include the Y-type zeolite. As used in the present disclosure, the term “Y-type zeolite” refers to a zeolite having an FAU framework type according to the IUPAC zeolite nomenclature and consisting of silica and alumina. In embodiments, the Y-type zeolite can comprise an ultrastable Y-type (USY) zeolite. USY zeolites can be produced via the dealumination of one or more Y-type zeolites. Without being bound by any particular theory, it is believed that the dealumination of the Y-type zeolite may result in a USY zeolite having a reduced number of acid sites. This reduced number of acid sites may result in a reduction of the rates of secondary reactions in the FCC system 130, such as the dehydrogenation or hydrogenation of olefins produced in the FCC system 130, when compared to Y-type zeolite that has not been dealuminated. As a result, USY zeolite may produce a greater yield of olefins and gasoline when compared to Y-type zeolite.

[0090] The molar ratio of silica to alumina in the USY zeolite can be from 5 to 80, from 5 to 50, from 5 to 25, from 5 to 10, from 10 to 80, from 10 to 50, from 10 to 25, from 25 to 80, or from 25 to 50, or about 30. In embodiments, the USY zeolite can comprise one or more transition metals, such as zirconium, titanium, or hafnium, substituted into the framework of the zeolite. The USY zeolite can have a specific surface area of from 200 m2 / g to 900 m2 / g, as determined according to the BET method. In embodiments, the USY zeolite may have an average surface area of from 200 m2 / g to 800 m2 / g, from 300 m2 / g to 900 m2 / g, from 300 m2 / g to 800 m2 / g, from 500 m2 / g to 900 m2 / g, or from 500 m2 / g to 800 m2 / g, as determined according to the BET method. The USY zeolite may have a total pore volume per unit weight of the USY zeolite of from 0.050 mL / g to 0.600 mL / g, such as from 0.050 mL / g to 0.500 mL / g, as determined through nitrogen physisorption and analysis of nitrogen physisorption isotherms, which is a well-known method.

[0091] In embodiments, one or more of the zeolite components of the cracking catalyst 134 can include one or more rare earth metals or rare earth metal oxides impregnated on the zeolite, where the rare earth metal can be one or more of lanthanum, cerium, dysprosium, europium, gadolinium, holmium, lutetium, neodymium, praseodymium, promethium, samarium, scandium, terbium, thulium, ytterbium, yttrium, or combinations of these. Without being bound by any particular theory, it is believed that rare earth metals or rare earth metal oxides can improve the stability of the unit cells of the zeolite component, increase the catalytic activity of the zeolite component, or both. Moreover, it is believed that rare earth metals or rare earth metal oxides can function as vanadium traps, which act to sequester vanadium in the light crude oil stream 104 and prevent deleterious effects that vanadium can have on the zeolite components of the cracking catalyst. In embodiments, one or more of the zeolite components can include one or more rare earth metals or rare earth metal oxides in an amount of from 1 wt. % to 10 wt. % based on the total weight of each zeolite component. In embodiments, one or more of the zeolite components can be impregnated with lanthanum or lanthanum oxide. In embodiments, one or more of the zeolite components, such as the USY zeolite, can include one or more lanthanum-containing compounds, such as but not limited to lanthanum oxide, in an amount of from 1 wt. % to 10 wt. %, from 1 wt. % to 7 wt. %, from 1 wt. % to 5 wt. %, from 1 wt. % to 4 wt. %, from 1 wt. % to 3 wt. %, from 1 wt. % to 2 wt. %, from 2 wt. % to 10 wt. %, from 2 wt. % to 7 wt. %, from 2 wt. % to 5 wt. %, from 2 wt. % to 4 wt. %, from 2 wt. % to 3 wt. %, from 3 wt. % to 10 wt. %, from 3 wt. % to 7 wt. %, from 3 wt. % to 5 wt. %, from 3 wt. % to 4 wt. %, from 4 wt. % to 10 wt. %, from 4 wt. % to 7 wt. %, or from 4 wt. % to 5 wt. %, or about 2.5 wt. % based on the total weight of each zeolite component. In embodiments, the cracking catalyst 134 can comprise USY zeolite impregnated with from 1 wt. % to 10 wt. %, ro about 2.5 wt. % lanthanum oxide (La2O3) based on the total weight of the USY zeolite.

[0092] In embodiments, the cracking catalyst 134 can include from 1 wt. % to 40 wt. %, from 1 wt. % to 30 wt. %, from 1 wt. % to 25 wt. %, from 5 wt. % to 40 wt. %, from 5 wt. % to 30 wt. %, from 5 wt. % to 25 wt. %, from 10 wt. % to 40 wt. %, from 10 wt. % to 30 wt. %, from 10 wt. % to 25 wt. %, from 15 wt. % to 40 wt. %, from 15 wt. % to 30 wt. %, or from 15 wt. % to 25 wt. % of the USY zeolite based on the total weight of the cracking catalyst 134.

[0093] As previously discussed, the cracking catalyst 134 can include a binder, matrix material, or both. 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 134 may comprise from 10 wt. % to 20 wt. % of the binder, per unit weight of the cracking catalyst, such as 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, of the binder, per unit weight of the cracking catalyst. In embodiments, the cracking catalyst 134 may comprise from 10 wt. % to 20 wt. % of the acid peptized alumina binder, per unit weight of the cracking catalyst 134.

[0094] Matrix materials may include clays, such as but not limited to kaolin, montmorilonite, halloysite, bentonite, or combinations of these. In embodiments, the cracking catalyst 134 may comprise from 20 wt. % to 60 wt. % of the matrix material, per unit weight of the cracking catalyst, such as 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, of the matrix materials per unit weight of the cracking catalyst. In embodiments, the cracking catalyst 134 may comprise from 20 wt. % to 60 wt. % kaolin clay per unit weight of the cracking catalyst 134. In embodiments, the cracking catalyst 134 may include colloidal silica, such as from 0 wt. % to 10 wt. % colloidal silica based on the total weight of cracking catalyst 134.

[0095] In embodiments, the cracking catalyst 134 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 134. The combined materials may be extruded to produce the cracking catalyst 134 in the form of composite particles comprising the various constituents of the cracking catalyst 134. In embodiments, cracking catalyst 134 may be prepared through a spray drying process, which may include forming a slurry comprising the zeolite components, the binder materials, and the matrix materials and then spray drying the slurry to produce the composite particles of the cracking catalyst 134. In embodiments, the cracking catalyst 134 may be prepared through extrusion and pelletizing or other process for forming composite catalyst particles.

[0096] The FCC reactor 132 may be configured to contact the treated plastic derived oil stream 126 and the light crude oil stream 104 with the cracking catalyst 134 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 132 may be configured to contact the treated plastic derived oil stream 126 and the light crude oil stream 104 with the cracking catalyst 134 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 132 may be configured to contact the treated plastic derived oil stream 126 and the light crude oil stream 104 with the cracking catalyst 134 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 132 may be operable to contact the treated plastic derived oil stream 126 and the light crude oil stream 104 with the cracking catalyst 134 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 132 is equal to an average ratio of a mass flow rate of the cracking catalyst 134 through the FCC reactor 132 divided by a mass flow rate of the hydrocarbons (treated plastic derived oil stream 126 and the light crude oil stream 104) in the FCC reactor 132 during steady state operation of the FCC system 130.

[0097] The FCC reactor 132 produces a reaction mixture comprising the cracking effluent 142 and the used cracking catalyst 144. The cracking effluent 142 may be separated from the used cracking catalyst 144 at or proximate to an outlet end of the FCC reactor 132. Referring again to FIG. 1, in embodiments, the reaction mixture, which may include the cracking effluent 142 and the used cracking catalyst 144, may be passed out of the FCC reactor 132 to the fluid-solid separation unit 140. As previously discussed, the fluid-solid separation unit 140 may be disposed at the outlet end of the FCC reactor 132. The fluid-solid separation unit 140 may be configured to separate the cracking effluent 142 from the solid particles of the used cracking catalyst 144. The cracking effluent 142 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 140 is depicted as a vessel disposed at the outlet end of the FCC reactor 132, where the vessel reduces the fluid velocity of the cracking effluent 142 to allow the solid particles of the used cracking catalyst 144 to separate and settle out from the fluid phase of the cracking effluent 142. The used cracking catalyst 144 may settle in the bottom of the fluid-solid separation unit 140, and the cracking effluent 142 may pass out of a top portion of the fluid-solid separation unit 140. In embodiments, the fluid-solid separation unit 140 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 cracking effluent 142. Other types of fluid-solid separation devices are contemplated for the fluid-solid separation unit 140. The used cracking catalyst 144 may be passed from the fluid-solid separation unit 140 to the catalyst regenerator 150.

