WO2023178157A1

WO2023178157A1 - Chemical recycling facility with electric process equipment

Info

Publication number: WO2023178157A1
Application number: PCT/US2023/064405
Authority: WO
Inventors: Daryl Bitting; Xianchun Wu; Michael Gary POLASEK; David Eugene SLIVENSKY
Original assignee: Eastman Chemical Company
Priority date: 2022-03-17
Filing date: 2023-03-15
Publication date: 2023-09-21

Abstract

Processes and facilities for providing recycled content hydrocarbon products (r-products) from the pyrolysis of waste plastic and cracking of the resulting recycled content streams are provided. Processing schemes are described herein that increase energy efficiency and help reduce overall environmental impact while producing valuable final products from chemically recycled waste plastic.

Description

CHEMICAL RECYCLING FACILITY WITH ELECTRIC PROCESS EQUIPMENT

BACKGROUND

[0001] Waste plastic pyrolysis plays a part in a variety of chemical recycling technologies. Typically, waste plastic pyrolysis facilities produce recycled content pyrolysis oil (r-pyoil) and recycled content pyrolysis gas (r- pygas) that can be further processed in, for example, steam cracking facilities to provide a variety of recycled content chemical products and intermediates, such as recycled content ethylene (r-ethylene), recycled content ethane (r- ethane), recycled content propylene (r-propylene), recycled content propane (r-propane) and others. Unfortunately, the operation of pyrolysis and/or cracking and product separation facilities can be energy intensive, which can be costly, and, depending on the source of the energy, can also have more of an environmental impact than may be desired.

SUMMARY

[0002] In one aspect, the present technology concerns a process for producing at least one recycled content hydrocarbon product (r-hydrocarbon product), said process comprising: (a) pyrolyzing mixed plastic waste in a pyrolysis facility to provide a recycled content pyrolysis vapor (r-pyrolysis vapor); and (b) introducing a feed stream into an electrically heated cracker furnace, wherein the feed stream comprises at least a portion of the r- pyrolysis vapor, wherein the feed stream into the cracker furnace has an average daily feed rate of at least 1000 pounds per hour (Ibs/hour).

[0003] In one aspect, the present technology concerns a process for producing at least one recycled content hydrocarbon product (r-hydrocarbon product), said process comprising: (a) pyrolyzing mixed plastic waste in a pyrolysis facility to provide a recycled content pyrolysis vapor (r-pyrolysis vapor); and (b) introducing a combined feed stream into an electrically-heated cracker furnace in a cracking facility, wherein the combined feed stream comprises a hydrocarbon stream and at least a portion of the pyrolysis vapor, and wherein the combined feed stream is introduced into the cracker furnace at an inlet temperature in the range of from 400 to 700°C.

[0004] In one aspect, the present technology concerns a process for producing at least one recycled content hydrocarbon product (r-hydrocarbon product), said process comprising: (a) introducing a recycled content hydrocarbon-containing feed (r-HC feed) stream into an inlet of a cracker furnace; and (b) cracking at least a portion of the r-HC feed stream in the cracker furnace, wherein the cracker furnace discharges less than 130 pounds of carbon dioxide equivalents (CO2-eq) per million BTU (MMBTU) of energy introduced into the cracker furnace.

BRIEF DESCRIPTION OF THE DRAWINGS

[0005] FIG. 1 is a schematic block flow diagram illustrating the main processes/facilities in a chemical recycling facility according to various embodiments of the present invention;

[0006] FIG. 2 is a schematic block flow diagram illustrating select portions of a plastics processing, pyrolysis, and cracking process/facility according to embodiments of the present invention, particularly illustrating the use of electricity to provide heat to the pyrolysis reactor;

[0007] FIG. 3 is a schematic block flow diagram illustrating select portions of a pyrolysis process/facility and a cracking process/facility according to embodiments of the present invention, particularly illustrating the introduction of a pyrolysis effluent stream into a cracker furnace;

[0008] FIG. 4a is a schematic cross-sectional diagram of a heating tube for a cracker furnace that includes a plurality of resistive heating elements; and [0009] FIG. 4b is a schematic cross-sectional diagram of a heating tube for a cracker furnace that includes a plurality of induction heating elements.

DETAILED DESCRIPTION

[0010] We have discovered a method of chemically recycling waste plastic that may facilitate improved energy efficiency and/or reduced greenhouse gas (GHG) emissions. Recycling facilities as described herein can include pyrolysis and/or cracking facilities, which may be operated separately or may be at least partially integrated. Reduction or elimination of conventional energy sources may help reduce overall operating costs and/or minimize emissions of gases such as carbon dioxide, carbon monoxide, NOx, and others that have been linked to adverse environmental effects.

[0011] Turning initially to FIG. 1 , a process and system for use in chemical recycling of waste plastic is provided. The chemical recycling facility 10 shown in FIG. 1 includes a plastics processing facility 12, a pyrolysis facility 14, and a cracking facility 16. Chemical recycling facilities are not the same as mechanical recycling facilities. As used herein, the terms “mechanical recycling” and “physical recycling” refer to a recycling process that includes a step of melting waste plastic and forming the molten plastic into a new intermediate product (e.g., pellets or sheets) and/or a new end product (e.g., bottles). Generally, mechanical recycling does not substantially change the chemical structure of the plastic being recycled. The chemical recycling facilities described herein may be configured to receive and process waste streams from and/or that are not typically processable by a mechanical recycling facility.

