Abstract: A continuous process for converting waste plastic into recycle for polypropylene polymerization is provided. The process integrates refinery operations to provide an effective and efficient recycle process. The process comprises selecting waste plastics containing polyethylene and polypropylene and then passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is separated into offgas, a naphtha/diesel fraction, a heavy fraction, and char. The naphtha/diesel fraction is passed to a refinery FCC unit, from which is recovered a liquid petroleum gas C3 olefin/paraffin mixture. The C3 paraffins and C3 olefins are separated into different fractions with a propane/propylene splitter. The C3 olefin fraction is passed to a propylene polymerization reactor.

Abstract: Provided is a hydrocracking process with a recycle loop for converting a petroleum feed to lower boiling products, which process comprises reacting a stream over a non-zeolite noble metal catalyst at a temperature of about 650° F. (343° C.) or less in a reactor positioned in the recycle loop of the hydrocracking reactor.

Abstract: Provided in one embodiment is a continuous process for converting waste plastic into recycle for polyethylene polymerization. The process comprises selecting waste plastics containing polyethylene and/or polypropylene, and passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is separated into offgas, a pyrolysis oil and optionally pyrolysis wax comprising a naphtha/diesel fraction and heavy fraction, and char. The pyrolysis oil and wax is passed to a refinery FCC feed pretreater unit. A heavy fraction is recovered and sent to a refinery FCC unit, from which a C3 olefin/paraffin mixture fraction is recovered, which is passed to a steam cracker for ethylene production. In another embodiment, a propane fraction (C3) is recovered from a propane/propylene splitter and passed to the steam cracker.

Abstract: Provided in one embodiment is a continuous process for converting waste plastic into recycle for polyethylene polymerization. The process comprises selecting waste plastics containing polyethylene and/or polypropylene, and passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is separated into offgas, a pyrolysis oil and optionally pyrolysis wax comprising a naphtha/diesel fraction and heavy fraction, and char. The pyrolysis oil and wax is passed to a refinery FCC feed pretreater unit. A heavy fraction is recovered and sent to a refinery FCC unit, from which a C3 olefin/paraffin mixture fraction is recovered, which is passed to a steam cracker for ethylene production. In another embodiment, a propane fraction (C3) is recovered from a propane/propylene splitter and passed to the steam cracker.

Abstract: Provided in one embodiment is a continuous process for converting waste plastic into recycle for polyethylene polymerization. The process comprises selecting waste plastics containing polyethylene and/or polypropylene, and passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is separated into offgas, a pyrolysis oil and optionally wax comprising a naphtha/diesel and heavy fraction, and char. The pyrolysis oil and wax is passed to a refinery FCC unit from which a liquid petroleum gas C3-C5 olefin/paraffin mixture fraction is recovered. The liquid petroleum gas C3-C5 olefin/paraffin mixture fraction is passed to a refinery alkylation unit, with a propane and butane fraction recovered from the alkylation unit. The propane and butane fraction is then passed to a steam cracker for ethylene production.

Abstract: A process of making a silica-alumina composition having improved properties is provided. The process includes (a) mixing an aqueous solution of a silicon compound and an aqueous solution of an aluminum compound and an acid, while maintaining a pH of the mixed solution in a range of 1 to 3, and obtaining an acidified silica-alumina sol; (b) adding an aqueous solution of a base precipitating agent to the acidified silica-alumina sol to a final pH in a range of 5 to 8, and co-precipitating a silica-alumina slurry, wherein the base precipitating agent is selected from ammonium carbonate, ammonium bicarbonate, and any combination thereof; (c) optionally, hydrothermally aging the silica-alumina slurry to form a hydrothermally aged silica-alumina slurry; and (d) recovering a precipitate solid from the silica-alumina slurry or the hydrothermally aged silica-alumina slurry, wherein the precipitate solid comprises the silica-alumina composition.

Abstract: A process of making a silica-alumina composition having improved properties is provided. The process includes (a) mixing an aqueous solution of a silicon compound and an aqueous solution of an aluminum compound and an acid, while maintaining a pH of the mixed solution in a range of 1 to 3, and obtaining an acidified silica-alumina sol; (b) adding an aqueous solution of a base precipitating agent to the acidified silica-alumina sol to a final pH in a range of 5 to 8, and co-precipitating a silica-alumina slurry, wherein the base precipitating agent is selected from ammonium carbonate, ammonium bicarbonate, and any combination thereof; (c) optionally, hydrothermally aging the silica-alumina slurry to form a hydrothermally aged silica-alumina slurry; and (d) recovering a precipitate solid from the silica-alumina slurry or the hydrothermally aged silica-alumina slurry, wherein the precipitate solid comprises the silica-alumina composition.