[0098] Referring again to FIG. 1, as previously discussed, the FCC system 130 includes the catalyst regenerator 150. The used cracking catalyst 144 may be passed from the fluid-solid separation unit 140 to the catalyst regenerator 150 and regenerated to produce a regenerated cracking catalyst 152. The regenerated cracking catalyst 152 may be passed back to the FCC reactor 132 as at least a portion of or all of the cracking catalyst 134. The catalyst regenerator 150 may be disposed downstream of the solid-fluid separation unit 140 and in fluid communication with an outlet of the solid-fluid separation unit 140 to pass the used cracking catalyst 144 from the solid-fluid separation unit 140 directly to the catalyst regenerator 150.

[0099] During the reactions in the FCC reactor 132, coke may deposit on the cracking catalyst 134 as a result of the cracking reactions to produce the used cracking catalyst 144. The coke may block reactive sites on the used cracking catalyst and reduce the catalytic activity of the used cracking catalyst for catalyzing the cracking reactions. The catalyst regenerator 150 may be configured to heat the used cracking catalyst 144 to a temperature sufficient to remove coke from the used cracking catalyst 144 to produce the regenerated cracking catalyst 152. In embodiments, the catalyst regenerator 150 may be configured to contact the used cracking catalyst 144 with the regeneration gas 154 at the regeneration temperature, which may be sufficient to combust coke deposits on the used cracking catalyst 144, increase the temperature of the regenerated cracking catalyst 152, or combinations thereof.

[0100] The regeneration temperature in the catalyst regenerator 150 may be sufficient to combust the coke deposits, increase the temperature of the catalyst particles, or both to produce the regenerated cracking catalyst 152. The regeneration gas 154 may be an oxygen-containing gas, such as but not limited to air. In embodiments, the regeneration gas 154 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 150, which can increase combustion of coke deposits, further increase the temperature of the regenerated cracking catalyst, or both. In embodiments, the regeneration temperature in the catalyst regenerator 150 may be greater than the operating temperature of the FCC reactor 132. In embodiments, the regeneration temperature in the catalyst regenerator 150 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.

[0101] Combustion gases produced through combustion of the coke deposits, and optionally any supplemental fuels added to the catalyst regenerator 150, may be passed out of the catalyst regenerator 150 in a flue gas 156. The flue gas 156 may exit from a top portion of the catalyst regenerator 150. The flue gas 156 may be passed to one or more downstream treatment systems for properly handling of the combustion gases to reduce environmental impact.

[0102] Referring again to FIG. 1, the catalyst regenerator 150 may be in fluid communication with the inlet end of the FCC reactor 132 to pass the regenerated cracking catalyst 152 back to the FCC reactor 132 as a portion of or all of the cracking catalyst 134. The FCC system 130 may further include a regenerated cracking catalyst transfer line 158 fluidly coupling the catalyst regenerator 150 and the inlet of the FCC reactor 132. The regenerated cracking catalyst transfer line 158 may be operable to pass the regenerated cracking catalyst 152 from the catalyst regenerator 150 to the FCC reactor 132. In embodiments, the FCC system 130 may further include a catalyst valve 159 disposed in the regenerated cracking catalyst transfer line 158 and operable to control a mass flow rate of the regenerated cracking catalyst 152 from the catalyst regenerator 150 to the FCC reactor 132.

[0103] The cracking effluent 142 may comprise fuel gases, light olefins, C2-C4 alkanes, light aromatic compounds, naphtha, light cycle oil (LCO), heavy cycle oil (HCO), or any combinations of these constituents. The cracking effluent 142 produced through co-processing the light crude oil stream 104 and the treated plastic derived oil stream 126 may comprise greater yield and concentration of light olefins (ethylene, propylene, butenes) and a smaller concentration of cycle oils (HCO and LCO) compared to an effluent produced through cracking only the light crude oil stream 104 without the treated plastic derived oil stream 126.

[0104] A yield of light olefins, such as but not limited to ethylene, propylene, mixed butenes, and combinations thereof, in the cracking effluent 142 may be from 35 wt. % to 60 wt. %, from 35 wt. % to 55 wt. %, from 37 wt. % to 60 wt. %, from 37 wt. % to 55 wt. %, from 38 wt. % to 60 wt. %, or from 38 wt. % to 55 wt. % based on the mass flow rate of the treated plastic derived oil stream 126 and the light crude oil stream 104 introduced to the FCC reactor 132. In embodiments, the cracking effluent 142 may comprise from 35 wt. % to 60 wt. %, from 35 wt. % to 55 wt. %, from 37 wt. % to 60 wt. %, from 37 wt. % to 55 wt. %, from 38 wt. % to 60 wt. %, or from 38 wt. % to 55 wt. % of the light olefins per unit weight of the cracking effluent 142.

[0105] A yield of naphtha in the cracking effluent 142 may be from 20 wt. % to 40 wt. %, from 20 wt. % to 35 wt. %, from 25 wt. % to 40 wt. %, or from 25 wt. % to 35 wt. % based on the mass flow rate of the treated plastic derived oil stream 126 and the light crude oil stream 104 introduced to the FCC reactor 132. In embodiments, the cracking effluent 142 may comprise from 20 wt. % to 40 wt. %, from 20 wt. % to 35 wt. %, from 25 wt. % to 40 wt. %, or from 25 wt. % to 35 wt. % of the naphtha per unit weight of the cracking effluent 142.

[0106] A yield of constituents having boiling point temperature greater than 221° C., which includes LCO and HCO, in the cracking effluent 142 may be less than or equal to 20 wt. %, such as less than or equal to 15 wt. %, less than or equal to 13 wt. %, from 0 wt. % to 20 wt. %, from 0 wt. % to 15 wt. %, from 0 wt. % to 14 wt. %, from 0 wt. % to 13 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 5 wt. % to 20 wt. %, from 5 wt. % to 15 wt. %, from 5 wt. % to 14 wt. %, or from 5 wt. % to 13 wt. %, based on the mass flow rate of the treated plastic derived oil stream 126 and the light crude oil stream 104 introduced to the FCC reactor 132. In embodiments, the cracking effluent 142 may comprise from 0 wt. % to 20 wt. %, from 0 wt. % to 15 wt. %, from 0 wt. % to 14 wt. %, from 0 wt. % to 13 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 5 wt. % to 20 wt. %, from 5 wt. % to 15 wt. %, from 5 wt. % to 14 wt. %, or from 5 wt. % to 13 wt. % of the constituents having boiling point temperature greater than 221° C. (LCO+HCO) per unit weight of the cracking effluent 142.

[0107] A yield of LCO in the cracking effluent 142 may be less than or equal to 12 wt. %, such as less than or equal to 10 wt. %, from 0 wt. % to 12 wt. %, from 0 wt. % to 10 wt. %, from 1 wt. % to 12 wt. %, from 1 wt. % to 10 wt. %, from 5 wt. % to 12 wt. %, or from 5 wt. % to 10 wt. %, based on the mass flow rate of the treated plastic derived oil stream 126 and the light crude oil stream 104 introduced to the FCC reactor 132. In embodiments, the cracking effluent 142 may comprise less than or equal to 12 wt. %, such as less than or equal to 10 wt. %, from 0 wt. % to 12 wt. %, from 0 wt. % to 10 wt. %, from 1 wt. % to 12 wt. %, from 1 wt. % to 10 wt. %, from 5 wt. % to 12 wt. %, or from 5 wt. % to 10 wt. % of the LCO per unit weight of the cracking effluent 142. A yield of HCO in the cracking effluent 142 may be less than or equal to 10 wt. %, such as less than or equal to 8 wt. %, less than or equal to 5, from 0 wt. % to 10 wt. %, from 0 wt. % to 8 wt. %, from 0 wt. % to 5 wt. %, from 1 wt. % to 10 wt. %, from 1 wt. % to 8 wt. %, or from 1 wt. % to 5 wt. %, based on the mass flow rate of the treated plastic derived oil stream 126 and the light crude oil stream 104 introduced to the FCC reactor 132. In embodiments, the cracking effluent 142 may comprise less than or equal to 10 wt. %, such as less than or equal to 8 wt. %, less than or equal to 5, from 0 wt. % to 10 wt. %, from 0 wt. % to 8 wt. %, from 0 wt. % to 5 wt. %, from 1 wt. % to 10 wt. %, from 1 wt. % to 8 wt. %, or from 1 wt. % to 5 wt. % of the HCO per unit weight of the cracking effluent 142.

