Patent Application
20220402845
The invention relates to recycle content in oxo alcohols and oxo plasticizers. In particular, this invention relates to oxo alcohols and oxo plasticizers where such recycle content was obtained directly or indirectly from effluents generated from pyrolyzing recycled waste material and thermally cracking the resulting recycle content pyoil or generating and using the pygas from the pyrolysis of the recycled waste material.
Oxo alcohols and oxo plasticizers are important products in organic synthesis. Formed by the hydroformylation of olefins with synthesis gas, the resulting aldehydes may be converted to alcohols, which can be hydrogenated and optionally further reacted to form these valuable chemicals. Many oxo alcohols and plasticizers are used in a variety of plasticized polymer compositions, including PVC. Additionally, oxo alcohols can be used as intermediates for other important chemicals, including, but not limited to acetates, glycol ethers, and acrylates.
Moreover, solid waste materials, especially non-biodegradable recycled waste materials, can negatively impact the environment when disposed of in landfills after a single use. Thus, from an environmental standpoint, it is desirable to recycle as much waste material as possible. However, recycling waste materials can be challenging from an economic standpoint.
While some waste materials are relatively easy and inexpensive to recycle, other waste materials require significant and expensive processing in order to be reused. Further, different types of waste materials often require different types of recycling processes.
To maximize recycling efficiency, it would be desirable for large-scale production facilities to be able to process feedstocks having recycle content originating from a variety of recycled waste materials. Commercial facilities involved in the production of non-biodegradable products or products that find their ultimate destination in a landfill could benefit greatly from using recycle content feedstocks.
Some recycling efforts involve complicated and detailed segregation of recycled waste streams, which contributes to the increased cost of obtaining streams of recycled waste content. For example, conventional methanolysis technologies require a high purity stream of PET. Some downstream products are also quite sensitive to the presence of dyes and inks on recycled waste products, and their pretreatment and removal also contributes to increased costs of feedstocks made from such recycled wastes. It would be desirable to establish a recycle content without the necessity for sorting down to a single type of plastic or recycled waste material, or which can tolerate a variety of impurities in recycled waste streams that flow through to a feedstock.
In some cases, it may be difficult to dedicate a product having a recycle content to a particular customer or downstream synthetic process for making a derivate of the product, particularly if the recycle content product is a gas or difficult to isolate. As related to a gas, there is a lack of infrastructure to segregate and distribute a dedicated portion of a gas made exclusively from a recycle content feedstock since the gas infrastructure is continuously fluid and often commingles gas streams from a variety of sources.
Further, it is recognized that some regions desire to move away from sole dependence on natural gas, ethane, or propane as the sole source for making raw materials products such as ethylene and propylene and their downstream derivatives, and alternative or supplemental feedstocks to crackers would be desirable.
It is also desirable to synthesize oxo alcohols and oxo plasticizers using existing equipment and processes and without the need to invest in additional and expensive equipment in order to establish a recycle content in the manufacture of the chemical compound or polymer.
It is also desirable to continue sourcing a raw material for making oxo alcohols and oxo plasticizers from olefins obtained from cracker facilities that may find themselves stranded as production from a natural gas field or petroleum becomes economically unattractive.
Further, it is desirable for manufacturers of oxo alcohols and oxo plasticizers to not be solely dependent on obtaining credits to establish a recycle content in oxo alcohols and oxo plasticizers and thereby provide the manufacturer with a variety of choices to establish recycle content.
It would also be desirable for manufacturers of oxo alcohols and oxo plasticizers to be able to determine the amount and timing of establishing recycle content. The manufacturers, at certain times or for different batches, may desire to establish more or less recycle content or no recycle content. The flexibility in this approach without the need to add significant assets is desirable.
There is now provided a method of obtaining a recycle content oxo alcohol or oxo plasticizer composition, a recycle content alkylene glycol, and a recycle content polyester, uses thereof, compositions thereof, and systems thereof, each as further described in the claims and detailed description.
