WO2024069637A1

WO2024069637A1 - A process for production of naphtha and light olefins

Info

Publication number: WO2024069637A1
Application number: PCT/IN2023/050020
Authority: WO
Inventors: Lavanya Meesala; Chetanand Tejram SHAHARE; Pramod Kumar
Original assignee: Hindustan Petroleum Corporation Limited
Priority date: 2022-10-01
Filing date: 2023-01-10
Publication date: 2024-04-04

Abstract

An aspect of the present disclosure provides a process for production of naphtha and light olefins comprising: (a) feeding a pyrolysis oil or fractionated heavy product thereof, and at least one of: used cooking oil (UCO) and vacuum gas oil (VGO) to a fluid catalytic cracking (FCC) reactor; (b) catalytically cracking said pyrolysis oil or fractionated heavy product thereof, and the at least one of: used cooking oil (UCO) and vacuum gas oil (VGO) in the fluid catalytic cracking (FCC) reactor to obtain a liquid stream of products, a gaseous stream of products comprising light olefins and a bottoms stream; and (c) subjecting the liquid stream of products to fractionation to obtain a naphtha stream. The advantageous, simple yet economical process of the present disclosure affords production of high quality hydrocarbon fuels such as LPG, naphtha and light olefins conserving energy and improving the overall productivity making the process technically and commercially feasible.

Description

A PROCESS FOR PRODUCTION OF NAPHTHA AND LIGHT OLEFINS

TECHNICAL FIELD

[0001] The present disclosure relates to a method for co-processing a pyrolysis oil or its fractionated heavy product with used cooking oil (UCO) and/or vacuum gas oil (VGO) to obtain value added hydrocarbon products therefrom.

BACKGROUND

[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

[0003] Diverse recycling pathways promote circular economy and waste management by implementing energy and material recovery processes. Recently, discovery of alternate sources of energy has been a prime focus to replace the conventional fossil based fuels. Important insights have been provided about waste tyres status (generation rate, waste regulations, valuable products and energy recovery processes) giving the prospective of waste tyre pyrolysis to support circular economy for restraining this waste. However, due to high aromatics and heteroatoms content, tyre pyrolysis oil (TPO) cannot be directly used as automotive fuel limiting its bulk scale valorization. Similarly, used cooking oil (UCO), a domestic waste is being produced in large quantities every year. Converting these low cost feedstocks to biofuels can be economically rewarding, while solving the problem of generation of large amounts of wastes.

[0004] The present disclosure provides a simple and economical process for converting pyrolysis oil, optionally, along with used cooking oil (UCO) into hydrocarbon fuels such as LPG, naphtha and light olefins at an industrial scale.

[0005] Each of the documents referred in the background section are incorporated herein, in its entirety, by way of reference. Further, none of the abovementioned documents are to be construed as relevant prior-art for the invention as embodied in the present disclosure. The sole intention of referring to and providing the abovementioned documents is to highlight some of the work already done in the instant technical field. OBJECTS OF THE INVENTION

[0006] An object of the present disclosure is to provide a process for converting pyrolysis oil optionally, along with used cooking oil into hydrocarbon fuels such as LPG, naphtha and light olefins.

[0007] Another object of the present disclosure is to provide a process for converting pyrolysis oil into hydrocarbon fuels that aids in conserving energy and improves overall productivity.

[0008] Another object of the present disclosure is to provide a process for converting pyrolysis oil into hydrocarbon fuels that is simple and economical.

[0009] Still further object of the present disclosure is to provide a process that is technically and commercially feasible.

[0010] Other objects of the present invention will be apparent from the description of the invention herein below.

SUMMARY

[0011] The present disclosure relates to a method for co-processing pyrolysis oil or its fractionated heavy product with used cooking oil (UCO) and/or vacuum gas oil (VGO) to obtain value added hydrocarbon products therefrom.