[0108] A yield of C2-C4 alkanes in the cracking effluent 142 may be from 0 wt. % to 10 wt. %, from 0 wt. % to 9 wt. %, from 0 wt. % to 8 wt. %, from 1 wt. % to 10 wt. %, from 1 wt. % to 9 wt. %, from 1 wt. % to 8 wt. %, from 5 wt. % to 10 wt. %, from 5 wt. % to 9 wt. %, or from 5 wt. % to 8 wt. % based on the mass flow rate of the treated plastic derived oil stream 126 and the light crude oil stream 104 introduced to the FCC reactor 132. In embodiments, the cracking effluent 142 may comprise from 0 wt. % to 10 wt. %, from 0 wt. % to 9 wt. %, from 0 wt. % to 8 wt. %, from 1 wt. % to 10 wt. %, from 1 wt. % to 9 wt. %, from 1 wt. % to 8 wt. %, from 5 wt. % to 10 wt. %, from 5 wt. % to 9 wt. %, or from 5 wt. % to 8 wt. % of the C2-C4 alkanes per unit weight of cracking effluent 142.

[0109] A yield of fuel gas in the cracking effluent 142 may be from 0 wt. % to 10 wt. %, from 0 wt. % to 8 wt. %, from 0 wt. % to 6 wt. %, from 1 wt. % to 10 wt. %, from 1 wt. % to 8 wt. %, from 1 wt. % to 6 wt. %, from 2 wt. % to 10 wt. %, from 2 wt. % to 8 wt. %, or from 2 wt. % to 6 wt. % based on the mass flow rate of the treated plastic derived oil stream 126 and the light crude oil stream 104 introduced to the FCC reactor 132. In embodiments, the cracking effluent 142 may comprise from 0 wt. % to 10 wt. %, from 0 wt. % to 8 wt. %, from 0 wt. % to 6 wt. %, from 1 wt. % to 10 wt. %, from 1 wt. % to 8 wt. %, from 1 wt. % to 6 wt. %, from 2 wt. % to 10 wt. %, from 2 wt. % to 8 wt. %, or from 2 wt. % to 6 wt. % of the fuel gas (CH4) per unit weight of cracking effluent 142.

[0110] The processes of the present disclosure may produce a yield of coke of less than 6 wt. %, less than 5 wt. %, from 0 to 6 wt. %, from 0 wt. % to 5 wt. %, from 1 wt. % to 6 wt. %, from 1 wt. % to 5 wt. %, from 2 wt. % to 6 wt. %, or from 2 wt. % to 5 wt. % based on the mass flow rate of the treated plastic derived oil stream 126 and the light crude oil stream 104 introduced to the FCC reactor 132.

[0111] Referring again to FIG. 1, the cracking effluent 142 may be passed to the cracking effluent separation system 160. The cracking effluent separation system 160 may be disposed downstream of the FCC reactor 132, such as downstream of the fluid-solid separation unit 140. The cracking effluent separation system 160 may be in fluid communication with the fluid-solid separation unit 140 to pass the cracking effluent 142 directly to the cracking effluent separation system 160. The cracking effluent 142 may be separated in the cracking effluent separation system 160 to produce at least one product stream. The cracking effluent separation system 160 can include one or a plurality of separation units, which, collectively, operate to separate the cracking effluent 142 into the plurality of product streams. In embodiments, the cracking effluent separation system 160 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.

[0112] The plurality of product streams can include one or more of a light gas stream 162, a light olefin stream 164, a naphtha stream 166, an LCO stream 168, an HCO stream 170, or any combination of these streams. The light olefin stream 164 can include one or more olefin streams comprising olefin compounds having from 2-4 carbon atoms. The light olefin streams 164 may include an ethylene stream, a propylene stream, a mixed butenes stream, or combinations of these. The naphtha stream 166 may comprise constituents having boiling point temperatures of from 0° C. to 221° C. The naphtha stream 166 may contain light aromatic compounds (aromatic compounds having from 6-8 carbon atoms) and gasoline components. The naphtha stream 166 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 LCO stream 168, which may include constituents having boiling point temperatures of from 221° C. to 343° C. In embodiments, the plurality of product streams may include the HCO stream 170, which may include constituents having boiling point temperatures of greater than 343° C. In embodiments, the cracking effluent separation system 160 further may be operable to produce the light gas stream 162 comprising light gases such as but not limited to hydrogen, methane, or both produced in the FCC reactor 132. In embodiments, the cracking effluent separation system 160 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 cracking effluent separation system 160.

[0113] Referring now to FIG. 2, one embodiment of the FCC reactor 132 comprising a fluidized bed reactor 200 having a riser reactor 202 (upflow reactor) is schematically depicted. FIG. 2 also schematically depicts one embodiment of a catalyst regenerator 240 for the fluidized bed reactor 200. 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 132 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, unless otherwise specifically stated.

[0114] The fluidized bed reactor 200 can include the riser reactor 202, a reaction zone 204 downstream of the riser reactor 202, and a separation zone 206 downstream of the reaction zone 204. The separation zone 206 in FIG. 2 corresponds to the fluid-solid separation unit 140 in FIG. 1. In operation of the fluidized bed reactor 200 of FIG. 2, the hydrocarbon feed 210 is introduced to the riser reactor 202. For the FCC reactor 132, the hydrocarbon feed 210 is the combination of the treated plastic derived oil stream 126 and the light crude oil stream 104. In embodiments, the hydrocarbon feed 210 may be combined with steam (not shown) upstream of the riser reactor 202. The hydrocarbon feed 210 may be combined with an effective quantity of heated catalyst 220 in the riser reactor 202. For the FCC reactor 132, the catalyst 220 may be the cracking catalyst 134 described herein.

[0115] The hydrocarbon feed 210 and the catalyst 220 (with optional steam) are contacted in the riser reactor 202 and passed upward through the riser reactor 202 into the reaction zone 204. In the riser reactor 202 and the reaction zone 204, the hydrocarbons from the hydrocarbon feed 210 are contacted with the catalyst 220 at the 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 the cracking effluent and the used catalyst. The reaction mixture comprising the used catalyst and cracking effluent may then be passed to the separation zone 206 downstream of the reaction zone 204. In the separation zone 206, the reaction mixture is separated to produce the cracking effluent 212 and the used catalyst 222. The separation zone 206 may include one or a plurality of fluid-solid separation devices, which may have any suitable configuration known in the art. Referring again to FIG. 1, the separation zone for the FCC reactor 132 may comprise the fluid-solid separation unit 140.

[0116] Referring again to FIG. 2, during the cracking reactions, the catalyst 220 can become coked resulting in the used catalyst 222, and the coke deposits can reduce access to the active catalytic sites on the used catalyst 222. The used catalyst 222 may also have a reduced temperature compared to the catalyst 220 introduced to the riser reactor 202. The used catalyst 222 may be passed from the separation zone 206 to the catalyst regenerator 240.

