Pyrolysis Oil Fractionation for Specific Applications

A method to treat pyrolysis oil from plastic waste and solid recovered fuel (SRF) to remove impurities and make it suitable for upgrading. The method involves selective hydrogenation of the feedstock containing pyrolysis oil at low hydrogen pressures and temperatures to reduce diene content without forming polymers. This is followed by hydroconversion in ebullated, entrained, or moving bed reactors with hydroconversion catalysts to further process the hydrogenated oil. The hydroconversion step removes metals, silicon, halogens, and foreign elements. The resulting hydrocarbon effluent can be further processed for upgrading applications.

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Integrated separation and energy recovery process for extracting oil and gas from oil sands pyrolysis. The process involves recirculating the pyrolysis oil and gas at different temperatures within the separation tower to extract energy. This eliminates the need for large water washing steps and allows higher energy recovery. The recirculation pumps and heat exchangers extract heat from the oil and gas at different sections. The bottom section recirculates hot oil, middle section recirculates intermediate oil, and top section recirculates cooled gas. This allows separating the oil fractions using stripping towers and condensing the gas for reuse.

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Method for processing feedstocks containing plastic pyrolysis oil and feedstocks derived from renewable resources to remove impurities that can cause handling problems and compatibility issues when using the oils as feedstocks for processes like steam cracking or polymerization. The method involves simultaneous hydrogenation, hydrodemetalation, hydrotreating, and hydrocracking of the feedstocks to purify them. This allows integrating renewable oils into existing processes without issues. The hydrogenation step removes insolubles and diolefins. Hydrodemetalation removes metals. Hydrotreating removes impurities like sulfur and nitrogen. Hydrocracking converts heavy compounds. This purifies the oils and allows higher yields of light olefins from pyrolysis oil. The renewable oils can be introduced at different steps based

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A method for producing fuel oil using pyrolysis oil from waste plastics as a replacement for high value fuel oil components like kerosene, gas oil, and residue. The pyrolysis oil is fractionated into distillate and heavy oil fractions. The heavy fraction is blended with the traditional fuel oil components to make the final fuel oil product. This allows recycling waste plastics back into fuel oil production and reduces the need for kerosene and other high value feedstocks. The method involves pyrolyzing mixed waste plastics to produce pyrolysis oil, then separating it into distillate and heavy fractions. The heavy fraction is blended with kerosene, gas oil, residue, etc. to make the final fuel oil.

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A continuous refining process for waste plastic pyrolysis oil that reduces impurities, improves quality, and mitigates process issues. The process involves three steps: 1) isodewaxing to improve pour point, 2) hydrotreating to remove chlorine and nitrogen, and 3) further hydrotreating to further reduce impurities. The process uses weak acid catalysts and specific temperature ranges in each step to optimize reactions without excessive side effects. The continuous refining device with reactors allows scaling up the process for commercial applications.

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Rapid separation of pyrolysis pine wood products to obtain high-value chemicals like alcohols, phenols, ketones, and levoglucosan. The separation involves sequential condensation and electric capture steps at temperatures from 90-120°C to -196°C. This allows selective collection of heavy oil, light oils, and tar fractions enriched in desired compounds.

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Refining high-quality light oil from pyrolysis oil to make it versatile as fuel. The process involves pre-treating the pyrolysis oil to remove impurities, stripping out heavy oil, cracking the remaining hydrocarbons, fractionally distilling the cracked oil, and filtering the final light oil to purify it. This refining method converts pyrolysis oil into high-quality light oil suitable as a general-purpose fuel.

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Producing detergents and surfactants from waste plastic feedstocks like pyrolyzed plastics using a combined feed of waste plastic oil and crude oil. The feedstocks are combined, pretreated, and fractionated to produce hydrocarbon streams for further processing into target chemicals like linear alkylbenzenes, oxo alcohols, and surfactants. This allows making detergents from waste plastic without requiring extensive cleanup of the pyrolysis oil.

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Fractionating pyrolysis oil into useful products like gasoline, distillate, heavy oil, and fuel gas while removing contaminants like halogens and metals. The process involves dehydrohalogenation, decontamination, and hydrogenation in a treatment catalyst bed above the pyrolysis oil inlet. The treated oil is then fractionated into light, middle, heavy, and bottom streams. The light stream is condensed to produce gasoline and fuel gas. The middle stream is stripped to make distillate. This allows extracting valuable components like gasoline while removing undesirable ones like halogens and metals.

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Optimizing recovery of recycled content products from waste plastic pyrolysis by separating and sending specific streams to downstream processing facilities like crackers. The process involves pyrolyzing waste plastic to produce a pyrolysis oil stream. Some of the oil is separated into a depleted raffinate stream and an enriched extract stream. The raffinate is sent to the cracker, while the extract is further processed. This allows recovering valuable aromatics and diolefins from the pyrolysis oil upstream of the cracker, improving recycled content product yield compared to direct feeding the pyrolysis effluent.