[0012] An aspect of the present disclosure provides a process for production of naphtha and light olefins, said process comprising: (a) feeding a pyrolysis oil or fractionated heavy product thereof, and at least one of: used cooking oil (UCO) and vacuum gas oil (VGO) to a fluid catalytic cracking (FCC) reactor; (b) catalytically cracking said pyrolysis oil or fractionated heavy product thereof, and the at least one of: used cooking oil (UCO) and vacuum gas oil (VGO) in the fluid catalytic cracking (FCC) reactor at a temperature ranging from 400°C to 700°C to obtain a liquid stream of products, a gaseous stream of products comprising light olefins, and a bottoms stream; and (c) subjecting the liquid stream of products to fractionation to obtain a naphtha stream.

[0013] In some embodiments, the step of catalytic cracking is effected in presence of a catalyst selected from: ZSM-5 catalyst and fluid catalytic cracking (FCC) catalyst. In some embodiments, the step of catalytic cracking is effected at a catalyst to oil ratio ranging from 1 to 12gram catalyst per gram of oil (gcat/goil). In some embodiments, the pyrolysis oil or fractionated heavy product thereof is not subjected to purification before feeding to the fluid catalytic cracking (FCC) reactor. In some embodiments, the used cooking oil (UCO)is not subjected to purification before feeding to the fluid catalytic cracking (FCC) reactor. [0014] In some embodiments, the pyrolysis oil or fractionated heavy product thereof and at least one of: used cooking oil (UCO) and vacuum gas oil (VGO) are blended before feeding to the fluid catalytic cracking (FCC) reactor. In some embodiments, the pyrolysis oil or fractionated heavy product thereof and the at least one of: used cooking oil (UCO) and vacuum gas oil (VGO) are blended in a mass ratio ranging from 1:1 to 1:20. In some embodiments, the pyrolysis oil or fractionated heavy product thereof and the at least one of: used cooking oil (UCO) and vacuum gas oil (VGO) are blended at a temperature ranging from 30°C to 80°C.

[0015] In some embodiments, the pyrolysis oil or fractionated heavy product thereof, used cooking oil (UCO) and vacuum gas oil (VGO) are blended before feeding to the fluid catalytic cracking (FCC) reactor. In some embodiments, the pyrolysis oil or fractionated heavy product thereof, used cooking oil (UCO) and vacuum gas oil (VGO) are blended in a mass ratio ranging from 1:1:2 to 1:1:18. In some embodiments, the pyrolysis oil or fractionated heavy product thereof, used cooking oil (UCO) and vacuum gas oil (VGO) are blended at a temperature ranging from 30°C to 80°C.

[0016] In some embodiments, the liquid stream of products is subjected to fractionation to obtain the naphtha stream, a Light Cycle Oil (LCO) stream, and a Heavy Cycle Oil (HCO) stream and/or a bottoms stream. In some embodiments, the HCO stream and/or the bottoms stream is recycled to the fluid catalytic cracking (FCC) reactor. In some embodiments, the naphtha stream and the LCO streamare subjected to hydro-treatment to obtain hydrocarbon fuels. In some embodiments, naphtha and diesel fraction streams from tyre pyrolysis oil (TPO) fractionation unit are subjected to hydro -treatment to obtain hydrocarbon fuels.

[0017] In some embodiments, the pyrolysis oil or fractionated heavy product thereof comprises pyrolysis oil, said pyrolysis oil being a Tyre Pyrolysis Oil (TPO). In some embodiments, the pyrolysis oil or fractionated heavy product thereof comprises a bottoms stream resulting from fractionation of a Tyre Pyrolysis Oil (TPO). In an embodiment, the Tyre Pyrolysis Oil (TPO) is obtained by: (a) taking tyre particles having particle size ranging from 0.5 mm to 5.0 mm; (b) subjecting the tyre particles to pyrolysis in a pyrolysis reactor at a temperature ranging from 300°C to 550°C; and (c) condensing the volatile hydrocarbon gases emanating from the pyrolysis reactor to obtain the Tyre Pyrolysis Oil (TPO).