[0117] Referring to FIG. 2, one embodiment of the catalyst regenerator 240 for the fluidized bed reactor 200 is schematically depicted. The catalyst regenerator 240 may be a riser catalyst regenerator comprising a riser 242 and a separation zone 248 disposed at the outlet end of the riser 242. During operation of the catalyst regenerator 240, the used catalyst 222 may be passed to the inlet 244 of the riser 242. A regeneration gas 246 may also be introduced to the inlet 244 of the riser 242. In embodiments, the regeneration gas 246 may be an oxygen-containing gas, such as air, compressed oxygen, or other oxygen-containing gas. In embodiments, the regeneration gas 246 may also include a fuel gas in addition to the oxygen-containing gas. The regeneration gas 246 and used catalyst 222 may be contacted at regeneration conditions, which may cause reaction between the used catalyst 222 and the regeneration gas 246. In embodiments, the regeneration gas 246 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 250. The regenerated catalyst 250 may have reduced coke deposits, greater temperature, or both compared to the used catalyst 222.

[0118] The regenerated catalyst 250 may be separated from combustion gases in the catalyst separation zone 248, which is disposed at the outlet end of the riser 242. The combustion gases may be removed from the catalyst regenerator 240 as a flue gas 252. The flue gas 252 may include unreacted regeneration gases 246 as well as combustion gases, which may be the reaction products produced through combustion of coke deposits and / or fuel gas in the riser 242. The regenerated catalyst 250 may be passed back to the fluidized bed reactor 200 as at least a portion of the catalyst 220. Although depicted in FIG. 2 as a riser-type catalyst regenerator, is it understood that other configurations for the catalyst regenerator 240 may be employed, such as but not limited to downer catalyst regenerators, fixed bed catalyst regenerators, or other type of catalyst regenerator.

[0119] Referring now to FIG. 3, in embodiments, the system 100 may include one or a plurality of fixed bed reactors 180 as the cracking reactor. The fixed bed reactor 180 may include the cracking catalyst 134 disposed in a fixed catalyst bed contained within the fixed bed reactor 180. The treated plastic derived oil stream 126 may be passed from the PDO separation system 120 to the fixed bed reactor 180. The light crude oil stream 104 may also be passed to the fixed bed reactor 180 or mixed with the treated plastic derived oil stream 126 upstream of the fixed bed reactor 180. The treated plastic derived oil stream 126 and the light crude oil stream 104 may be contacted with the cracking catalyst 134 in the fixed catalyst bed of the fixed bed reactor 180, where the contacting causes hydrocarbons in the treated plastic derived oil stream 126 and the light crude oil stream 104 to undergo cracking reactions to produce a cracking effluent 182. The cracking effluent 182 may be passed out of the fixed bed reactor 180. In embodiments the cracking effluent 182 may be passed downstream to the cracking effluent separation system 160.

[0120] Over time, the cracking catalyst 134 may accumulate coke deposits, which reduce the catalytic activity of the cracking catalyst 134 for cracking reactions. Periodically, the cracking catalyst 134 may be subjected to an in-place regeneration process to remove the coke deposits. The in-place regeneration process may include stopping the flow of the treated plastic derived oil stream 126 and light crude oil stream 104 to the fixed bed reactor 180, introducing a regeneration gas 184 to the fixed bed reactor 180 for a period of time sufficient to combust coke from the used cracking catalyst to produce a regenerated cracking catalyst contained within the fixed catalyst bed. The combustion products from the combustion of coke and any supplemental fuel used in the regeneration process may exit from the fixed bed reactor 180 in a flue gas stream 186.

[0121] The system 100 in FIG. 3 may further include the dehalogenation unit 10, the pyrolysis reactor 20, the acid gas removal unit 110, and the PDO separation system 120 upstream of the fixed bed reactor 180. The system 100 may also include the cracking effluent separation system 160 disposed downstream of the fixed bed reactor 180. The dehalogenation unit 10, the pyrolysis reactor 20, the acid gas removal unit 110, the PDO separation system 120, and the cracking effluent separation system 160 may have any of the features or operating conditions previously discussed for these unit operations. Other types of reactors may be used for the cracking reactor.

[0122] Referring again to FIG. 1, the system 100 can be used in processes for producing circular chemicals, low carbon fuels, or both from the plastic derived oil stream 102 and the light crude oil stream 104. The processes include producing a plastic derived oil stream 102 and treating the plastic derived oil stream to produce a treated plastic derived oil stream 126. 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. The treated plastic derived oil stream 126 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 126 and a light crude oil stream 104 to the cracking reactor (FCC reactor 132 or fixed bed reactor 180).

[0123] The processes include contacting the treated plastic derived oil stream 126 and the light crude oil stream 104 with the cracking catalyst 134 in the cracking reactor at reaction conditions. Contact of the treated plastic derived oil stream 126 and the light crude oil stream 104 with the cracking catalyst 134 at reaction conditions produces the cracking effluent 142 comprising the circular chemicals (olefins, light aromatic compounds or both), low-carbon fuels (light naphtha, jet fuel, diesel), or combinations thereof. The light crude oil stream 104 may have any of the compositions, properties, or other features previously discussed in the present disclosure for the light crude oil stream 104. The cracking catalyst 134 may have any of the compositions, features, or properties previously described herein for the cracking catalyst 134. The cracking catalyst 134 may contact the hydrocarbon molecules in the treated plastic derived oil stream 126 and the light crude oil stream 104 and crack at least a portion of the hydrocarbon molecules, which may produce greater value circular chemicals and low-carbon fuels, such as but not limited to the light olefins, naphtha, LCO, HCO, or any combination thereof.

[0124] The treated plastic derived oil stream 126 and the light crude oil stream 104 may be combined upstream of the cracking reactor or may be separately and independently passed to the cracking reactor and combined within the cracking reactor. The weight ratio of the treated plastic derived oil stream to the light crude oil stream introduced to the cracking reactor is from 0.1 to 1, such as from 0.1 to 0.8, from 0.1 to 0.6, from 0.1 to 0.5, from 0.1 to 0.4, from 0.2 to 1, from 0.2 to 0.8, from 0.2 to 0.6, from 0.2 to 0.5, from 0.2 to 0.4, from 0.3 to 1, from 0.3 to 0.8, from 0.3 to 0.6, from 0.3 to 0.5, from 0.5 to 1, from 0.5 to 0.8, or from 0.6 to 1.

[0125] Treating the plastic derived oil stream 102 may include contacting the plastic derived oil stream 102 with the 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, such as halogen gases, from the plastic derived oil stream 102 to produce the acid gas removal effluent 114. The acid gas removal catalyst may be a solid alkali metal salt. 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 processes may further include separating the acid gas removal effluent 114 to produce the treated plastic derived oil stream 126 and a non-condensable gas stream 124. The acid gas removal effluent 114 may be separated in the PDO separation system 120, which may have any of the features or configurations previous described for the PDO separation system 120.

[0126] The processes of the present disclosure may include contacting the treated plastic derived oil stream and the light crude oil with the cracking catalyst in the cracking reactor 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 and the light crude oil stream with the cracking catalyst in the cracking 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. The cracking reactor may be a fixed bed reactor, a moving bed reactor, a fluidized catalytic cracking reactor or any other type of reactor. Referring again to FIG. 2, in embodiments, the cracking reactor may be the fixed bed reactor 180, which may have any of the features, configurations, or operating conditions previously described herein for the fixed bed reactor 180.

[0127] Referring again to FIG. 1, in embodiments, the cracking system may be the FCC system 130, which may have any of the features, configurations, catalysts, or operating conditions described in the present disclosure for the FCC system 130. Referring again to FIG. 1, the processes disclosed herein may include combining the treated plastic derived oil stream 126 and the light crude oil stream 104 and the cracking catalyst 134, such as the regenerated cracking catalyst 152, at the inlet end of the FCC reactor 132, where the treated plastic derived oil stream 126, the light crude oil stream 104, and the cracking catalyst 134 may be contacted and may travel together through the FCC reactor 132. The processes may include contacting the treated plastic derived oil stream 126 and the light crude oil stream 104 with the cracking catalyst 134 in the FCC reactor 132 at 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 134 through the FCC reactor 132 divided by the total combined mass flow rate of the treated plastic derived oil stream 126 and the light crude oil stream 104 to the FCC reactor 132. In embodiments, the catalyst-to-oil weight ratio in the FCC reactor 132 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.