[0012] In one embodiment or in combination with any other mentioned embodiments, at least two of the plastics processing facility 12, the pyrolysis facility 14, and the cracking facility 16 may be co-located. As used herein, the term “co-located” refers to the characteristic of at least two objects being situated on a common physical site, and/or within 1 , within 0.75, within 0.5, or within 0.25 miles of each other, measured as a straight-line distance between two designated points.

[0013] When two or more facilities are co-located, the facilities may be integrated in one or more ways. Examples of integration include, but are not limited to, heat integration, utility integration, waste-water integration, mass flow integration via conduits, office space, cafeterias, integration of plant management, IT department, maintenance department, and sharing of common equipment and parts, such as seals, gaskets, and the like. [0014] One or more, or all, of the plastics processing facility 12, the pyrolysis facility 14, and the cracking facility 16 can be commercial scale facilities. For example, in one embodiment or in combination with any other mentioned embodiments, the plastics processing facility/step and/or the pyrolysis facility/step can accept a stream of mixed waste plastic at an average annual feed rate of at least 500, at least 1000, at least 1500, at least 2000, at least 5000, at least 10,000, at least 50,000, or at least 100,000 pounds per hour, averaged over one year. In one embodiment or in combination with any other mentioned embodiments, the pyrolysis facility 14 and/or the cracking facility 16 can produce one or more recycled content product streams (or receive one or more feed streams) at an average annual rate of at least 100, or at least 1000, at least 1500, at least 2000, at least 2500, at least 5000, at least 10,000, at least 50,000, or at least 75,000 pounds per hour, averaged over one year. When more than one r-product stream is produced, these rates can apply to the combined rate of all r-products. Alternatively, or in addition, the feed stream or streams introduced into one or more of these facilities can have an average mass flow rate of at least 500, at least 1000, at least 2500, at least 5000, at least 10,000, or at least 50,000 pounds per hour, averaged over one year.

[0015] One or more, or all, of the plastic processing facility 12, the pyrolysis facility 14, and the cracking facility 16 can be operated in a continuous manner. For example, each of the processes within each of the facilities and/or the process amongst the facilities may be operated continuously and may not include batch or semi-batch operation. In one embodiment or in combination with any other mentioned embodiments, at least a portion of one or more of the facilities may be operated in a batch or semi-batch manner, but the operation amongst the facilities may be continuous overall. [0016] As shown in FIG. 1 , mixed waste plastic can be introduced into the plastics processing facility 12, wherein it can be separated into a waste plastic stream comprising predominantly polyolefin (PO) and a waste plastic stream comprising predominantly non-PO plastics, such as polyethylene terephthalate (PET), polyvinyl chloride (PVC), and others. As used herein, the term “predominantly” means at least 50 weight percent. In one embodiment or in combination with any other mentioned embodiments, the predominantly PO waste plastic stream comprises at least 50, at least 60, at least 70, at least 80, at least 90, or at least 95 weight percent of PO, based on the total weight of the stream.

[0017] As used herein, the terms “mixed plastic waste” and “MPW” refer to a mixture of at least two types of waste plastics including, but not limited to the following plastic types: polyethylene terephthalate (PET), one or more polyolefins (PO), and polyvinylchloride (PVC). In one embodiment or in combination with any other mentioned embodiments, the MPW can include at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, or at least 95 weight percent PO, based on the total weight of the stream. Alternatively, or in addition, the MPW comprises not more than 99.9, not more than 99, not more than 97, not more than 92, not more than 90, not more than 85, not more than 80, not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, not more than 45, not more than 40, not more than 35, not more than 30, not more than 25, not more than 20, not more than 15, not more than 10, or not more than 5 weight percent PO, based on the total weight of the stream.

[0018] In addition to PO, the MPW can include non-PO components, such as other plastics (e.g., PET, PVC, and others), as well as non-plastic components such as glass, metals, dirt, sand, and cardboard. In one embodiment or in combination with any other mentioned embodiments, the non-PO components can include other plastics in an amount in the range of from 2 to 35 weight percent, 5 to 30 weight percent, or 10 to 25 weight percent, based on the total weight of the stream. The amount of non-plastic components can be at 2, at least 5, at least 10, at least 15, at least 20, at least 30, at least 40, at least 50, or 55 weight percent and/or not more than 70, not more than 60, not more than 50, not more than 40, not more than 30, not more than 20, not more than 15, not more than 10, not more than 7, or not more than 5 weight percent, based on the total weight of mixed plastic waste. [0019] In the plastics processing facility 12, the MPW can be separated to removing non-PO plastic and/or non-plastic components (e.g., glass, metal, cardboard and paper, and dirt and sand) from the waste plastic. Such separation can be performed mechanically and can include utilize a fluid such as air. In one embodiment or in combination with any other mentioned embodiments, the separation may include a sink-float step where different types of plastic are separated by density, usually using water or a pH- controlled liquid (e.g., caustic solution). In one embodiment or in combination with any other mentioned embodiments, the separation may include use of a hydrocyclone.