[0018] In some embodiments, the pyrolysis oil has a density ranging from 0.80 to 0.99 g/cc, kinetic viscosity ranging from 4.00 to 40.0 mm²/s when measured at 40°C and flash point ranging from 20°C to 80°C, and wherein the used cooking oil (UCO) has a density ranging from 0.80 to 0.99 g/cc, and kinetic viscosity ranging from 35 to 65 mm²/s when measured at 40°C.

DETAILED DESCRIPTION

[0019] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.

[0020] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the “invention” may in some cases refer to certain specific embodiments only. In other cases, it will be recognized that references to the “invention” will refer to subject matter recited in one or more, but not necessarily all, of the claims.

[0021] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

[0022] All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

[0023] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.

[0024] The present disclosure relates to a method for co-processing a pyrolysis oil or its fractionated heavy product with used cooking oil (UCO) and/or vacuum gas oil (VGO) to obtain value added hydrocarbon products therefrom. [0025] An aspect of the present disclosure provides a process for production of naphtha and light olefins, said process comprising: (a) feeding a pyrolysis oil or fractionated heavy product thereof, and at least one of: used cooking oil (UCO) and vacuum gas oil (VGO) to a fluid catalytic cracking (FCC) reactor; (b) catalytically cracking said pyrolysis oil or fractionated heavy product thereof, and the at least one of: used cooking oil (UCO) and vacuum gas oil (VGO) in the fluid catalytic cracking (FCC) reactor at a temperature ranging from 400°C to 700°C to obtain a liquid stream of products, a gaseous stream of products comprising light olefins, and a bottoms stream; and (c) subjecting the liquid stream of products to fractionation to obtain a naphtha stream. In some embodiments, the step of catalytic cracking is effected in presence of a catalyst selected from: ZSM-5 catalyst and fluid catalytic cracking (FCC) catalyst. In some embodiments, the step of catalytic cracking is effected at a catalyst to oil ratio ranging from 1 to 12 gram catalyst per gram of oil (gcat/goil).

[0026] Pyrolysis oil, for example, tyre pyrolysis oil (TPO) is known to contain significant amounts of impurities such as heavy metals, sulfur and nitrogen compounds, poly-aromatic hydrocarbons (PAH) etc., owing to which direct processing of the pyrolysis oil (particularly, tyre pyrolysis oil) has been considered as non-feasible. Consequently, significant research has been doneso far to reduce the amounts of impurities present in the pyrolysis oil by subjecting it to various purification processes such as, subjecting the pyrolysis oil to hydrogenation (hydroprocessing reaction) in presence of hydrogenation catalyst and the likes. However, such purification steps/techniques adds significant cost to the overall processing while making the overall process energy intensive, laborious and complex. The process of the present disclosure is amenable to use of pyrolysis oil or fractionated heavy product thereof that has not been subjected to any purification process(es). Simply put, pyrolysis oil or fractionated heavy product thereof that has not been subjected to any purification process(es) can be directly used as feedstock in the process of the present disclosure, making the process of the present disclosure further cost-effective and simple, precluding the need of additional processing units/equipments. Accordingly, advantageously, in some embodiments, the pyrolysis oil or fractionated heavy product thereof is not subjected to purification before feeding to the fluid catalytic cracking (FCC) reactor. Similarly, in some embodiments, the used cooking oil (UCO)is not subjected to purification before feeding to the fluid catalytic cracking (FCC) reactor.

[0027] In some embodiments, the pyrolysis oil or fractionated heavy product thereof and at least one of: used cooking oil (UCO) and vacuum gas oil (VGO) are blended before feeding to the fluid catalytic cracking (FCC) reactor. In some embodiments, the pyrolysis oil or fractionated heavy product thereof and the at least one of: used cooking oil (UCO) and vacuum gas oil (VGO) are blended in a mass ratio ranging from 1:1 to 1:20. In some embodiments, the pyrolysis oil or fractionated heavy product thereof and the at least one of: used cooking oil (UCO) and vacuum gas oil (VGO) are blended at a temperature ranging from 30°C to 80°C.