[0128] The processes may include separating the cracking effluent 142 from the used cracking catalyst 144 downstream of the FCC reactor 132. Separating the cracking effluent 142 from the used cracking catalyst 144 may be accomplished by the fluid-solid separation unit 140 disposed at the outlet end of the FCC reactor 132. The processes may include passing the contents of the FCC reactor 132 to the fluid-solid separation unit 140 that separates the contents of the FCC reactor 132 into the cracking effluent 142 and the used cracking catalyst 144. The cracking effluent 142 may comprise the circular chemicals, low carbon fuel components, or both. The circular chemicals, low carbon fuel components, or both may include but are not limited to light olefins, naphtha, light cycle oil (LCO), heavy cycle oil (HCO), or any combinations of these constituents. The cracking effluent 142 may have a greater concentration of light olefins, such as but not limited to ethylene, propylene, mixed butenes, or combinations thereof; naphtha; or combinations thereof compared the combination of the treated plastic derived oil stream 126 and the light crude oil stream 104. In embodiments, the cracking effluent 142 may comprise less than 100 ppmw halogen-containing compounds based on the total weight of the cracking effluent 142, 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 cracking effluent 142.

[0129] The processes of the present disclosure may include passing the used cracking catalyst 144 to the catalyst regenerator 150, and regenerating the used cracking catalyst 144 in the catalyst regenerator 150 to produce the regenerated cracking catalyst 152. The regenerated cracking catalyst 152 may have a reduced concentration of halogens compared to the used cracking catalyst 144 prior to regeneration. The regenerated cracking catalyst 152 may also have reduced coke deposits, greater temperature, or both compared to the used cracking catalyst 144 prior to regeneration. In embodiments, regenerating the used cracking catalyst 144 may include contacting the used cracking catalyst 144 with the regeneration gas 154 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 154 may be an oxygen-containing gas, such as but not limited to air. In embodiments, regenerating the used cracking catalyst 144 may include contacting the used cracking catalyst 144 with the regeneration gas 154 in the catalyst regenerator 150 at the regeneration temperature that is greater than the operating temperature of the FCC reactor 132, 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 154 for the catalyst regenerator 150 may also include a fuel gas or a fuel oil. Combustion of the fuel gas and / or fuel oil in the catalyst regenerator 150 may increase the heat generated in the catalyst regenerator 150, thereby increasing the regeneration temperature in the catalyst regenerator 150. The processes may further include passing a flue gas 156 out of the catalyst regenerator 150, wherein the flue gas 156 may comprise unreacted regeneration gases and combustion gases produced from combustion of the coke deposits and any fuel gases added to the catalyst regenerator 150. The catalyst regenerator 150 may have any of the other features, configuration, or operating conditions described herein for the catalyst regenerator.

[0130] The processes of the present disclosure may further include separating the cracking effluent 142 in the cracking effluent separation system 160 to produce a plurality of product streams, such as but not limited to an ethylene stream, a propylene stream, a mixed butenes stream, a naphtha stream, an LCO stream, an HCO stream, or combinations of these product streams. In embodiments, the product streams may include a light gas stream 162, one or more light olefin streams 164, a naphtha stream 166, an LCO stream 168, an HCO stream 170, or any combinations of these product streams.

[0131] 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 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 and melting and dehalogenating 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 reactor 20 and subjecting the liquefied plastic stream 14 to pyrolysis in the pyrolysis reactor 20 to produce the plastic derived oil stream 102. The solid waste plastic 12 may comprise mixed plastics of different compositions, as previous discussed herein. Melting and dehalogenating the solid waste plastic 12 may comprise increasing a temperature of the solid waste plastic 12 to a temperature of from 250° C. and 300° C. Subjecting the liquefied plastic stream 14 to pyrolysis in the pyrolysis reactor 20 may comprise increasing a temperature of the liquefied plastic stream 14 to a temperature of from 350° C. to 1000° C. in the pyrolysis reactor 20.EXAMPLES

[0132] 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.Cracking Evaluation

[0133] In the Examples of the present disclosure, hydrocarbon feed streams (plastic derived oil, light crude oil, or both) were catalytically cracked with a cracking catalyst using a micro activity test (MAT) instrument having a quartz reactor. The MAT instrument was obtained from Sakuragi Rikagaku (Japan). The cracking of the various hydrocarbon feed streams was conducted and evaluated according to standard test method ASTM D-3907.

[0134] Referring to FIG. 4, the MAT unit 300 used for the MAT testing in these examples is schematically depicted. The MAT unit 300 includes a fixed bed quartz tubular reactor 303. The catalyst 304 is loaded into the fixed bed quartz tubular reactor 303 in between layers of quartz wool 306. The catalyst 304 is steam deactivated at 810° C. for six hours prior to the reaction to hydrothermally age the catalyst 304 to mimic the equilibrium catalyst in commercial operation. The catalyst 304 in the fixed bed quartz tubular reactor 303 is heated by a furnace 322, which includes a top heater 324, a middle heater 326, and a bottom heater 328. The feed 302 is injected into the top of the fixed bed quartz tubular reactor 303 through a feed syringe. The feed 302 can be heated prior to injection with the syringe heater 318. The injection site can be heated prior to injection by the pre-heater 320. The feed 302 is in contact with the catalyst 304 for a time on stream of thirty seconds per reaction test cycle. The reaction temperature is controlled using temperature controller 316, which is integrated with the furnace 322. After contacting the feed 302 with the catalyst 304, the reaction effluent, which comprises liquid products and gaseous products, is passed out of the fixed bed quartz tubular reactor 303. After the reaction, the catalyst 304 is stripped using nitrogen gas 314, which enters the fixed bed quartz tubular reactor at 30 cm3 / min.

[0135] The liquid products created by the reaction are collected in the liquid receiver 308, and the gaseous products created by the reaction are collected in the gas collectors 310 through water displacement. The liquid receiver 308 is submerged in a low temperature circulating bath maintained at −10° C. to condense the liquid products. The gaseous products are then analyzed by the gas chromatograph 312. The liquid products are analyzed by simulated distillation according to test method EN 15199-2 using the Agilent 7890 gas chromatograph and naphtha analysis techniques.Example 1: Co-Cracking of Plastic Derived Oil and AL Crude Oil

[0136] In Example 1, AL crude oil was co-processed with a plastic derived oil through fluidized catalytic cracking using a cracking catalyst. The cracking catalyst for Example 1 is provided in Table 3. The composition and properties for the plastic derived oil stream (PDO) used for Example 1 is provided in Table 1, and the composition and properties for the AL crude oil of Example 1 are found in Table 2. For Example 1, the hydrocarbon feed introduced to the MAT unit consisted of 10 wt. % of the plastic derived oil (PDO) and 90 wt. % of the AL crude oil.TABLE 3Cracking Catalyst for Example 1ComponentWeight %NotesZSM-520Phosphorus impregnated at 7.5 wt %P2O5 on zeoliteUSY21Lanthanum impregnated at 2.5 wt %La2O3 on zeoliteAlumina8Pural SB from SasolClay49KaolinSilica2Added as colloidal silica Ludox TM-40

[0137] In Example 1, the catalytic cracking of the hydrocarbon feed comprising the AL crude oil and the plastic derived oil with the cracking catalyst was carried out in the MAT unit 300 of FIG. 3 according to standard test method ASTM D-3907. Prior to evaluation, the cracking catalyst was steam deactivated in a 100% steam environment at 810° C. for 6 hours prior to conducting the cracking reactions. The AL crude oil and the plastic derived oil were combined and mixed thoroughly to produce a homogeneous hydrocarbon feed prior to introducing the hydrocarbon feed to the MAT unit 300. The experiment was conducted in the MAT unit 300 at 30 seconds time-on-stream (TOS). The cracking reaction was conducted at a temperature of 650° C. The catalyst-to-oil weight ratio for Example 1 was about 5.