[0020] As a result, the predominantly PO waste plastic can include at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, at least 85, at least 90, at least 95, at least 97, at least 99, at least 99.5, or at least 99.9 weight percent PO, based on the total weight of plastic in the predominantly PO waste plastic stream. This stream may also include not more than 1 , not more than 0.5, or not more than 0.1 weight percent polyvinyl chloride (PVC) and PET in an amount of not more than 5, not more than 2, not more than 1 , or not more than 0.5 weight percent, based on the total weight of the predominantly PO waste plastic.

[0021] In one embodiment or in combination with any other mentioned embodiments, at least a portion of the non-PO (or PET) waste plastic can itself be chemically recycled in the same or a different chemical recycling facility. Examples of chemical recycling processes to which the non-PET (or PO) waste plastic can be subjected include, but are not limited to, solvolysis, molecular reforming, and combinations thereof.

[0022] As shown in FIG. 1 , the predominantly PO waste plastic stream can be introduced into a pyrolysis facility 14 and pyrolyzed in at least one pyrolysis reactor (not shown). The pyrolysis reaction involves chemical and thermal decomposition of the sorted waste plastic introduced into the reactor.

Although all pyrolysis processes may be generally characterized by a reaction environment that is substantially free of oxygen, pyrolysis processes may be further defined by other parameters such as the pyrolysis reaction temperature within the reactor, the residence time in the pyrolysis reactor, the reactor type, the pressure within the pyrolysis reactor, and the presence or absence of pyrolysis catalysts.

[0023] The pyrolysis reaction performed in the pyrolysis reactor can be carried out at a temperature of less than 700, less than 650, or less than 600°C and at least 300, at least 350, or at least 400°C. The feed to the pyrolysis reactor can comprise, consists essentially of, or consists of waste plastic, and the feed stream can have a number average molecular weight (Mn) of at least 3000, at least 4000, at least 5000, or at least 6000 g/mole. If the feed to the pyrolysis reactor contains a mixture of components, the Mn of the pyrolysis feed is the average Mn of all feed components, based on the weight of the individual feed components. The waste plastic in the feed to the pyrolysis reactor can include post-consumer waste plastic, post-industrial waste plastic, or combinations thereof. In one embodiment or in combination with any other mentioned embodiments, the feed to the pyrolysis reactor comprises less than 5, less than 2, less than 1 , less than 0.5, or about 0.0 weight percent coal and/or biomass (e.g., lignocellulosic waste, switchgrass, fats and oils derived from animals, fats and oils derived from plants, etc.). The feed to the pyrolysis reaction can also comprise less than 5, less than 2, less than 1 , or less than 0.5, or about 0.0 weight percent of a co-feed stream, including steam and/or sulfur-containing co-feed streams. [0024] Additionally, or alternatively, the pyrolysis reactor may comprise a film reactor, a screw extruder, a tubular reactor, a stirred tank reactor, a riser reactor, a fixed bed reactor, a fluidized bed reactor, a rotary kiln, a vacuum reactor, a microwave reactor, or an autoclave. The reactor may also utilize a feed gas and/or lift gas for facilitating the introduction of the feed into the pyrolysis reactor. The feed gas and/or lift gas can comprise nitrogen and can comprise less than 5, less than 2, less than 1 , or less than 0.5, or about 0.0 weight percent of steam and/or sulfur-containing compounds.

[0025] The pyrolysis reaction can involve heating and converting the waste plastic feedstock in an atmosphere that is substantially free of oxygen or in an atmosphere that contains less oxygen relative to ambient air. For example, the atmosphere within the pyrolysis reactor may comprise not more than 5, not more than 4, not more than 3, not more than 2, not more than 1 , or not more than 0.5 weight percent of oxygen.

[0026] The temperature in the pyrolysis reactor can be adjusted to facilitate the production of certain end products. In one embodiment or in combination with any other mentioned embodiments, the peak pyrolysis temperature in the pyrolysis reactor can be at least 325°C, or at least 350°C, or at least 375°C, or at least 400°C. Additionally or alternatively, the peak pyrolysis temperature in the pyrolysis reactor can be not more than 800°C, not more than 700°C, or not more than 650°C, or not more than 600°C, or not more than 550°C, or not more than 525°C, or not more than 500°C, or not more than 475°C, or not more than 450°C, or not more than 425°C, or not more than 400°C. More particularly, the peak pyrolysis temperature in the pyrolysis reactor can range from 325 to 800°C, or 350 to 600°C, or 375 to 500°C, or 390 to 450°C, or 400 to 500°C.

[0027] The residence time of the feedstock within the pyrolysis reactor can be at least 1 , or at least 5, or at least 10, or at least 20, or at least 30, or at least 60, or at least 180 seconds. Additionally, or alternatively, the residence time of the feedstock within the pyrolysis reactor can be less than 2, or less than 1 , or less than 0.5, or less than 0.25, or less than 0.1 hours. More particularly, the residence time of the feedstock within the pyrolysis reactor can range from 1 second to 1 hour, or 10 seconds to 30 minutes, or 30 seconds to 10 minutes.