[0028] In some embodiments, the pyrolysis oil or fractionated heavy product thereof, used cooking oil (UCO) and vacuum gas oil (VGO) are blended before feeding to the fluid catalytic cracking (FCC) reactor. In some embodiments, the pyrolysis oil or fractionated heavy product thereof, used cooking oil (UCO) and vacuum gas oil (VGO) are blended in a mass ratio ranging from 1:1:2 to 1:1:18. In some embodiments, the pyrolysis oil or fractionated heavy product thereof, used cooking oil (UCO) and vacuum gas oil (VGO) are blended at a temperature ranging from 30°C to 80°C.

[0029] In some embodiments, the liquid stream of products from the fluid catalytic cracking (FCC) reactor is subjected to fractionation to obtain the naphtha stream, a Light Cycle Oil (LCO) stream, and a Heavy Cycle Oil (HCO) stream and/or a bottoms stream. In some embodiments, the HCO stream and/or the bottoms stream is recycled to the fluid catalytic cracking (FCC) reactor. In some embodiments, the naphtha stream and the LCO stream are subjected to hydro-treatment to obtain hydrocarbon fuels. In some embodiments, naphtha and diesel fraction streams from tyre pyrolysis oil (TPO) fractionation unit are subjected to hydro-treatment to obtain hydrocarbon fuels.

[0030] In some embodiments, the pyrolysis oil or fractionated heavy product thereof comprises pyrolysis oil, said pyrolysis oil being a Tyre Pyrolysis Oil (TPO). In some embodiments, the pyrolysis oil or fractionated heavy product thereof comprises a bottoms stream resulting from fractionation of a Tyre Pyrolysis Oil (TPO). In an embodiment, the Tyre Pyrolysis Oil (TPO) is obtained by: (a) taking tyre particles having particle size ranging from 0.5 mm to 5.0 mm; (b) subjecting the tyre particles to pyrolysis in a pyrolysis reactor at a temperature ranging from 300°C to 550°C; and (c) condensing the volatile hydrocarbon gases emanating from the pyrolysis reactor to obtain the Tyre Pyrolysis Oil (TPO).

[0031] In some embodiments, the pyrolysis oil has a density ranging from 0.8 to 0.99 g/cc, kinetic viscosity ranging from 4.00 to 40.0 mm²/s when measured at 40°C and flash point ranging from 20°C to 80°C, and wherein the used cooking oil (UCO) has a density ranging from 0.80 to 0.99 g/cc, and kinetic viscosity ranging from 35 to 65 mm²/s when measured at 40°C. [0032] FIG. 1 illustrates an exemplary process for converting pyrolysis oil into high quality hydrocarbon fuels, in accordance with an embodiment of the present disclosure. As can be seen from FIG. 1, pyrolysis oil and at least one of: used cooking oil (UCO) and vacuum gas oil (VGO) are fed to a fluid catalytic cracking (FCC) reactor for catalytic cracking thereof to obtain liquid and gaseous product streams and a bottoms stream. Alternatively, pyrolysis oil, used cooking oil (UCO) and vacuum gas oil (VGO) can be fed to a fluid catalytic cracking (FCC) reactor for catalytic cracking thereof. Temperature within the FCC reactor ranges from 400°C to 700°C, preferably, between 400°C and 650°C. Catalytic cracking can be effected in presence of a catalyst selected from: ZSM-5 catalyst and fluid catalytic cracking (FCC) catalyst. Catalyst to oil ratio ranges from 1 to 12 gram catalyst per gram of oil (gcat/goil), preferably, ranging from 4 to 10 gram catalyst per gram of oil (gcat/goil). Gaseous product stream typically contains dry gas mostly having hydrogen, methane, CO and CO2, and light olefins containing C2= to C4= hydrocarbons. Liquid product stream is fed to a fractionator to obtain naphtha, light cycle oil (LCO), heavy cycle oil (HCO) and bottom hydrocarbon products streams. As can also be seen from FIG. 1, the pyrolysis oil is obtained by: (a) taking tyre particles, preferably, particles having particle size ranging from 0.5 mm to 5.0 mm; (b) subjecting the tyre particles to pyrolysis in a pyrolysis reactor at a temperature ranging from 300°C to 550°C; and (c) condensing the volatile hydrocarbon gases emanating from the pyrolysis reactor to obtain the Tyre Pyrolysis Oil (TPO).The heat or cokebalance required in a fluid catalytic cracking (FCC) reactor may be met, at least in part, by sending pyrolysis gas or solid char to the fluid catalytic cracking (FCC) reactor. In some embodiments, the pyrolysis reactor can be operatively coupled with the FCC reactor such that the pyrolysis oil from the reactor can be fed to the FCC reactor.