Abstract: Provided is a continuous process for converting waste plastic into recycle for polyethylene polymerization. In one embodiment, the process comprises selecting waste plastics containing polyethylene and/or polypropylene and passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is separated into offgas, a naphtha/diesel fraction, a heavy fraction, and char. The naphtha/diesel fraction is passed to a crude unit distillation column in a refinery where a straight run naphtha (C5-C8) fraction or a propane/butane (C3-C4) fraction is recovered. The straight run naphtha fraction (C5-C8) or the propane/butane (C3-C4) fraction is passed to a steam cracker for ethylene production. The heavy fraction from the pyrolysis unit can also be passed to an isomerization dewaxing unit to produce a base oil.

Abstract: Provided is a continuous process for converting waste plastic into recycle for polyethylene polymerization or for normal alpha olefins. The process comprises selecting waste plastics containing polyethylene and/or polypropylene and then passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is separated into offgas, a naphtha/diesel fraction, a heavy fraction, and char. The naphtha/diesel fraction is passed to a crude unit in a refinery from which is recovered a straight run naphtha fraction (C5-C8) or a propane/butane (C3-C4) fraction. The straight run naphtha fraction, or propane and butane (C3-C4) fraction, is passed to a steam cracker for ethylene production. The ethylene is converted to normal alpha olefin and/or polyethylene. Also, a heavy fraction from the pyrolysis reactor can be combined with a heavy fraction of normal alpha olefin stream recovered from the steam cracker.

Abstract: Processes for the direct alkylation of ethylene with isobutane or isopentane using a highly active ionic liquid alkylation catalyst are described. Ethylene is sent to a high-temperature alkylation reactor loop, and C3, C4, and C5 olefins are routed to a low temperature alkylation reactor loop. In each reactor, the olefins are contacted with an excess of isobutane or isopentane in the presence of a highly active ionic liquid catalyst. Portions of the reactor effluent streams are fed to a common downstream catalyst separation and product fractionation sections. The remainder of the reactor effluent is recycled back to the respective alkylation reactor.

Abstract: Processes for the direct alkylation of ethylene with isobutane or isopentane using a highly active ionic liquid alkylation catalyst are described. Ethylene is sent to a high-temperature alkylation reactor loop, and C3, C4, and C5 olefins are routed to a low temperature alkylation reactor loop. In each reactor, the olefins are contacted with an excess of isobutane or isopentane in the presence of a highly active ionic liquid catalyst. Portions of the reactor effluent streams are fed to a common downstream catalyst separation and product fractionation sections. The remainder of the reactor effluent is recycled back to the respective alkylation reactor.

Abstract: Provided in one embodiment is a continuous process for converting waste plastic comprising polyethylene and/or polypropylene into recycle for polyethylene polymerization. The process comprises selecting waste plastics containing polyethylene, polypropylene, or a mixture thereof, and passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is separated into offgas, a pyrolysis oil comprising a naphtha, diesel and heavy fractions, and char. The pyrolysis oil, or at least a fraction, is passed to a filtration/metal oxide treatment, with the treated product passed to a refinery FCC unit. A liquid petroleum gas C3 olefin/paraffin mixture fraction is recovered from the FCC unit, as well as a C4 olefin/paraffin mixture fraction. The liquid petroleum gas C3 olefin/paraffin mixture fraction is passed to a steam cracker for ethylene production.

Abstract: Provided is a continuous process for converting waste plastic into recycle for polyethylene polymerization or for normal alpha olefins. The process comprises selecting waste plastics containing polyethylene and/or polypropylene and then passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is separated into offgas, a naphtha/diesel fraction, a heavy fraction, and char. The naphtha/diesel fraction is passed to a crude unit in a refinery from which is recovered a straight run naphtha fraction (C5-C8) or a propane/butane (C3-C4) fraction. The straight run naphtha fraction, or propane and butane (C3-C4) fraction, is passed to a steam cracker for ethylene production. The ethylene is converted to normal alpha olefin and/or polyethylene. Also, a heavy fraction from the pyrolysis reactor can be combined with a heavy fraction of normal alpha olefin stream recovered from the steam cracker.

