US 5,969,201 AGranted

Process for the conversion of plastic to produce a synthetic crude oil

AssigneeUop LLC

InventorsTom N. Kalnes, Robert B. James, Jr.

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Abstract

A process for the conversion of plastic to produce a synthetic crude oil by means of contacting the plastic with a hydrocarbonaceous recycle stream in a liquefying zone operated at liquefying conditions to produce a liquefied stream of plastic containing non-distillable particulate matter and at least a portion thereof is filtered. The filtered stream having a reduced concentration of finely divided particulate matter and the balance, if any, of the original liquefied stream together with hydrogen is contacted with a hydro-demetallization catalyst in a hydro-demetallization zone at hydro-demetallization conditions to produce gaseous, water-soluble inorganic compounds. The effluent from the hydro-demetallization zone is contacted with a hydrocracking catalyst in a hydrocracking zone to produce lower boiling hydrocarbons suitable for use as a synthetic crude oil. A recovered hydrogen-rich gaseous stream is preferably recycled to the hydro-demetallization zone. The gaseous, water-soluble inorganic compounds are removed by scrubbing the hydrocracking zone effluent with an aqueous stream. A portion of the hydrocarbons recovered from the hydrocracking zone effluent is recycled to the liquefying zone.

Claims26

Dependent claims

A process for the conversion of plastic to produce a synthetic crude oil which process comprises:

(a) contacting said plastic with a hydrocarbonaceous recycle stream in a liquefying zone operated at liquefying conditions to at least partially liquefy said plastic and produce a liquefied stream comprising liquefied plastic and finely divided particulate matter;
(b) filtering at least a portion of said liquefied stream to produce a filtered stream having a reduced concentration of finely divided particulate matter;
(c) contacting at least a portion of said filtered stream from step (b) and hydrogen with a hydro-demetallization catalyst in a hydro-demetallization zone operated at hydro-demetallization conditions;
(d) contacting a resulting hydrogen-hydrocarbon containing stream from step (c) with a hydrocracking catalyst in a hydrocracking zone operated at hydrocracking conditions to produce an effluent comprising lower boiling hydrocarbons and gaseous, water-soluble inorganic compounds;
(e) condensing at least a portion of the resulting effluent from said hydrocracking zone to produce a gaseous stream comprising hydrogen and said gaseous, water-soluble inorganic compounds, and a liquid stream comprising hydrocarbons;
(f) contacting said gaseous stream comprising hydrogen and said gaseous, water-soluble inorganic compounds with an aqueous solution to recover said gaseous, water-soluble inorganic compounds and to produce a hydrogen-rich gaseous stream;
(g) recycling at least a portion of said liquid stream comprising hydrocarbons to provide the hydrocarbonaceous recycle stream in step (a);
and
(h) recovering at least a portion of said liquid stream comprising hydrocarbons.

6 more elements

A process for the conversion of plastic to produce a synthetic crude oil which process comprises:

(a) contacting said plastic with a hydrocarbonaceous recycle stream in a liquefying zone operated at liquefying conditions to at least partially liquefy said plastic and produce a liquefied stream comprising liquefied plastic and finely divided particulate matter;
(b) separating said liquefied stream to produce a distillable lower boiling stream and a higher boiling stream containing finely divided particulate matter;
(c) filtering said higher boiling stream to produce a filtered stream having a reduced concentration of finely divided particulate matter;
(d) contacting at least a portion of said distillable lower boiling stream from step (b), at least a portion of said filtered stream from step (c), and hydrogen with a hydro-demetallization catalyst in a hydro-demetallization zone operated at hydro-demetallization conditions;
(e) contacting a resulting hydrogen-hydrocarbon containing stream from step (d) with a hydrocracking catalyst in a hydrocracking zone operated at hydrocracking conditions to produce an effluent comprising lower boiling hydrocarbons and gaseous, water-soluble inorganic compounds;
(f) condensing at least a portion of the resulting effluent from said hydrocracking zone to produce a gaseous stream comprising hydrogen and said gaseous, water-soluble inorganic compounds, and a liquid stream comprising hydrocarbons;
(g) contacting said gaseous stream comprising hydrogen and said gaseous, water-soluble inorganic compounds with an aqueous solution to recover said gaseous, water-soluble inorganic compounds and to produce a hydrogen-rich gaseous stream;
(h) recycling at least a portion of said liquid stream comprising hydrocarbons to provide the hydrocarbonaceous recycle stream in step (a);
and
(i) recovering at least a portion of said liquid stream comprising hydrocarbons.

7 more elements

Dependencies are inferred from the claim text.