As used herein, “containing” and “including” are open ended and synonymous with “comprising.”
The term “recycle content” is used herein i) as a noun to refer to a physical component (e.g., compound, molecule, or atom) at least a portion of which is derived directly or indirectly from recycled waste or ii) as an adjective modifying a particular composition (e.g., a compound, polymer, feedstock, product, or stream) at least a portion of which is directly or indirectly derived from recycled waste.
As used herein, “recycle content composition,” “recycle composition,” and “r-composition” mean a composition having recycle content.
The term “pyrolysis recycle content” is used herein i) as a noun to refer to a physical component (e.g., compound, molecule, or atom) at least a portion of which is derived directly or indirectly from the pyrolysis of recycled waste or ii) as an adjective modifying a particular composition (e.g., a feedstock, product, or stream) at least a portion of which is directly or indirectly derived from the pyrolysis of recycled waste. For example, pyrolysis recycle content can be directly or indirectly derived from recycle content pyrolysis oil, recycle content pyrolysis gas, or the cracking of recycle content pyrolysis oil such as through thermal steam crackers or fluidized catalytic crackers.
As used herein, “pyrolysis recycle content composition,” “pyrolysis recycle composition,” and “pr-composition” mean a composition (e.g., a compound, polymer, feedstock, product, or stream) having pyrolysis recycle content. A pr-composition is a subset of a r-composition, where at least a portion of the recycle content of the r-composition is derived directly or indirectly from the pyrolysis of recycled waste.
As used herein, a composition (e.g., compound, polymer, feedstock, product, or stream) “directly derived” or “derived directly” from recycled waste has at least one physical component that is traceable to recycled waste, while a composition (e.g., a compound, polymer, feedstock, product, or stream) “indirectly derived” or “derived indirectly” from recycled waste has associated with it a recycle content allotment and may or may not contain a physical component that is traceable to recycled waste.
As used herein, a composition (e.g., compound, polymer, feedstock, product, or stream) “directly derived” or “derived directly” from the pyrolysis of recycled waste has at least one physical component that is traceable to the pyrolysis of recycled waste, while a composition (e.g., a compound, polymer, feedstock, product, or stream) “indirectly derived” or “derived indirectly” from the pyrolysis of recycled waste has associated with it a recycle content allotment and may or may not contain a physical component that is traceable to the pyrolysis of recycled waste.
As used herein, “pyrolysis oil” or “pyoil” mean a composition of matter that is liquid when measured at 25° C. and 1 atm and at least a portion of which is obtained from pyrolysis.
As used herein, “recycle content pyrolysis oil,” “recycle pyoil,” “pyrolysis recycle content pyrolysis oil” and “r-pyoil” mean pyoil, at least a portion of which is obtained from pyrolysis, and having recycle content.
As used herein, “pyrolysis gas” and “pygas” mean a composition of matter that is gas when measured at 25° C. and 1 atm and at least a portion of which is obtained from pyrolysis.
As used herein, “recycle content pyrolysis gas,” “recycle pygas,” “pyrolysis content pyrolysis gas” and “r-pygas” mean pygas, at least a portion of which is obtained from pyrolysis, and having recycle content.
As used herein, “Et” is ethylene composition (e.g., a feedstock, product, or stream) and “Pr” is propylene composition (e.g., a feedstock, product, or stream).
As used herein, “recycle content ethylene,” “r-ethylene” and “r-Et” mean Et having recycle content; and “recycle content propylene,” “r-propylene” and “r-Pr” mean Pr having recycle content.
As used herein, “pyrolysis recycle content ethylene” and “pr-Et” mean r-Et having pyrolysis recycle content; and “pyrolysis recycle content propylene” and “pr-Pr” mean r-Pr having pyrolysis recycle content.
As used herein, “recycle content aldehyde,” “recycle aldehyde,” “pyrolysis content aldehyde,” and “r-aldehyde” mean aldehyde, at least a portion of which is obtained from pyrolysis, having recycle content.