[0138] For conducting the cracking reaction, the feed syringe and fixed bed quartz tubular reactor 303 were placed in the heating zone of the syringe heater 318 and furnace 322, respectively. Before feed injection, the system was purged with nitrogen (N2) flow at 30 cm3 / min for about 15 min. The liquid receiver 308 with the product vial was then connected to the bottom of the fixed bed quartz tubular reactor 303. The other end of the liquid receiver 308 was connected to the gas collectors 310 (i.e., burette) for gas collection. A leak test was performed and a low-temperature bath was raised to cover the liquid receiver 308. The system was continuously purged with N2 gas for another 15 min. The fixed bed quartz tubular reactor 303 was charged with a known amount of the cracking catalyst, which had been previously steam deactivated. The hydrocarbon feed was then fed to the fixed bed quartz tubular reactor 303 for the time on stream of 30 seconds along with 30 cm3 / min of N2 flow.

[0139] After each reaction, the cracking catalyst was stripped using nitrogen (N2) at a flow rate of 30 cubic centimeters per minute (cm3 / min) for 5 minutes. The liquid products were collected in the liquid receiver 308 and the gaseous products were collected in the gas collectors 310 (i . . . e., gas burette) by water displacement and sent to the gas chromatograph (GC) for analysis. The gaseous products were 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.

[0140] For the simulated distillation, the analysis was conducted for four distillation fractions: (1) light hydrocarbon gases having 1-4 carbon atoms; (2) a naphtha fraction having a boiling point range of from 0° C. to 221° C.; (3) an LCO fraction having a boiling point range of from 221° C. to 343° C.; and (4) an HCO fraction having boiling point temperatures of greater than 343° C. The light hydrocarbon gases were further classified into fuel gas (CH4), C2-C4 paraffin compounds, ethylene, propylene, and butenes. 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, and then passing the combustion gases through a CO2 analyzer, which included a calibrated infrared analyzer. The MAT results of Example 1 for cracking the hydrocarbon feed comprising the AL crude oil and the plastic derived oil is provided in FIG. 5 and in Table 4.Comparative Example 2: Cracking of Plastic Derived Oil Only

[0141] For Comparative Example 2, the plastic derived oil, by itself (no AL crude oil), was contacted with the cracking catalyst in the MAT unit 300 according to the testing methods discussed above in Example 1. The composition of the plastic derived oil for Comparative Example 2 is in Table 1, and the cracking catalyst was the same as the cracking catalyst used in Example 1. 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 Example 1. The results for Comparative Example 2 (CE-2) are provided in Table 4 and FIG. 5.Comparative Example 3: Cracking of Light Crude Oil Only

[0142] For Comparative Example 3 (CE-3), the light crude oil, by itself (no plastic derived oil), was contacted with the cracking catalyst in the MAT unit 300 according to the testing methods discussed above in Example 1. For Comparative Example 3, the light crude oil was the AL crude oil, for which the composition and properties are provided in Table 2. The cracking catalyst was the same as the cracking catalyst used in Example 1. The cracking catalyst was steam deactivated, as previously discussed, and then contacted with the AL crude oil under the same reaction conditions provided herein for Example 2 and Comparative Example 2. The results for Comparative Example 3 (CE-3) are provided in Table 4 and FIG. 5.Co-Cracking Testing Results

[0143] The results of the catalytic cracking testing for Example 1 and Comparative Examples 2 and 3 are provided in Table 4 and in FIG. 5.TABLE 4MAT Testing Results for Example 1and Comparative Examples 2 and 3Example 1CE-2CE-3Feed Composition10% PDO + 90%100% PDO100% ALAL Crude OilCrude OilTime on Stream (seconds)303030Temperature (° C.)650650650Catalyst-to-Oil Ratio555Overall Conversion(%)88.7894.6584.62Fuel Gas (CH4) (wt. %)5.054.173.31C2-C4 paraffin (wt. %)7.606.566.41Ethylene (wt. %)8.8911.348.27Propylene (wt. %)19.0926.3417.48Butenes (wt. %)10.9015.759.74Naphtha (wt. %)33.1629.3433.95LCO (wt. %)9.094.9112.72HCO (wt. %)2.130.442.66Coke (wt. %)4.081.155.47

[0144] Referring to FIG. 5 and Table 4, the results show that the plastic derived oil can be directly cracked to produce light olefins and fuel components through catalytic cracking. The results in FIG. 5 and Table 4 also show that co-processing of 10% by weight of the plastic derived oil with the AL crude oil can improve the conversion of the AL crude to enhance the product distribution. In particular, the conversion increased from 84.62% for AL crude by itself to 88.78% for the combination of AL crude and 10 wt. % plastic derived oil. In contrast, cracking 10 wt. % plastic derived oil by itself at 94.65% conversion and cracking 90 wt. % AL crude oil by itself at 84.62% conversion would result in a combined conversion of only about 85.6% (10 wt. %*94.65% conversion)+ (90 wt. %*84.62% conversion)=85.623%). Thus, combining the plastic derived oil and the AL crude oil and co-processing the plastic derived oil and the AL crude oil resulted in an unexpected synergistic effect that further increased the conversion by an amount greater than expected compared to cracking AL crude oil by itself.

[0145] Co-cracking the plastic derived oil and the AL crude oil also increased the yields of light olefins (ethylene, propylene, butenes) compared to the yield of light olefins from cracking the AL crude oil by itself. The yield of light olefins from co-cracking the plastic derived oil and the AL crude oil were also found to be greater than would be expected from cracking the AL crude oil by itself, cracking the plastic derived oil by itself, and adding the yields. For propylene, the yield of propylene from co-cracking the AL Crude oil and plastic derived oil was 19.09 wt. %. However, if 10 wt. % plastic derived oil is cracked by itself at 29.34 wt. % yield of propylene, 90 wt. % AL crude oil is cracked by itself at 17.48 wt. % yield of propylene, and the results added together, the total combined yield of propylene would be expected to be 18.66 wt. % ((10 wt. %*29.34 wt. %)+ (90 wt. %*17.48 wt. %)=18.66 wt. %). Thus, co-processing the AL crude oil and plastic derived oil in the catalytic cracking process resulted in an unexpected synergistic effect that further increased the yields of the light olefins by an amount greater than expected compared to cracking each by itself.

[0146] The yield of naphtha was about the same. Co-processing of the AL crude oil and plastic derived oil reduced the yields of LCO and HCO compared to cracking the AL crude oil by itself. Co-cracking of the AL crude oil and plastic derived oil also reduced the yield of coke from the catalytic cracking process.

[0147] A first aspect of the present disclosure may be directed to a process for producing circular chemicals and low-carbon fuels. The process may comprise producing a plastic derived oil stream from solid waste plastic; treating the plastic derived oil stream to produce a treated plastic derived oil stream having 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 light crude oil stream to a cracking reactor; and contacting the treated plastic derived oil stream and the light crude oil stream with a cracking catalyst in the cracking reactor. Contacting of the treated plastic derived oil stream and the light crude oil stream with the cracking catalyst at a reaction temperature in the cracking reactor may cause at least a portion of hydrocarbons from the treated plastic derived oil stream and the light crude oil stream to undergo catalytic cracking reactions to produce a cracking effluent comprising circular chemicals, low-carbon fuels, or both.

[0148] A second aspect of the present disclosure may include the first aspect, where a weight ratio of the treated plastic derived oil stream to the light crude oil stream introduced to the cracking reactor may be from 0.1 to 1.

[0149] A third aspect of the present disclosure may include any one of the first or second aspects, where the light crude oil stream may be an Arab light crude oil.

[0150] A fourth aspect of the present disclosure may include any one of the first through third aspects, where the light crude oil stream may have one or more of the following: a concentration of paraffin compounds of less than 50 wt. % per unit weight of the light crude oil stream; a concentration of aromatic compounds of greater than or equal to 20 wt. % per unit weight of the light crude oil stream; a concentration of naphthenes of greater than or equal to 25 wt. % per unit weight of the light crude oil stream; or any combination thereof.

[0151] A fifth aspect of the present disclosure may include any one of the first through fourth aspects, where the light crude oil stream may have one or more of the following: less than 30 ppmw vanadium, such as less than 25 ppmw or less than 20 ppmw; less than 15 ppmw nickel, such as less than 10 ppmw nickel; less than 5 ppmw iron, such as less than 2 ppmw iron; or any combinations thereof.