Abstract: Provided in one embodiment is a continuous process for converting waste plastic into recycle for polyethylene polymerization. The process comprises selecting waste plastics containing polyethylene and/or polypropylene, and passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is separated into offgas, a pyrolysis oil and optionally wax comprising a naphtha/diesel and heavy fraction, and char. The pyrolysis oil and wax is passed to a refinery FCC unit from which a liquid petroleum gas C3-C5 olefin/paraffin mixture fraction is recovered. The liquid petroleum gas C3-C5 olefin/paraffin mixture fraction is passed to a refinery alkylation unit, with a propane and butane fraction recovered from the alkylation unit. The propane and butane fraction is then passed to a steam cracker for ethylene production.

Abstract: A continuous process for converting waste plastic into recycle for polypropylene polymerization is provided. The process integrates refinery operations to provide an effective and efficient recycle process. The process comprises selecting waste plastics containing polyethylene and polypropylene and then passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is separated into offgas, a naphtha/diesel fraction, a heavy fraction, and char. The naphtha/diesel fraction is passed to a refinery FCC unit, from which is recovered a liquid petroleum gas C3 olefin/paraffin mixture. The C3 paraffins and C3 olefins are separated into different fractions with a propane/propylene splitter. The C3 olefin fraction is passed to a propylene polymerization reactor.

Abstract: Provided is a continuous process for converting waste plastic into recycle for polypropylene polymerization. The process comprises selecting waste plastics containing polyethylene and/or polypropylene, and passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is separated into offgas, a naphtha/diesel fraction, a heavy fraction, and char. Pyrolysis oil and wax, comprising naphtha/diesel and heavy fractions, is passed to a refinery FCC unit. A liquid petroleum gas C3 olefin/paraffin mixture is recovered from the FCC unit. The C3 paraffins and C3 olefins are separated into different fractions with the C3 olefin fraction passed to a propylene polymerization reactor, and the C3 paraffin fraction passed optionally to a dehydrogenation unit to produce additional propylene.

Abstract: Provided is a continuous process for converting waste plastic into recycle for polyethylene polymerization. In one embodiment, the process comprises selecting waste plastics containing polyethylene and/or polypropylene and passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is separated into offgas, a naphtha/diesel fraction, a heavy fraction, and char. The naphtha/diesel fraction is passed to a crude unit distillation column in a refinery where a straight run naphtha (C5-C8) fraction or a propane/butane (C3-C4) fraction is recovered. The straight run naphtha fraction (C5-C8) or the propane/butane (C3-C4) fraction is passed to a steam cracker for ethylene production. The heavy fraction from the pyrolysis unit can also be passed to an isomerization dewaxing unit to produce a base oil.

Abstract: Provided in one embodiment is a continuous process for converting waste plastic into recycle for polyethylene polymerization. The process comprises selecting waste plastics containing polyethylene and/or polypropylene, and passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is separated into offgas, a pyrolysis oil and optionally pyrolysis wax comprising a naphtha/diesel fraction and heavy fraction, and char. The pyrolysis oil and wax is passed to a refinery FCC feed pretreater unit. A heavy fraction is recovered and sent to a refinery FCC unit, from which a C3 olefin/paraffin mixture fraction is recovered, which is passed to a steam cracker for ethylene production. In another embodiment, a propane fraction (C3) is recovered from a propane/propylene splitter and passed to the steam cracker.

Abstract: Provided in one embodiment is a continuous process for converting waste plastic into recycle for polyethylene polymerization. The process comprises selecting waste plastics containing polyethylene and/or polypropylene, and passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is separated into offgas, a pyrolysis oil and optionally wax comprising a naphtha/diesel and heavy fraction, and char. The pyrolysis oil and wax is passed to a refinery FCC unit from which a liquid petroleum gas C3-C5 olefin/paraffin mixture fraction is recovered. The liquid petroleum gas C3-C5 olefin/paraffin mixture fraction is passed to a refinery alkylation unit, with a propane and butane fraction recovered from the alkylation unit. The propane and butane fraction is then passed to a steam cracker for ethylene production.

Abstract: A continuous process for converting waste plastic into recycle for polypropylene polymerization is provided. The process integrates refinery operations to provide an effective and efficient recycle process. The process comprises selecting waste plastics containing polyethylene and polypropylene and then passing the waste plastics through a pyrolysis reactor to thermally crack at least a portion of the polyolefin waste and produce a pyrolyzed effluent. The pyrolyzed effluent is separated into offgas, a naphtha/diesel fraction, a heavy fraction, and char. The naphtha/diesel fraction is passed to a refinery FCC unit, from which is recovered a liquid petroleum gas C3 olefin/paraffin mixture. The C3 paraffins and C3 olefins are separated into different fractions with a propane/propylene splitter. The C3 olefin fraction is passed to a propylene polymerization reactor.