[0033] FIG. 2 illustrates an exemplary process for converting pyrolysis oil into high quality hydrocarbon fuels, in accordance with an embodiment of the present disclosure. As can be seen from FIG. 2, the tyre particles are subjected to pyrolysis in a pyrolysis reactor at a temperature ranging from 300°C to 550°C to obtain Tyre Pyrolysis Oil (TPO). The size of tyre particles is in the range of 0.5-5mm. The heat requirement of pyrolysis reactor may be met, at least in part, by burning pyrolysis gas, as the pyrolysis gas has high heating value of 25-35 MJ/ Kg. Tyre Pyrolysis Oil (TPO) so obtained is then subjected to fractionation in a fractionation column (Fractionation- 1) to obtain a naphtha stream, a diesel fraction stream and a bottoms stream. The naphtha stream and diesel fraction stream from the fractionation column are fed to a hydro -treatment unit to remove Sulphur and Oxygen impurities. [0034] The bottoms stream from the fractionation column is blended with any or a combination of: used cooking oil (UCO) and vacuum gas oil (VGO)in a mass ratio ranging from 1:1 to 1:20, preferably, in a mass ratio ranging from 1:1 to 1:10 and more preferably, in a mass ratio ranging from 1:1 to 1 : 8. Alternatively, the bottoms stream from the fractionation column is blended with used cooking oil (UCO) and vacuum gas oil (VGO)in a mass ratio ranging from 1:1:2 to 1:1:18, preferably, in a mass ratio ranging from 1:1:3 to 1:1:8 and more preferably, in a mass ratio ranging from 1:1:4 to 1:1:9. The blending is done at a temperature ranging from 30°C to 80°C in a vessel (for example, a stainless steel vessel). Shear mixing may be done to obtain a uniform blend. The blend is then fed to a fluid catalytic cracking (FCC) reactor. Any conventional fluid catalytic cracking (FCC) reactor may be used. Catalytic cracking of the blend feed is then done at a temperature ranging from 400°C to 700°C, preferably, between 400°C and 650°C, in presence of catalyst, such as a FCC catalyst like Equilibrium fluid catalytic cracking catalyst (E-Cat) and/or ZSM-5 catalyst to obtain a liquid stream of products, a gaseous stream of products, and a bottoms stream. The gaseous stream of products typically contains dry gas mostly having hydrogen, methane, CO and CO2, and light olefins containing C2= to C4= hydrocarbons. The liquid stream of products is fed to a fractionation column (Fractionation-2) to obtain a naphtha stream, a light cycle oil (LCO) stream, a heavy cycle oil (HCO) stream and/ora bottoms hydrocarbon products stream. The HCO stream and/or the bottoms stream is recycled/fed to the fluid catalytic cracking (FCC) reactor. The naphtha stream and the LCO stream from the fractionation column (Fractionation-2) are fed (co-fed) along with the naphtha stream and diesel fraction stream from the fractionation column (Fractionation- 1) to a hydrotreatment unit. The hydrotreatment unit can be a fixed bed rector operated at a temperature in the range of 250- 450°C and pressure in the range of 0-100bar, preferably 3O-8Obarin presence of a hydrotreating catalyst. The product stream from the hydrotreatment unit may be fed to a separator to separate hydrocarbon products like gasoline, kerosene and diesel.