As used herein, “pyrolysis recycle content aldehyde” and “pr-aldehyde” mean r-aldehyde having pyrolysis recycle content.
As used herein, “recycle content α,β-α,β-aldehyde,” “recycle α,β-aldehyde,” “pyrolysis content α,β-aldehyde,” and “r-α,β-aldehyde” mean α,β-aldehyde, at least a portion of which is obtained from pyrolysis, having recycle content.
As used herein, “pyrolysis recycle content α,β-aldehyde” and “pr-α,β-aldehyde” mean r-α,β-aldehyde having pyrolysis recycle content.
As used herein, “recycle content oxo alcohol,” “recycle oxo alcohol,” “pyrolysis content oxo alcohol,” and “r-oxo alcohol” mean oxo alcohol, at least a portion of which is obtained from pyrolysis, having recycle content.
As used herein, “pyrolysis recycle content oxo alcohol” and “pr-oxo alcohol” mean r-oxo alcohol having pyrolysis recycle content.
As used herein, “recycle content oxo plasticizer,” “recycle oxo plasticizer,” “pyrolysis content oxo plasticizer,” and “r-oxo plasticizer” mean oxo plasticizer, at least a portion of which is obtained from pyrolysis, having recycle content.
As used herein, “pyrolysis recycle content oxo plasticizer” and “pr-oxo plasticizer” mean r-oxo plasticizer having pyrolysis recycle content.
As used throughout, the generic description of the compound, composition or stream does not require the presence of its species, but also does not exclude and may include its species. For example, an “oxo alcohol” or “oxo plasticizer” or “any oxo alcohol” or “any oxo plasticizer” can include a oxo alcohol and oxo plasticizer made by any process and may or may not contain recycle content and may or may not be made from non-recycle content feedstocks or from recycle content feedstocks, and may or may not include r-oxo alcohol, r-oxo plasticizer, pr-oxo alcohol, or pr-oxo plasticizer. Likewise, r-oxo alcohol and r-oxo plasticizer may or may not include pr-oxo alcohol or pr-oxo plasticizer, although the mention of r-oxo alcohol and r-oxo plasticizer does require that each have recycle content. In another example, an “aldehyde” or “olefin” or “any aldehyde” or “any olefin” can include any aldehyde or olefin made by any process and may or may not have recycle content, and may or may not include r-olefin, r-aldehyde, pr-olefin or pr-aldehyde. Likewise, r-aldehyde or r-olefin may or may not include pr-aldehyde or pr-olefin, although the mention of r-olefin and r-aldehyde does require each have recycle content.
“Pyrolysis recycle content” is a specific subset/type (species) of “recycle content” (genus). Wherever “recycle content” and “r-” are used herein, such usage should be construed as expressly disclosing and providing claim support for “pyrolysis recycle content” and “pr-,” even if not expressly so stated. For example, whenever the term “recycle content oxo alcohol” or “r-oxo alcohol” is used herein, it should be construed as also expressly disclosing and providing claim support for “pyrolysis recycle content oxo alcohol” and “pr-oxo alcohol.” Additionally, whenever the term “recycle content oxo plasticizer” or “r-oxo plasticizer” is used herein, it should be construed as also expressly disclosing and providing claim support for “pyrolysis recycle content oxo plasticizer” and “pr-oxo plasticizer.”
Similarly, whenever the term “olefin,” or “r-olefin,” is used herein, it should be construed as also expressly disclosing and providing claim support for “pyrolysis recycle content olefin,” and “pr-olefin,” as the term “aldehyde,” or “r-aldehyde,” is used herein, it should be construed as also expressly disclosing and providing claim support for “pyrolysis recycle content aldehyde,” and “pr-aldehyde.”