[0152] A sixth aspect of the present disclosure may include any one of the first through fifth aspects, where the light crude oil stream may have an API gravity of from 30 degrees to 35 degrees, such as from 31 degrees to 34 degrees, from 31 degrees to 33 degrees, or about 32.8 degrees.

[0153] A seventh aspect of the present disclosure may include any one of the first through sixth aspects, where the light crude oil stream may have a density of from 0.85 g / cm3 to 0.87 g / cm3.

[0154] An eighth aspect of the present disclosure may include any one of the first through seventh aspects, where the light crude oil stream may have a nitrogen concentration of from 500 ppmw to 1600 ppmw, such as from 500 ppmw to 1000 ppmw, per unit weight of the light crude oil stream.

[0155] A ninth aspect of the present disclosure may include any one of the first through eighth aspects, where the light crude oil stream may have a sulfur concentration of less than 2.4 wt. %, such as from 1.9 wt. % to 2.4 wt. %, per unit weight of the light crude oil stream.

[0156] A tenth aspect of the present disclosure may include any one of the first through ninth aspects, where the light crude oil stream may have an initial boiling point from 20° C. to 40° C. and an end boiling point less than or equal to 720° C.

[0157] An eleventh aspect of the present disclosure may include any one of the first through tenth aspects, where the light crude oil stream may have a 50 wt. % boiling point temperature of from 290° C. to 350° C., a 90 wt. % boiling point temperature of from 550° C. to 700° C., or both.

[0158] A twelfth aspect of the present disclosure may include any one of the first through eleventh aspects, where the plastic derived oil stream may have a density of from 0.65 g / cm3 to 1.1 g / cm3.

[0159] A thirteenth aspect of the present disclosure may include any one of the first through twelfth aspects, where the plastic derived oil stream may have a chloride concentration of greater than or equal to 100 ppmw based on the total weight of the plastic derived oil stream.

[0160] A fourteenth aspect of the present disclosure may include any one of the first through thirteenth aspects, where the plastic derived oil stream may have an oxygen content of from 100 ppmw to 10,000 ppmw based on the total weight of the plastic derived oil stream.

[0161] A fifteenth aspect of the present disclosure may include any one of the first through fourteenth aspects, where the plastic derived oil stream may have an initial boiling point temperature of from 20° C. to 100° C.

[0162] A sixteenth aspect of the present disclosure may include any one of the first through fifteenth aspects, where the plastic derived oil stream may have a final boiling point temperature of from 300° C. to 600° C.

[0163] A seventeenth aspect of the present disclosure may include any one of the first through sixteenth aspects, where the plastic derived oil stream may have a 50% boiling point temperature of from 150° C. to 350° C.

[0164] An eighteenth aspect of the present disclosure may include any one of the first through seventeenth 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.

[0165] A nineteenth aspect of the present disclosure may include any one of the first through eighteenth aspects, where treating the plastic derived oil stream may comprise: 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 may remove acid gases from the plastic derived oil stream to produce an acid gas removal effluent; and separating the acid gas removal effluent to produce the treated plastic derived oil stream and a non-condensable gas stream.

[0166] A twentieth aspect of the present disclosure may include the nineteenth aspect, where the acid gas removal catalyst may be a solid inorganic alkali metal salt.

[0167] A twenty-first aspect of the present disclosure may include any one of the first through twentieth aspects, where the cracking catalyst may comprise a USY zeolite and a ZSM-5 zeolite.

[0168] A twenty-second aspect of the present disclosure may include any one of the first through twenty-first aspects, where the cracking catalyst may comprise ultrastable Y-type zeolite (USY zeolite) impregnated with lanthanum, ZSM-5 zeolite impregnated with phosphorous, an alumina binder, colloidal silica, and a matrix material.

[0169] A twenty-third aspect of the present disclosure may include any one of the first through twenty-second aspects, where the cracking catalyst may comprise: from 10 wt. % to 30 wt. % USY-type zeolite based on the total weight of the cracking catalyst, where the USY-type zeolite may comprise from 1 wt. % to 10 wt. % lanthanum oxide (La2O3) based on the total weight of the USY-type zeolite; from 10 wt. % to 30 wt. % ZSM-5 zeolite based on the total weight of the cracking catalyst, where the ZSM-5 zeolite may be impregnated with from 1 wt. % to 15 wt. % phosphorous pentoxide based on the total weight of the ZSM-5 zeolite; from 10 wt. % to 20 wt. % alumina binder based on the total weight of the cracking catalyst; from 20 wt. % to 60 wt. % Kaolin clay based on the total weight of the cracking catalyst; and from 0 wt. % to 10 wt. % colloidal silica based on the total weight of the cracking catalyst.

[0170] A twenty-fourth aspect of the present disclosure may include any one of the first through twenty-third aspects, further comprising contacting the plastic derived oil stream and the light crude oil stream with the cracking catalyst in the cracking reactor at a reaction temperature of from 500° C. to 650° C.

[0171] A twenty-fifth aspect of the present disclosure may include any one of the first through twenty-fourth aspects, further comprising contacting the plastic derived oil stream and the light crude oil stream with the cracking catalyst in the cracking 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.

[0172] A twenty-sixth aspect of the present disclosure may include any one of the first through twenty-fifth aspects, where the cracking reactor may comprise a fluidized catalytic cracking (FCC) reactor and the process further may comprise contacting the treated plastic derived oil stream and the light crude oil stream with the cracking catalyst in the FCC reactor at 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 light crude oil stream to the FCC reactor.

[0173] A twenty-seventh aspect of the present disclosure may include the twenty-sixth aspect, further comprising separating used cracking catalyst from the cracking effluent in a fluid-solid separation unit disposed 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.

[0174] A twenty-eighth aspect of the present disclosure may include any one of the first through twenty-seventh aspects, where the cracking reactor may comprise a fixed bed reactor.

[0175] A twenty-ninth aspect of the present disclosure may include any one of the first through twenty-eighth aspects, where producing the plastic derived oil stream from solid waste plastic may comprise: 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.

[0176] A thirtieth aspect of the present disclosure may include the twenty-ninth aspect, 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.

[0177] A thirty-first aspect of the present disclosure may include either one of the twenty-ninth or thirtieth 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.

[0178] A thirty-second aspect of the present disclosure may be directed to a system for upgrading solid waste plastics and light crude oil into circular chemicals and low carbon fuels. The system may comprise a plastic derived oil stream derived from solid waste plastic; 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 cracking reactor system disposed downstream of the acid gas removal unit and comprising a cracking reactor and a cracking catalyst disposed in the cracking reactor, where the cracking 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 cracking reactor; and a light crude oil stream in fluid communication with the cracking reactor to pass the light crude oil stream to the cracking reactor. The cracking reactor may be configured to contact the treated plastic derived oil stream and the light crude oil stream with the cracking catalyst under reaction conditions to produce a cracking effluent comprising circular chemicals, low carbon fuels, or both.

[0179] A thirty-third aspect of the present disclosure may include the thirty-second aspect, further comprising a plastic derived oil separation system downstream of the acid gas remove unit and upstream of the cracking system, where the plastid derived oil separation system may be configured to separate an effluent from the acid gas removal unit to produce the treated plastic derived oil stream and a non-condensable gas stream.

[0180] A thirty-fourth aspect of the present disclosure may include either one of the thirty-second or thirty-third aspects, 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; and a pyrolysis reactor disposed downstream of the dehalogenation unit and upstream of the acid gas removal unit, the pyrolysis reactor configured to pyrolyze the liquid plastic stream to produce the plastic derived oil stream.

[0181] A thirty-fifth aspect of the present disclosure may include any one of the thirty-second through thirty-fourth aspects, where the acid gas removal catalyst may be a solid inorganic alkali metal salt.

[0182] A thirty-sixth aspect of the present disclosure may include any one of the thirty-second through thirty-fifth aspects, where the cracking catalyst may comprise a USY zeolite and a ZSM-5 zeolite.