[0035] FIG. 3 illustrates an exemplary schematic representation of a fluid catalytic cracking (FCC) reactor, which can be used for effecting process of the present disclosure. As can be seen from FIG. 3, the FCC reactor 300 includes a reactor 25 and a catalyst regenerator 15. Spent (or used)catalyst is subjected to combustion in the catalyst regenerator 15 in presence of air to remove char/coke deposited thereon to regenerate the catalyst. Catalyst regeneration is well-known to skilled artisans and hence, the catalyst regeneration process is not detailed herein. The Spent (or used) catalyst from the reactor 25 is supplied to the catalyst regenerator 15 via line 60, and air required for the catalyst regeneration is supplied to the regenerator via line 30. Gases emanating from the catalyst regenerator 15 are removed via line 40. Regenerated catalyst from catalyst regenerator 15 is supplied to the reactor via line 70.

[0036] The fossil based hydrocarbon feed stream (such as vacuum gas oil) is injected via line 10, and the tyre pyrolysis oil (TPO) is injected downstream of the fossil based hydrocarbon stream (such as VGO stream) via line 20 into the reactor 25. Alternatively, tyre pyrolysis oil (TPO) feed stream is blended with the fossil based hydrocarbon feed stream (VGO stream) prior to injection and the blended feed stream is injected via line 10. Similarly, used cooking oil (UCO) is blended with the tyre pyrolysis oil (TPO) and injected via line 20, downstream of the fossil based hydrocarbon feed (VGO stream). Still alternatively, tyre pyrolysis oil (TPO) is injected via line 10 and used cooking oil (UCO) via line 20. The recycled heavy fraction (HCO/bottoms stream) from the fractionation column (Fractionation- 2) is blended with the fossil based hydrocarbon feed stream (VGO stream) and injected via line 10. The heat required for the cracking is supplied by hot regenerated catalyst from regenerator 15. The product stream from the reactor 25 is removed via line 50.

[0037] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

EXAMPLES

[0038] PRODUCTION OF WASTE TYRE OIL

[0039] About 500gm of waste tyre particles having particle size in the range from 0.8-2.0 mm were placed inside a vertical stainless steel reactor above the bed of alumina balls. The tyre particles were free from stainless teel and synthetic fibers. The reactor was kept at steady state temperature of 480±10°C for about 4 hours in order to ensure complete pyrolysis of waste tyre particles. During the whole pyrolysis process, continuous nitrogen supply of about 6SLPM was maintained to ensure inert conditions inside the pyrolysis reactor. The cooling system was maintained at -10°C to condense the volatile hydrocarbon gases to collect the pyrolysis oil. After completion of pyrolysis, the tyre pyrolysis oil (TPO) was collected and analyzed for its properties. The properties of the waste tyre pyrolysis oil (TPO) are provided in Table 1 below. Table 1: Properties of tyre pyrolysis oil (TPO)

[0040] CATALYTIC CO-CRACKING OF TYRE PYROLYSIS OIL (TPO)WITH VACUUM GAS OIL (VGO) [0041] Catalytic cracking experiments were conducted at lab scale in Advanced Cracking

Evaluation (ACE) unit, which is bench scale fluid catalytic cracking (FCC) unit using equilibrium commercial FCC catalyst. The reaction conditions were: temperature: 560°C, and Cat/oil ratio (C/O):4 to 9.6 gcat/goil. During cracking experiments, feed was injected for 30seconds with feed rate of 2.5gm/min. After the experiment, the liquid product was condensed and collected in a glass receiver maintained at -15°C. In-house produced tyre pyrolysis oil (TPO), produced in Example above, was blended with vacuum gas oil (VGO) in a mass ratio of 1:4 and used for cracking experiments. The experimental results are shown in Table 2 below.

Table 2: Product distribution at ROT of 560°C

[0042] It could be observed that TPO and VGO+TPO blend resulted in 12% and 4% increase in naphtha fraction with C/O ratio of 8 compared to VGO. The blend resulted in higher naphtha and LCO yield compared to pure VGO. By processing blended feedstock value addition happened to TPO.