[0028] The pyrolysis reactor can be maintained at a pressure of at least 0.1 , or at least 0.2, or at least 0.3 barg and/or not more than 60, or not more than 50, or not more than 40, or not more than 30, or not more than 20, or not more than 10, or not more than 8, or not more than 5, or not more than 2, or not more than 1 .5, or not more than 1 .1 barg. The pressure within the pyrolysis reactor can be maintained at atmospheric pressure or within the range of 0.1 to 60, or 0.2 to 10, or 0.3 to 1 .5 barg.

[0029] The pyrolysis reaction in the reactor can be thermal pyrolysis, which is carried out in the absence of a catalyst, or catalytic pyrolysis, which is carried out in the presence of a catalyst. When a catalyst is used, the catalyst can be homogenous or heterogeneous and may include, for example, certain types of zeolites and other mesostructured catalysts.

[0030] Turning now to FIG. 2, one embodiment of a pyrolysis facility 14 is illustrated as including a pyrolysis reactor 18 for pyrolyzing mixed waste plastic and a solids separation zone 20 for separating the recycled content pyrolysis effluent (r-pyrolysis effluent) into a stream of recycled content pyrolysis residue (r-pyrolysis residue) and a recycled content pyrolysis vapor (r-pyrolysis vapor) stream. As used herein, the term “r-pyrolysis effluent” refers to the outlet stream withdrawn from the pyrolysis reactor 18, and the term “r-pyrolysis vapor” refers to a vapor-phase stream withdrawn from a separator used to remove r-pyrolysis residue from the r-pyrolysis effluent. As used herein, the term “r-pyrolysis residue” refers to a composition obtained from waste plastic pyrolysis that comprises predominantly pyrolysis char and pyrolysis heavy waxes. As used herein, the term “pyrolysis char” refers to a carbon-containing composition obtained from pyrolysis that is solid at 200°C and 1 atm. As used herein, the term “pyrolysis heavy waxes” refers to C20+ hydrocarbons obtained from pyrolysis that are not pyrolysis char, pyrolysis gas, or pyrolysis oil. [0031] The r-pyrolysis vapor can include a range of hydrocarbon materials and may comprise both recycled content pyrolysis gas (r-pygas) and recycled content pyrolysis oil (r-pyoil). As used herein, the term “r-pygas” refers to a composition obtained from waste plastic pyrolysis that is gaseous at 25°C at 1 atm. As used herein, the terms “r-pyoil” refers to a composition obtained from waste plastic pyrolysis that is liquid at 25°C and 1 atm. In one embodiment or in combination with any other mentioned embodiments, the pyrolysis facility 14 may include an additional separator (not shown) to separate the r-pyoil and r-pygas into separate streams, while in other embodiments (such as shown in FIG. 1 ), the entire stream of r-pyrolysis vapor may be removed from the pyrolysis facility 14.

[0032] In one embodiment or in combination with any other mentioned embodiments, the r-pyrolysis vapor can include at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 50, at least 75 or at least 90 weight percent of r-pyoil and/or not more than 99, not more than 90, not more than 75, not more than 65, not more than 60, not more than 55, not more than 50, not more than 45, or not more than 40 weight percent of r-pyoil, and at least 5, at least 10, at least 20, at least 25, at least 30, at least 35, or at least 40 weight percent r-pygas and/or not more than 75, not more than 70, not more than 65, not more than 60, not more than 55, not more than 50, not more than 40, not more than 25, or not more than 10 weight percent r-pygas. The r-pyrolysis vapor can include little or no r-pyrolysis residue (e.g., pyrolysis heavy waxes or char) and can, for example, include not more than 10, not more than 5, not more than 2, not more than 1 , not more than 0.5, or not more than 0.1 weight percent of r-pyrolysis residue including, for example, heavy waxes.

[0033] The r-pyrolysis vapor can include C1 to C30 hydrocarbon components in an amount of at least 75, at least 90, at least 95, or at least 99 weight percent. The pyrolysis vapor can include at least 30, at least 35, at least 40, at least 45, at least 50, at least 55, at least 60, at least 65, at least 70, at least 75, at least 80, or at least 85 weight percent of C5 and heavier components, or of C6 and heavier components, or of C8 and heavier components, or of C10 and heavier components. As used herein, the terms “Cx” or “Cx hydrocarbon” or “Cx component” refers to a hydrocarbon compound including “x” total carbons per molecule, and encompasses all olefins, paraffins, aromatics, heterocyclic, and isomers having that number of carbon atoms. For example, each of normal, iso, and tert-butane and butene and butadiene molecules would fall under the general description “C4” or “C4 components.” As used herein, the term “heavier” means having a higher boiling point and “lighter” means having a lower boiling point.

[0034] In one embodiment or in combination with any other mentioned embodiments, as generally shown in FIG. 2, at least a portion of the energy provided to the pyrolysis reactor 18 can be electric energy from an electricity source 22. The electric energy can be provided directly by, for example, use of electric heating elements within the pyrolysis reactor 18 (not shown) or indirectly by, for example, use of electric energy to warm a heat transfer medium (HTM) 24 which is then used to heat the contents of the pyrolysis reactor 18, as generally shown in FIG. 2. In one embodiment or in combination with any other mentioned embodiments, at least 50, at least 60, at least 70, at least 80, at least 90, or at least 95 percent of the total amount of energy introduced into the pyrolysis reactor 18 can be directly or indirectly from electric energy.