As used throughout, whenever a cracking of r-pyoil is mentioned, such cracking can be conducted by a thermal cracker, or a thermal steam cracker, in a liquid fed furnace, or in a gas fed furnace, or in any cracking process. In one embodiment or in combination with any of the mentioned embodiments, the cracking is not catalytic or is conducted in the absence of an added catalyst or is not a fluidized catalytic cracking process.
As used throughout, whenever mention is made of pyrolysis of recycle waste, or r-pyoil, all embodiments also include (i) the option of cracking the effluent of pyrolyzing recycle waste or cracking r-pyoil and/or (ii) the option of cracking the effluent or r-pyoil as a feed to a gas fed furnace or to the tubes of gas furnace/cracker.
As used throughout, a “Family of Entities” means at least one person or entity that directly or indirectly controls, is controlled by, or is under common control with another person or entity, where control means ownership of at least 50% of the voting shares, or shared management, common use of facilities, equipment, and employees, or family interest. As used throughout, the mention of a person or entity provides claim support for and includes any person or entity among the Family of Entities.
In an embodiment or in combination with any other mentioned embodiments, the mention of r-olefin and r-aldehyde also includes pr-olefin and pr-aldehyde obtained directly or indirectly from the cracking of r-pyoil or obtained from r-pygas; and r-oxo alcohol also includes pr-oxo alcohol and r-oxo plasticizers include pr-oxo plasticizers, obtained directly or indirectly from the cracking of r-pyoil or obtained from r-pygas.
In one embodiment or in combination with any of the mentioned embodiments, there is provided a method for making an r-aldehyde composition by hydroformylating an olefin feed comprising propylene. The propylene can be an r-propylene. In one embodiment, the method for making an r-aldehyde starts with feeding r-propylene to an hydroformylation reactor for making r-aldehyde. The r-aldehyde, such as r-butyraldehyde, may then be further condensed to provide an r-α,β-aldehyde. In one embodiment, the method for making an r-oxo alcohol starts with feeding r-olefin, r-aldehyde, or r-α,β-aldehyde to a reaction zone (or series of reactors) for making oxo alcohol.
In one embodiment, an oxo plasticizer may be formed by reacting the oxo alcohol with an esterifying agent to form an ester based oxo plasticizer. The esterifying agent can include an acid or anhydride. In one embodiment, the method for making an r-oxo plasticizer starts with feeding r-olefin, r-aldehyde, r-α,β-aldehyde, or an r-oxo alcohol to a reaction zone (or series of reactors) for making oxo plasticizer.
As shown in
As used herein, a furnace includes the convection zone and the radiant zone. A convection zone includes the tubes and/or coils inside the convection box that can also continue outside the convection box downstream of the coil inlet at the entrance to the convection box. For example, as shown in
Unless otherwise specified, all component amounts provided herein (e.g. for feeds, feedstocks, streams, compositions, and products) are expressed on a dry basis.
As used herein, a “r-pyoil” or “r-pyrolysis oil” are interchangeable and mean a composition of matter that is liquid when measured at 25° C. and 1 atm, at least a portion of which is obtained from pyrolysis, and which has recycle content. In one embodiment or in combination with any of the mentioned embodiments, at least a portion of the composition is obtained from the pyrolysis of recycled waste (e.g., waste plastic or waste stream).
In one embodiment or in combination with any of the mentioned embodiments, the “r-ethylene” can be a composition comprising: (a) ethylene obtained from cracking of a cracker feed containing r-pyoil, or (b) ethylene having a recycle content value attributed to at least a portion of the ethylene; and the “r-propylene” can be a composition comprising (a) propylene obtained from cracking of a cracker feed containing r-pyoil, or (b) propylene having a recycle content value attributed to at least a portion of the propylene.
Reference to a “r-ethylene molecule” means ethylene molecule derived directly or indirectly from recycled waste and reference to a “pr-ethylene molecule” means ethylene molecule derived directly or indirectly from r-pyrolysis effluent (e.g., r-pyoil and/or r-pygas).