5 [0043] CATALYTIC CO-CRACKING OF TYRE PYROLYSIS OIL (TPO)WITH

USED COOKING OIL(UCO) USING EQUILIBRIUM FCC CATALYST (E-CAT) [0044] The cracking experiments were conducted at lab scale in Advanced Cracking Evaluation (ACE) unit, which is bench scale FCC unit using equilibrium commercial FCC catalyst. The reaction conditions were - temperature: about 560°C, Cat/oil ratio (C/O): 4 to

10 9.6 gcat/goil. During cracking experiments, feed was injected for about 30seconds with feed rate of about 2.5gm/min. After experiment, the liquid product was condensed and collected in a glass receiver maintained at about -15°C. In house produced TPO (from Example above) was blended with UCO in 1:4 mass ratio and used for cracking experiments. The properties of UCO are shown in Table 3 below. The catalytic cracking experimental results are shown in

15 Table 4 below.

Table 3: Properties of Used Cooking Oil (UCO)

Table 4: Yield of total light olefins using TPO+UCO blend with E-Cat

[0045] The total light olefins yield was found to be approx. 17% using UCO at C/O of 9.6. In case of blend, approximately 16% light olefins produced at C/O of 9.6. The blend of UCO and TPO resulted in approximately 50% gasoline in case of cat/oil ratio of 4, whereas other cat/oil ratios resulted in more than 51% gasoline.

[0046] CATALYTIC CO-CRACKING OF TYRE PYROLYSIS OIL (TPO)WITH USED COOKING OIL(UCO) USING EQUILIBRIUM FCC CATALYST (E-CAT) AND ZSM-5

[0047] The cracking experiments were conducted at lab scale in Advanced Cracking Evaluation (ACE) unit, which is bench scale FCC unit, using ZSM-5 (30wt%) added with equilibrium commercial FCC catalyst (E-Cat). The reaction conditions were - temperature: about 560°C, Cat/oil ratio(C/O):4 to 9.6 gcat/goil. During cracking experiments, feed was injected for about 30seconds with feed rate of about 2.5gm/min. After experiment, the liquid product was condensed and collected in a glass receiver maintained at about -15°C. In house produced TPO (from Example above) was blended with UCO in 1:4 mass ratio and used for cracking experiments. The catalytic cracking experimental results are shown in Table 5 below.

Table 5: Yield of total light olefins using TPO+UCO blend with E-Cat + ZSM-5

[0048] It could be observed that in presence of ZSM-5, the naphtha yield has been decreased slightly. On the other hand, LPG and dry gas yield increased significantly. Upon blending with UCO, TPO resulted in 28.24-29.45wt% total light olefins and up to 42.35 - 46.78 wt% Naphtha as compared to that using 100% TPO (i.e. using TPO alone).

[0049] Although the subject matter has been described herein with reference to certain preferred embodiments thereof, other embodiments are possible. As such, the spirit and scope of the appended claims should not be limited to the description of the preferred embodiment contained therein. Furthermore, precise and systematic details on all above aspects are currently being made. Work is still underway on this invention. It will be obvious to those skilled in the art to make various changes, modifications and alterations to the invention described herein. To the extent that these various changes, modifications and alterations do not depart from the scope of the present invention, they are intended to be encompassed therein.

ADVANTAGES

[0050] The present disclosure provides a process for converting pyrolysis oil optionally, along with used cooking oil into high quality hydrocarbon fuels such as LPG, naphtha and light olefins.

[0051] The present disclosure provides a process for converting pyrolysis oil into high quality hydrocarbon fuels that aids in conserving energy and improves overall productivity.

[0052] The present disclosure provides a process for converting pyrolysis oil into high quality hydrocarbon fuels that is simple and economical.

[0053] The present disclosure provides a process that is technically and commercially feasible.

[0054] The present disclosure provides a process for waste tyre management and to bring back waste tyre into circular economy by reducing carbon foot print.