[0035] Referring again to FIG. 1 , all or a portion of at least one stream from the pyrolysis facility 14 (e.g., the r-pyrolysis vapor) can be introduced into a cracking facility 16, wherein the stream can be cracked to form lighter hydrocarbon products. The cracking facility 16 generally includes a cracker furnace 26 for thermally cracking the hydrocarbon-containing feed, a quench zone 28 for cooling the cracked effluent, a compression zone 30 for increasing the pressure of the cooled, cracked stream, and a separation zone 32 for separating out one or more recycled content hydrocarbon product (r- hydrocarbon product) streams from the compressed effluent. Examples of r- product streams can include, but are not limited to, recycled content ethylene (r-ethylene), recycled content ethane (r-ethane), recycled content propylene (r-propylene), recycled content propane (r-propane), recycled content butylene (r-butylene), recycled content butane (r-butane), and recycled content C5 and heavier (r-C5+).

[0036] All or a portion of the r-pyrolysis vapor can be directly introduced into the cracker furnace 26, and/or the r-pyrolysis vapor can be combined with a stream of hydrocarbon-containing material introduced into inlet of the cracker furnace 26. At least 50, at least 60, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 97 weight percent of the r-pyrolysis vapor withdrawn from the pyrolysis facility 14 can be introduced into the cracker furnace 26.

[0037] The cracking reaction performed in the cracker furnace 26 can be carried out at a temperature of at least 700, at least 750, at least 800, or at least 850°C. The feed to the cracker furnace 26 can have a number average molecular weight (Mn) of less than 3000, less than 2000, less than 1000, or less than 500 g/mole. If the feed to the pyrolysis reactor contains a mixture of components, the Mn of the cracker feed is the average Mn of all feed components, based on the weight of the individual feed components. The feed to the cracker furnace 26 can include virgin (i.e. , not recycled) feedstock and can comprise less than 5, less than 2, less than 1 , less than 0.5, or 0.0 weight percent of coal, biomass, and/or other solids. In one embodiment or in combination with any other mentioned embodiments, a co-feed stream, such as steam or a sulfur-containing stream (for metal passivation) cam be introduced into the cracker furnace 26. The cracker furnace 26 can include both convection and radiant sections and can have a tubular reaction zone. Typically, the residence time of the streams passing through the reaction zone (from the convection section inlet to the radiant section outlet) can be less than 20 seconds, less than 15 seconds, or less than 10 seconds.

[0038] T urning now to FIG. 3, a block flow diagram of a portion of the process/facility shown in FIG. 1 is provided, particularly illustrating introduction of r-pyrolysis vapor into the cracker furnace 26 according to one embodiment or in combination with any other mentioned embodiments. As shown in FIG. 3, a stream of r-pyrolysis vapor from the pyrolysis facility 14 may be combined with a hydrocarbon-containing feed stream and the combined stream may be introduced into the cracker furnace 26. In one embodiment or in combination with any other mentioned embodiments (not shown), the r-pyrolysis vapor may be further separated in the pyrolysis facility 14 into a stream of predominantly recycled content pyrolysis gas (r-pygas) and recycled content pyrolysis oil (r-pyoil) and all or a portion of those streams may be introduced into the cracker facility upstream and/or downstream of the cracker furnace 26.

[0039] In one embodiment or in combination with any other mentioned embodiments, the r-pyrolysis vapor may not be significantly cooled and/or condensed prior to being introduced into the cracker furnace 26. For example, less than 10, less than 5, less than 2, or less than 1 weight percent of the r-pyrolysis vapor may be condensed prior to combination with the hydrocarbon-containing feed stream and/or prior to being introduced into the cracker furnace 26. The r-pyrolysis vapor may not pass through a heat exchanger or condenser, as shown in FIG. 1 , and any cooling and/or condensation that does occur may be due to line losses. As a result, the absolute value of the difference between the temperature of the r-pyrolysis vapor withdrawn from the pyrolysis facility 14 and the r-pyrolysis vapor combined with the hydrocarbon-containing feed and/or introduced into the cracker furnace 26 is not more than 225, not more than 220, not more than 210, not more than 100, not more than 175, not more than 150, not more than 125, or not more than 100°C.

[0040] The hydrocarbon-containing feed stream introduced into the cracker furnace 26 as shown in FIG. 3 may comprise predominantly C2 to C5 hydrocarbon components, predominantly C2 to C4 hydrocarbon components, predominantly C2 hydrocarbon components, or predominantly C3 hydrocarbon components. As used herein, the term “predominantly” means at least 50 weight percent. In such cases, the hydrocarbon-containing feed stream may be in the gas phase and the cracker furnace 26 may be considered a gas cracker furnace.

[0041] In other embodiments, the hydrocarbon-containing feed stream may comprise predominantly C5 to C22 hydrocarbon components, or predominantly C5 to C20 components, or predominantly C5 to C18 components. In such cases, the hydrocarbon-containing feed stream may be in the liquid phase and the cracker furnace 26 may be considered a liquid cracker furnace. Alternatively, at least a portion of the furnace coils in the cracker furnace 26 may be configured to receive and process a gas phase hydrocarbon feed and at least a portion of the furnace coils in the cracker furnace 26 may be configured to process a liquid hydrocarbon feed so that the cracker furnace 26 may be considered a split furnace.