As used herein, a “Site” means a largest continuous geographical boundary owned by an oxo alcohol or oxo plasticizer manufacturer, as the case may be, or by one person or entity, or combination of persons or entities, among its Family of Entities, wherein the geographical boundary contains one or more manufacturing facilities at least one of which is an oxo alcohol or oxo plasticizer manufacturing facility.
As used herein, the term “predominantly” means more than 50 percent by weight, unless expressed in mole percent, in which case it means more than 50 mole %. 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, or if expressed as mole %, means a product that contains more than 50 mole % propane.
As used herein, a composition that is “directly derived” from cracking r-pyoil has at least one physical component that is traceable to an r-composition at least a portion of which is obtained by or with the cracking of r-pyoil, while a composition that is “indirectly derived” from cracking r-pyoil has associated with it a recycle content allotment and may or may not contain a physical component that is traceable to an r-composition at least a portion of which is obtained by or with the cracking of r-pyoil.
As used herein, “recycle content value” and “r-value” mean a unit of measure representative of a quantity of material having its origin in recycled waste. The r-value can have its origin in any type of recycled waste processed in any type of process.
As used herein, the term “pyrolysis recycle content value” and “pr-value” mean a unit of measure representative of a quantity of material having its origin in the pyrolysis of recycled waste. The pr-value is a specific subset/type of r-value that is tied to the pyrolysis of recycled waste. Therefore, the term r-value encompasses, but does not require, a pr-value.
The particular recycle content value (r-value or pr-value) can be by mass or percentage or any other unit of measure and can be determined according to a standard system for tracking, allocating, and/or crediting recycle content among various compositions. A recycle content value can be deducted from a recycle content inventory and applied to a product or composition to attribute recycle content to the product or composition. A recycle content value does not have to originate from making or cracking r-pyoil unless so stated. In one embodiment or in combination with any mentioned embodiments, at least a portion of the r-pyoil from which an allotment is obtained is also cracked in a cracking furnace as described throughout the one or more embodiments herein.
As used herein, “recycle content allotment” or “allotment” means a recycle content value that is:
As used herein, “pyrolysis recycle content allotment” and “pyrolysis allotment” or “pr-allotment” mean a pyrolysis recycle content value that is:
A pyrolysis recycle content allotment is a specific type of recycle content allotment that is tied to the pyrolysis of recycled waste. Therefore, the term recycle content allotment encompasses pyrolysis recycle content allocation.
In one embodiment or in combination with any of the mentioned embodiments, a pyrolysis recycle content allotment or pyrolysis allotment may have a recycle content value that is:
An allotment can be an allocation or a credit.
A recycle content allotment can include a recycle content allocation or a recycle content credit obtained with the transfer or use of a raw material. In one embodiment or in combination with any of the mentioned embodiments, the composition receiving the recycle content allotment can be a non-recycle composition, to thereby convert the non-recycle composition to an r-composition.
As used herein, “non-recycle” means a composition (e.g., compound, polymer, feedstock, product, or stream) none of which was directly or indirectly derived from recycled waste.
As used herein, a “non-recycle feed” in the context of a feed to the cracker or furnace means a feed that is not obtained from a recycled waste stream. Once a non-recycle feed obtains a recycle content allotment (e.g. either through a recycle content credit or recycle content allocation), the non-recycle feed become a recycle content feed, composition, or Recycle PIA.
As used herein, the term “recycle content allocation” is a type of recycle content allotment, where the entity or person supplying a composition sells or transfers the composition to the receiving person or entity, and the person or entity that made the composition has an allotment at least a portion of which can be associated with the composition sold or transferred by the supplying person or entity to the receiving person or entity. The supplying entity or person can be controlled by the same entity or person(s), or Family of Entities, or a different Family of Entities. In one embodiment or in combination with any mentioned embodiments, a recycle content allocation travels with a composition and with the downstream derivates of the composition. In one embodiment or in combination with any mentioned embodiments, an allocation may be deposited into a recycle content inventory and withdrawn from the recycle content inventory as an allocation and applied to a composition to make an r-composition or a Recycle PIA.