[0183] A thirty-seventh aspect of the present disclosure may include any one of the thirty-second through thirty-sixth aspects, where the cracking catalyst may comprise ultrastable Y-type zeolite (USY zeolite) impregnated with lanthanum, ZSM-5 zeolite impregnated with phosphorous, an alumina binder, colloidal silica, and a matrix material.

[0184] A thirty-eighth aspect of the present disclosure may include any one of the thirty-second through thirty-seventh aspects, where the cracking catalyst may comprise from 10 wt. % to 30 wt. % USY-type zeolite based on the total weight of the cracking catalyst, where the USY-type zeolite comprises from 1 wt. % to 10 wt. % lanthanum oxide (La2O3) based on the total weight of the USY-type zeolite; from 10 wt. % to 30 wt. % ZSM-5 zeolite based on the total weight of the cracking catalyst, where the ZSM-5 zeolite is impregnated with from 1 wt. % to 15 wt. % phosphorous pentoxide based on the total weight of the ZSM-5 zeolite; from 10 wt. % to 20 wt. % alumina binder based on the total weight of the cracking catalyst; from 20 wt. % to 60 wt. % Kaolin clay based on the total weight of the cracking catalyst; and from 0 wt. % to 10 wt. % colloidal silica based on the total weight of the cracking catalyst.

[0185] A thirty-ninth aspect of the present disclosure may include any one of the thirty-second through thirty-eighth aspects, where the cracking reactor system may comprise a fluidized catalytic cracking (FCC) system and the cracking reactor comprises an FCC reactor.

[0186] A fortieth aspect of the present disclosure may include the thirty-ninth aspect, 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.

[0187] A forty-first aspect of the present disclosure may include any one of the thirty-second through thirty-eighth aspects, where the cracking reactor system may comprise a fixed bed reactor system and the cracking reactor may comprise a fixed bed reactor.

[0188] A forty-second aspect of the present disclosure may include any one of the thirty-second through forty-first aspects, where the light crude oil stream may be an Arab light crude oil.

[0189] A forty-third aspect of the present disclosure may include any one of the thirty-second through forty-second aspects, where the light crude oil stream may have one or more of the following: a concentration of paraffin compounds of less than 50 wt. % per unit weight of the light crude oil stream; a concentration of aromatic compounds of greater than or equal to 20 wt. % per unit weight of the light crude oil stream; a concentration of naphthenes of greater than or equal to 25 wt. % per unit weight of the light crude oil stream; or any combination thereof.

[0190] A forty-fourth aspect of the present disclosure may include any one of the thirty-second through forty-third aspects, where the light crude oil stream may have one or more of the following: less than 30 ppmw vanadium, such as less than 25 ppmw or less than 20 ppmw; less than 15 ppmw nickel, such as less than 10 ppmw nickel; less than 5 ppmw iron, such as less than 2 ppmw iron; or any combinations thereof.

[0191] A forty-fifth aspect of the present disclosure may include any one of the thirty-second through forty-fourth aspects, where the light crude oil stream may have one or more of the following characteristics: an API gravity of from 30 degrees to 35 degrees, such as from 31 degrees to 34 degrees, from 31 degrees to 33 degrees, or about 32.8 degrees; a density of from 0.85 g / cm3 to 0.87 g / cm3; a nitrogen concentration of from 500 ppmw to 1600 ppmw, such as from 500 ppmw to 1000 ppmw, per unit weight of the light crude oil stream; a sulfur concentration of less than 2.4 wt. %, such as from 1.9 wt. % to 2.4 wt. %, per unit weight of the light crude oil stream; an initial boiling point from 20° C. to 40° C.; an end boiling point less than or equal to 720° C.; a 50 wt. % boiling point temperature of from 290° C. to 350° C.; a 90 wt. % boiling point temperature of from 550° C. to 700° C.; or any combinations thereof.

[0192] A forty-sixth aspect of the present disclosure may include any one of the thirty-second through forty-fifth 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.

[0193] 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.

[0194] It is noted that one or more of the following claims utilize the term “where” as a transitional phrase, which 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.”

[0195] 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.

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;treating the plastic derived oil stream with an acid gas removal catalyst to produce a treated plastic derived oil stream having 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 light crude oil stream to a cracking reactor; andcontacting the treated plastic derived oil stream and the light crude oil stream with a cracking catalyst in the cracking reactor, where the contacting of the treated plastic derived oil stream and the light crude oil stream with the cracking catalyst at a reaction temperature in the cracking reactor causes at least a portion of hydrocarbons from the treated plastic derived oil stream and the light crude oil stream to undergo catalytic cracking reactions to produce a cracking effluent comprising circular chemicals, low-carbon fuels, or both.

2. The process of claim 1, where a weight ratio of the treated plastic derived oil stream to the light crude oil stream introduced to the cracking reactor is from 0.1 to 1.

3. The process of claim 1, where the light crude oil stream is an Arab light crude oil.

4. The process of claim 1, where the light crude oil stream has an API gravity of from 30 degrees to 35 degrees, a density of from 0.85 g / cm3 to 0.87 g / cm3, or both.

5. The process of claim 1, where the light crude oil stream has an initial boiling point from 20° C. to 40° C. and an end boiling point less than or equal to 720° C.

6. The process of claim 1, where the light crude oil stream has a 50 wt. % boiling point temperature of from 290° C. to 350° C., a 90 wt. % boiling point temperature of from 550° C. to 700° C., or both.

7. The process of claim 1, where the plastic derived oil stream has a density of from 0.65 g / cm3 to 1.1 g / cm3.

8. The process of claim 1, where the plastic derived oil stream has a chloride concentration of greater than or equal to 100 ppmw based on the total weight of the plastic derived oil stream.

9. The process of claim 1, where the plastic derived oil stream has an initial boiling point temperature of from 20° C. to 100° C. and a final boiling point temperature of from 300° C. to 600° C.

10. 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.

11. The process of claim 1, where treating the plastic derived oil stream with the acid gas removal catalyst comprises:contacting the plastic derived oil stream with the 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 an acid gas removal effluent; andseparating the acid gas removal effluent to produce the treated plastic derived oil stream and a non-condensable gas stream.

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

13. The process of claim 1, where the cracking catalyst comprises a USY zeolite and a ZSM-5 zeolite.

14. The process of claim 1, further comprising contacting the plastic derived oil stream and the light crude oil stream with the cracking catalyst in the cracking reactor at a reaction temperature of from 500° C. to 650° C., a pressure of 101 kPa to 303 kPa, a gas hourly space velocity of from 0.2 per hour (h−1) to 100 h−1, or combinations thereof.

15. The process of claim 1, where the cracking reactor comprises a fluidized catalytic cracking (FCC) reactor and the process further comprises contacting the treated plastic derived oil stream and the light crude oil stream with the cracking catalyst in the FCC reactor at 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 light crude oil stream to the FCC reactor.

16. The process of claim 15, further comprising separating used cracking catalyst from the cracking effluent in a fluid-solid separation unit disposed 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.

17. The process of claim 1, where the cracking reactor comprises a fixed bed reactor.

18. A system for upgrading solid waste plastics and light crude oil into circular chemicals and low carbon fuels, the system comprising:a plastic derived oil stream derived from solid waste plastic;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 cracking reactor system disposed downstream of the acid gas removal unit and comprising a cracking reactor and a cracking catalyst disposed in the cracking reactor, where the cracking 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 cracking reactor; anda light crude oil stream in fluid communication with the cracking reactor to pass the light crude oil stream to the cracking reactor;where the cracking reactor is configured to contact the treated plastic derived oil stream and the light crude oil stream with the cracking catalyst under reaction conditions to produce a cracking effluent comprising circular chemicals, low carbon fuels, or both.

19. The system of claim 18, wherein the acid gas removal unit further comprises a plastic derived oil separation system downstream of the reaction vessel and upstream of the cracking reactor system, where the plastic derived oil separation system is configured to separate an acid gas removal effluent from the reaction vessel to produce the treated plastic derived oil stream and a non-condensable gas stream.

20. The system of claim 18, 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 and upstream of the acid gas removal unit, the pyrolysis reactor configured to pyrolyze the liquid plastic stream to produce the plastic derived oil stream.

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