[0042] In one embodiment or in combination with any other mentioned embodiments, the hydrocarbon-containing feed stream introduced into the cracker furnace 26 can comprise a recycled content hydrocarbon feed (r-HC feed). The r-HC feed can directly or indirectly include recycled content from waste plastic. In one embodiment or in combination with any other mentioned embodiments, the hydrocarbon feed may comprise non-recycled content hydrocarbon as well, or it may include no recycled content hydrocarbon.

[0043] As shown in FIG. 3, in one embodiment or in combination with any other mentioned embodiments, at least a portion of the hydrocarbon containing feed stream can be pre-heated 34 before being combined with the r-pyrolysis vapor stream and/or introduced into the cracker furnace 26. In one embodiment or in combination with any other mentioned embodiments, the temperature of the hydrocarbon-containing feed stream can be greater than the r-pyrolysis vapor withdrawn from the pyrolysis facility 14 by at least 25, at least 50, at least 75, at least 100, at least 125°C. The combined stream introduced into the cracker furnace 26 can have a temperature of at least 400, at least 450, at least 500, or at least 550°C, and/or not more than 750, not more than 700, not more than 675, or not more than 650°C. The r-pyrolysis vapor stream can have a temperature of not more than 700, not more than 675, not more than 650, not more than 625, not more than 600, or not more than 575°C when withdrawn from the pyrolysis facility 14. In one embodiment or in combination with any other mentioned embodiments, heating the hydrocarbon-containing feed stream can provide some heat to the r-pyrolysis vapor stream in order to ensure the combined stream introduced into the cracker furnace 26 is in the range of from 400 to 700°C, 450 to 675°C, or 500 to 650 °C.

[0044] As shown in FIG. 3, the hydrocarbon feed stream (or combined stream) can further include steam. In one embodiment or in combination with any other mentioned embodiments, the stream fed into the cracker furnace 26 can have a molar ratio of steam to hydrocarbon of at least 0.10:1 , at least 0.20:1 , at least 0.25:1 , at least 0.30:1 , or at least 0.35:1 and/or not more than 0.65:1 , not more than 0.60:1 , not more than 0.55:1 , not more than 0.50:1 , not more than 0.45:1 , or not more than 0.40:1 .

[0045] Turning again to FIG. 1 , the cracking facility 16 may utilize electric energy from an electricity source 38 in one (two, three) or more of the cracker furnace 26, the quench zone 28, the compression zone 30, and the separation zone 32. In one embodiment or in combination with any other mentioned embodiments, each of these zones may utilize electric energy and less than 25, less than 20, less than 15, less than 10, or less than 5 percent of the energy utilized in one or more of these zones may be from a source other than electric energy. In one embodiment or in combination with any other mentioned embodiments, for example, at least one pump in the quench 28 and/or separation zone 32 may be electrically driven, while, in the compression zone 30, one or more or all of the compressors may be electrically driven. Such electric energy can be used by the equipment directly (e.g., an electric turbine) or it may be used indirectly (e.g., electric energy used to generate steam, which is then used in a heat exchanger). [0046] When electrically heated, the cracker furnace 26 can receive at least 75, at least 80, at least 85, at least 90, at least 95, at least 97, or at least 99 percent of its total input energy from electricity. Examples of electrically heated cracker furnaces can include induction furnaces, electric arc furnaces, and electric resistance furnaces.

[0047] The electrically heated cracker furnace 26 may include at least one electric heating element 40 positioned on, near, or in one or more of the furnace tubes 36. In one embodiment or in combination with any other mentioned embodiments, on average, there may be at least 5, at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, or at least 50 individual electric heating elements per tube and/or not more than 100, not more than 90, not more than 80, not more than 70, not more than 60, not more than 50, not more than 40, not more than 30, or not more than 25 electric heating elements per tube. In one embodiment or in combination with any other mentioned embodiments, the average number of heating elements per tube can range from 30 to 60, from 35 to 55, or from 40 to 50 electric heating elements, while in other cases, each tube can include from 5 to 30, from 10 to 25, or from 15 to 20 heating elements.

[0048] Each electric heating element 40 can have an energy output of at least 10, at least 15, at least 20, at least 25, at least 30, at least 35, at least 40, at least 45, or at least 50 kilowatts (kW) and/or not more than 150, not more than 125, not more than 100, not more than 90, not more than 80, not more than 70, not more than 60, or not more than 50 kW, while the entire furnace can have an energy input of at least 15, at least 20, at least 25, at least 30 and/or not more than 100, not more than 75, not more than 25, or not more than 20 megawatts (MW) per furnace.

[0049] Schematic cross-sectional views resistance and induction heating elements are provided in FIGS. 4a and 4b, respectively. When the electrically heated cracker furnace is a resistance furnace, each of the tubes may include one or more resistance heating elements, as generally shown in FIG. 4a. Each resistance heating element can have a voltage of at least 250, at least 400, at least 350 volts (V) and/or not more than 500, not more than 450, not more than 400, or not more than 375 V, or each resistance heating element can have a voltage of at least 750, at least 800, at least 850 V and/or not more than 1000, not more than 950, or not more than 900 V. Examples of inductive heating elements are provided in FIG. 4b.