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Refining waste plastic pyrolysis oil to produce high value-added hydrocarbon oil with a high content of naphtha and kerosene. The refining process involves hydrotreating the waste plastic pyrolysis oil in a first reactor region to remove impurities like nitrogen, chlorine, and olefins. Then, the hydrotreated oil is further hydrocracked in a second reactor region to produce naphtha and kerosene. The two reaction zones are separated and operated at lower pressures and optimized LHSV ratios to maximize naphtha/kerosene yields.

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Refining waste plastic pyrolysis oil to produce high value-added hydrocarbon oil with high naphtha and kerosene content. The refining process involves two reactors in series. In the first reactor, the waste pyrolysis oil and hydrogen react to remove impurities. In the second reactor, the oil from the first reactor is split into two regions. In the first region, secondary hydrotreating removes further impurities. In the second region, hydrocracking converts the oil into naphtha and kerosene. The dual reactor setup with staged hydrotreating and hydrocracking allows efficient impurity removal and high naphtha/kerosene yield from waste pyrolysis oil.

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A process to make fuel products from waste rubber pyrolysis oil with improved stability and flash point for marine fuels. The process involves pyrolyzing waste rubber like tires to extract an oil. The oil is then separated to remove solids and further processed to obtain a fuel product with specific properties. The fuel has a flash point above 40°C, low boiling point, low density, low acid number, low styrene, and low halogen content. This fuel can be blended into marine fuels to improve stability without the need for expensive specialized storage and transportation equipment.

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Method to purify liquid pyrolysis oil from waste plastic without fouling and instability issues. The method involves pyrolyzing the plastic to produce a gaseous pyrolysis product. This is then condensed into liquid pyrolysis oil fractions. Next, the fractions are further purified by removing heterogenates using extraction, adsorption, or precipitation. This results in stable, clear, and unsaturated pyrolysis oil fractions that can be used for chemical applications without fouling issues. The purification steps avoid problems like fouling, filming, and gelling that can occur in the raw pyrolysis oil.

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A process for fractionating biomass pyrolysis oil into two distinct phases: a hydrophobic aromatic fraction (HAF) and a concentrated aqueous solution of water soluble organics. The fractionation uses solvent/anti-solvent concepts to quantitatively separate the hydrophobic and hydrophilic components in pyrolysis oil. The process involves phase separation of pyrolysis oil using a solvent that selectively extracts the hydrophobic aromatic fraction. The solvent is then distilled to recover it along with the aromatic fraction. The aqueous phase is further processed by liquid-liquid extraction with solvents to extract and recover water soluble organics like pyrolytic sugars and low molecular weight phenolics. This allows selective extraction of valuable components from pyrolysis oil for various applications like fuel,

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Process to produce both un-hydrogenated and hydrogenated C9+ hydrocarbons from pyrolysis gasoline. The process involves separating the pyrolysis gasoline stream to produce a first stream containing primarily un-hydrogenated C9+ compounds. A portion of the un-hydrogenated stream is hydrogenated to produce hydrogenated C9+ compounds in a separate step. This allows concurrent production of both un-hydrogenated and hydrogenated C9+ hydrocarbons.

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A method for separating tar components from high temperature oil and gas produced by pyrolysis of organic materials like coal and biomass. The method involves fractional condensation followed by rectification. The condensation stages are sequential condensers that cool and condense the oil and gas stream at progressively lower temperatures. This allows separation of the tar components into fractions based on boiling point. The condensed fractions are then further separated by rectification to purify and concentrate specific tar components. This two-stage process provides improved recovery of light oil and purity compared to just condensation. It also reduces organic matter in the water phase.

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Upgrading mixed waste plastic pyrolysis oil to make it suitable for use as a diesel fuel. The process involves hydroprocessing the pyrolysis oil in a section with separate units for heavy, middle, and light fractions. The fractions are dynamically adjusted based on desired diesel properties and fed to the corresponding units. This allows customization of the upgrading conditions for each fraction to optimize conversion and improve the overall product quality.

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Fractionation of biomass-based materials like crude tall oil (CTO) to separate out components like rosin acid and fatty acids while minimizing degradation. The process involves using a series of thin film evaporators (TFEs) and short path evaporators (SPEs) in sequence for dealkitration. This allows partial liquefaction of the feed before distillation, reducing vapor load and pressure drop in subsequent columns. It also enables lower temperatures compared to single TFEs to prevent degradation.

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Efficient and effective methods for separating pyrolysis oil from tire pyrolysis into commercially desirable fractions and a fuel oil fraction. The methods involve initial thin-film distillation to separate a lighter fraction and a heavier fraction. The lighter fraction is further fractionally distilled to obtain improved quality products. The heavier fraction is processed to remove sulfur and nitrogen for use as a fuel oil. The thin-film distillation allows stable separation of the fractions due to low wall temperatures. Vacuum thin-film distillation at 100-400 torr further improves separation.

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