Claims

We Claim:

1. A process for production of naphtha and light olefins, said process comprising:

(a) feeding a pyrolysis oil or fractionated heavy product thereof, and at least one of: used cooking oil (UCO) and vacuum gas oil (VGO) to a fluid catalytic cracking (FCC) reactor;

(b) catalytically cracking said pyrolysis oil or fractionated heavy product thereof, and the at least one of: used cooking oil (UCO) and vacuum gas oil (VGO) in the fluid catalytic cracking (FCC) reactor at a temperature ranging from 400°C to 700°C to obtain a liquid stream of products, a gaseous stream of products comprising light olefins and a bottoms stream; and

(c) subjecting the liquid stream of products to fractionation to obtain naphtha.

2. The process as claimed in claim 1, wherein said pyrolysis oil or fractionated heavy product thereof is not subjected to purification before feeding to the fluid catalytic cracking (FCC) reactor, further wherein the used cooking oil (UCO) is not subjected to purification before feeding to the fluid catalytic cracking (FCC) reactor.

3. The process as claimed in claim 1, wherein said pyrolysis oil or fractionated heavy product thereof and at least one of: used cooking oil (UCO) and vacuum gas oil (VGO) are blended before feeding to the fluid catalytic cracking (FCC) reactor.

4. The process as claimed in claim 2, wherein said pyrolysis oil or fractionated heavy product thereof and the at least one of: used cooking oil (UCO) and vacuum gas oil (VGO) are blended in a mass ratio ranging from 1:1 to 1:20.

5. The process as claimed in claim 2, wherein said pyrolysis oil or fractionated heavy product thereof and the at least one of: used cooking oil (UCO) and vacuum gas oil (VGO) are blended at a temperature ranging from 30°C to 80°C.

6. The process as claimed in claim 2, wherein said pyrolysis oil or fractionated heavy product thereof, used cooking oil (UCO) and vacuum gas oil (VGO) are blended in a mass ratio ranging from 1:1:2 to 1: 1:18.

7. The process as claimed in claim 6, wherein said pyrolysis oil or fractionated heavy product thereof, used cooking oil (UCO) and vacuum gas oil (VGO) are blended at a temperature ranging from 30°C to 80°C.

8. The process as claimed in claim 1, wherein the step of catalytic cracking is effected in presence of a catalyst selected from: ZSM-5 catalyst, and FCC catalyst, at a catalyst to oil ratio ranging from 1 to 12 gram catalyst per gram of oil (gcat/goil).

9. The process as claimed in claim 1, wherein the liquid stream of products is subjected to fractionation to obtain the naphtha stream, a Light Cycle Oil (LCO) stream, and a Heavy Cycle Oil (HCO) stream and/or a bottoms stream.

10. The process as claimed in claim 9, wherein the HCO stream and/or the bottoms stream is recycled to the fluid catalytic cracking (FCC) reactor.

11. The process as claimed in claim 9, wherein the naphtha stream and the LCO stream are subjected to hydrotreatment to obtain hydrocarbon fuels.

12. The process as claimed in claim 1, wherein said pyrolysis oil or fractionated heavy product thereof comprises pyrolysis oil, said pyrolysis oil being a Tyre Pyrolysis Oil (TPO).

13. The process as claimed in claim 1, wherein said pyrolysis oil or fractionated heavy product thereof comprises a bottoms stream resulting from fractionation of a Tyre Pyrolysis Oil (TPO).

14. The process as claimed in any one of claims 12 and 13, wherein the Tyre Pyrolysis Oil (TPO) is obtained by: (a) taking tyre particles having particle size ranging from 0.5 mm to 5.0 mm; (b) subjecting the tyre particles to pyrolysis in a pyrolysis reactor at a temperature ranging from 300°C to 550°C; and (c) condensing the volatile hydrocarbon gases emanating from the pyrolysis reactor to obtain the Tyre Pyrolysis Oil (TPO).

15. The process as claimed in claim 1, wherein the pyrolysis oil has a density ranging from 0.80 to 0.99 g/cc, kinetic viscosity ranging from 4.00 to 40.0 mm²/s when measured at 40°C and flash point ranging from 20°C to 80°C, and wherein the used cooking oil (UCO) has a density ranging from 0.80 to 0.99 g/cc, and kinetic viscosity ranging from 35 to 65 mm²/s when measured at 40°C.