[0050] When electrically heated, the cracker furnace may not have a convection section as is typically present in most fuel-fired furnaces. This may occur when, for example, the electric furnace is newly constructed. Alternatively, the electrically heated cracker furnace may have a convection section, but it may be operated below its typical capacity. This may occur when, for example, the electric heating elements are retrofitted into a previously fuel-fired furnace. In one embodiment or in combination with any other mentioned embodiments, at least 75, at least 80, at least 85, at least 90, at least 95, or at least 99 percent of the feed introduced into the cracker furnace is introduced into the radiant section.

[0051] In one embodiment or in combination with any other mentioned embodiments, an existing fuel-fired cracker furnace can be retrofitted to be an electrically heated furnace. For example, during an initial period, the cracker furnace may be a fuel-fired furnace and may obtain at least 75, at least 85, at least 95, or at least 99 percent of its energy from petroleum-based fuel, such as liquid petroleum-based fuels like natural gas, liquefied petroleum gas (LPG), and fuel oil, or solid fuels such as coal. Then during the retrofit, one or more electric heating elements may be added to the tubes of the furnace, so that at least 75, at least 85, at least 95, or at least 99 percent of the energy obtained by the furnace is electric energy. Such a modification can occur simultaneously with or prior to the modification of an upstream co-located and/or integrated pyrolysis facility to accept mixed waste plastic and/or with or prior to the modification of the cracker facility to accept recycled content hydrocarbon feed.

[0052] Advantageously, the electrically heated cracker furnace may discharge lower-than-expected levels of greenhouse gases, measured in terms of carbon dioxide equivalents (CO2-eq). As used herein, the term “greenhouse gas,” refers to an atmospheric gas that absorbs and traps heat (e.g., infrared radiation) from Earth. Examples of greenhouse gases include, but are not limited to, carbon dioxide, methane, and nitrous oxide (N2O), as well as many halogenated compounds. The Global Warming Potential (GWP) of each gas can be determined by converting each to a carbon dioxide equivalent (CO2-eq) by using the 100-year time horizon global warming potentials (GWP) factors laid out in the IPCC Fifth Assessment Report (2014). The cracker furnace may discharge less than 130, less than 120, less than 110, less than 100, less than 90, less than 80, less than 70, less than 60, less than 50, less than 40, less than 30, or less than 25 CO2-eq, which can be less than conventionally fired furnaces.

[0053] In one embodiment or in combination with any other mentioned embodiments, the cracker furnace may discharge less than 2, less than 1 , less than 0.5, less than 0.25, less than 0.20, or less than 0.10 pounds of nitrogen oxides (NOx), including nitrous oxide, per million BTU (MMBTU) of energy introduced into the cracker furnace. Additionally, or in the alternative, the cracker furnace may discharge less than 100, less than 75, less than 50, less than 25, or less than 15 pounds of carbon dioxide per MMBTU of energy introduced into the cracker furnace.

[0054] In one embodiment or in combination with any other mentioned embodiments, the cracker furnace may also discharge lower-than-expected amounts of other gases, such as carbon monoxide (CO) and sulfur oxides (SOx). For example, the cracker furnace may discharge less than 2, less than 1 , less than 0.5, less than 0.25, less than 0.20, or less than 0.10 lb of CO per MMBTU of energy introduced into the cracker furnace. Additionally, or in the alternative, the cracker furnace may discharge less than 0.02, less than 0.01 , less than 0.0075, or less than 0.0050 lb of SOx per MMBTU of energy introduced into the cracker furnace.

DEFINITIONS

[0055] It should be understood that the following is not intended to be an exclusive list of defined terms. Other definitions may be provided in the foregoing description, such as, for example, when accompanying the use of a defined term in context.

[0056] As used herein, the terms “a,” “an,” and “the” mean one or more.

[0057] As used herein, the term “and/or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing components A, B, and/or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination, B and C in combination; or A, B, and C in combination.

[0058] As used herein, the phrase “at least a portion” includes at least a portion and up to and including the entire amount or time period.

[0059] As used herein, the term “chemical recycling” refers to a waste plastic recycling process that includes a step of chemically converting waste plastic polymers into lower molecular weight polymers, oligomers, monomers, and/or non-polymeric molecules (e.g., hydrogen, carbon monoxide, methane, ethane, propane, ethylene, and propylene) that are useful by themselves and/or are useful as feedstocks to another chemical production process(es). [0060] As used herein, the term “co-located” refers to the characteristic of at least two objects being situated on a common physical site, and/or within one mile of each other.

[0061] As used herein, the term “commercial scale facility” refers to a facility having an average annual feed rate of at least 500 pounds per hour, averaged over one year.

[0062] As used herein, the terms “comprising,” “comprises,” and “comprise” are open-ended transition terms used to transition from a subject recited before the term to one or more elements recited after the term, where the element or elements listed after the transition term are not necessarily the only elements that make up the subject. [0063] As used herein, the term “cracking” refers to breaking down complex organic molecules into simpler molecules by the breaking of carboncarbon bonds.

[0064] As used herein, the terms “including,” “include,” and “included” have the same open-ended meaning as “comprising,” “comprises,” and “comprise” provided above.

[0065] As used herein, the term “predominantly” means more than 50 percent by weight. For example, a predominantly propane stream, composition, feedstock, or product is a stream, composition, feedstock, or product that contains more than 50 weight percent propane.

[0066] As used herein, the term “pyrolysis” refers to thermal decomposition of a feedstock of a biomass and/or a plastic material in solid or liquid form at elevated temperatures in an inert (i.e., substantially molecular oxygen free) atmosphere.

[0067] As used herein, the term “pyrolysis effluent” refers to the outlet stream withdrawn from the pyrolysis reactor in a pyrolysis facility.

[0068] As used herein, the terms “pyrolysis gas” and “pygas” refer to a composition obtained from pyrolysis that is gaseous at 25°C.

[0069] As used herein, the terms “pyrolysis oil” or “pyoil” refers to a composition obtained from pyrolysis that is liquid at 25°C and 1 atm.

[0070] As used herein, the term “pyrolysis residue” refers to a composition obtained from pyrolysis that is not pyrolysis gas or pyrolysis oil and that comprises predominantly pyrolysis char and pyrolysis heavy waxes.

[0071] As used herein, the term “pyrolysis vapor” refers to the overhead or vapor-phase stream withdrawn from the separator in a pyrolysis facility used to remove r-pyrolysis residue from the r-pyrolysis effluent.

[0072] As used herein, the term “recycled content” refers to being or comprising a composition that is directly and/or indirectly derived from recycled material.

[0073] As used herein, the term “waste material” refers to used, scrap, and/or discarded material. [0074] As used herein, the terms “waste plastic” and “plastic waste” refer to used, scrap, and/or discarded plastic materials.

CLAIMS NOT LIMITED TO DISCLOSED EMBODIMENTS [0075] The preferred forms of the invention described above are to be used as illustration only and should not be used in a limiting sense to interpret the scope of the present invention. Modifications to the exemplary embodiments, set forth above, could be readily made by those skilled in the art without departing from the spirit of the present invention. [0076] The inventors hereby state their intent to rely on the Doctrine of

Equivalents to determine and assess the reasonably fair scope of the present invention as it pertains to any apparatus not materially departing from but outside the literal scope of the invention as set forth in the following claims.

Claims

CLAIMS What is claimed is -

1 . A process for producing at least one recycled content hydrocarbon product (r-hydrocarbon product), said process comprising:

(a) pyrolyzing mixed plastic waste in a pyrolysis facility to provide a recycled content pyrolysis vapor (r-pyrolysis vapor); and

(b) introducing a feed stream into an electrically heated cracker furnace, wherein the feed stream comprises at least a portion of the r-pyrolysis vapor, wherein the feed stream into the cracker furnace has an average daily feed rate of at least 1000 pounds per hour (Ibs/hour).

2. The process of claim 1 , wherein the feed stream introduced into the cracker furnace has an average daily feed rate of at least 1500 (2000, 2500, or 5000) Ibs/hour.

3. The process of either of claims 1 or 2, wherein the feed stream introduced into the cracker furnace has an average temperature in the range of from 400 to 700 (450 to 675, or 500 to 650)°C.

4. The process of claim 3, further comprising heating at least a portion of the feed stream prior to the introducing of step (b).

5. The process of claim 4, wherein at least a portion of the r-pyrolysis vapor withdrawn from the pyrolysis facility has a temperature of not more than 700 (675, 650, 625, 600, or 575)°C.

6. The process of any of claims 1 -5, further comprising combining the r-pyrolysis vapor with a hydrocarbon stream to form a combined stream, wherein the feed stream introduced into the cracker furnace in step (b) comprises at least a portion of the combined stream.

7. The process of claim 6, wherein the hydrocarbon stream comprises predominantly C2 to C4 hydrocarbons.

8. The process of claim 6, wherein the hydrocarbon stream comprises predominantly C3 hydrocarbons.

9. The process of claim 6, wherein the hydrocarbon stream comprises predominantly C2 hydrocarbons.

10. The process of claim 6, wherein the hydrocarbon stream comprises predominantly C5 to C22 hydrocarbons.

1 1 . The process of claim 6, wherein the hydrocarbon-containing feed has recycled content.

12. The process of claim 6, wherein the hydrocarbon-containing feed does not have recycled content.

13. The process of claim 6, wherein the temperature of the hydrocarbon stream is at least 25 (50, 75, 100, or 125)°C warmer than the temperature of the r-pyrolysis stream when the streams are combined.

14. The process of claim 13, further comprising, heating at least a portion of the hydrocarbon stream to provide the hydrocarbon stream combined with the r-pyrolysis vapor.

15. The process of any of claims 1 -14, wherein the cracker furnace is an induction furnace.

16. The process of any of claims 1 -14, wherein the cracker furnace is an electric arc furnace.

17. The process of any of claims 1 -14, wherein the cracker furnace is an electric resistance furnace.

18. The process of any of claims 1-17, wherein the cracker furnace does not have a convection section.

19. The process of any of claims 1-18, wherein the introducing of step (b) includes introducing at least 75 (80, 85, 90, 95, or 99) percent of the feed stream into a radiant section of the cracker furnace.

20. The process of any of claims 1 -19, further comprising cracking at least a portion of the feed stream in a plurality of tubes disposed in the cracker furnace, wherein each of the tubes includes one or more electric heating elements.