As used herein, “recycle content credit” and “credit” mean a type of recycle content allotment, where the allotment is not restricted to an association with compositions made from cracking r-pyoil or their downstream derivatives, but rather have the flexibility of being obtained from r-pyoil and (i) applied to compositions or PIA made from processes other than cracking feedstocks in a furnace, or (ii) applied to downstream derivatives of compositions, through one or more intermediate feedstocks, where such compositions are made from processes other than cracking feedstocks in a furnace, or (iii) available for sale or transfer to persons or entities other than the owner of the allotment, or (iv) available for sale or transfer by other than the supplier of the composition that is transferred to the receiving entity or person. For example, an allotment can be a credit when the allotment is taken from r-pyoil and applied by the owner of the allotment to a BTX composition, or cuts thereof, made by said owner or within its Family of Entities, obtained by refining and fractionation of petroleum rather than obtained by cracker effluent products; or it can be a credit if the owner of the allotment sells the allotment to a third party to allow the third party to either re-sell the product or apply the credit to one or more of a third party's compositions.
A credit can be available for sale or transfer or use, or can be sold or transferred or used, either:
without the sale of a composition, or
with the sale or transfer of a composition but the allotment is not associated with the sale or transfer of the composition, or
is deposited into or withdrawn from a recycle content inventory that does not track the molecules of a recycle content feedstock to the molecules of the resulting compositions which were made with the recycle content feedstocks, or which does have such tracking capability but which did not track the particular allotment as applied to a composition.
In one embodiment or in combination with any of the mentioned embodiments, an allotment may be deposited into a recycle content inventory, and a credit or allocation may be withdrawn from the inventory and applied to a composition. This would be the case where an allotment is created by making a first composition from the pyrolysis of recycle waste, or from r-pyoil or the cracking of r-pyoil, or by any other method of making a first composition from recycle waste, depositing the allocation associated with such first composition into a recycle content inventory, and deducting a recycle content value from the recycle content inventory and applying it to a second composition that is not a derivate of the first composition or that was not actually made by the first composition as a feedstock. In this system, one need not trace the source of a reactant back to the cracking of pyoil or back to any atoms contained in olefin-containing effluent, but rather can use any reactant made by any process and have associated with such reactant a recycle content allotment.
In one embodiment or in combination with any mentioned embodiments, a composition receiving an allotment is used as a feedstock to make downstream derivatives of the composition, and such composition is a product of cracking a cracker feedstock in a cracker furnace. In one embodiment or in combination with any mentioned embodiments, there is provided a process in which:
The steps b. and c. do not have to occur simultaneously. In one embodiment or in combination with any mentioned embodiments, they occur within a year of each other, or within six (6) months of each other, or within three (3) months of each other, or within one (1) month of each other, or within two (2) weeks of each other, or within one (1) week of each other, or within three (3) days of each other. The process allows for a time lapse between the time an entity or person receiving the r-pyoil and creating the allotment (which can occur upon receipt or ownership of the r-pyoil or deposit into inventory) and the actual processing of the r-pyoil in a cracker furnace.
As used herein, “recycle content inventory” and “inventory” mean a group or collection of allotments (allocations or credits) from which deposits and deductions of allotments in any units can be tracked. The inventory can be in any form (electronic or paper), using any or multiple software programs, or using a variety of modules or applications that together as a whole tracks the deposits and deductions. Desirably, the total amount of recycle content withdrawn (or applied to compositions) does not exceed the total amount of recycle content allotments on deposit in the recycle content inventory (from any source, not only from cracking of r-pyoil). However, if a deficit of recycle content value is realized, the recycle content inventory is rebalanced to achieve a zero or positive recycle content value available. The timing for rebalancing can be either determined and managed in accordance with the rules of a particular system of accreditation adopted by the olefin-containing effluent manufacturer or by one among its Family of Entities, or alternatively, is rebalanced within one (1) year, or within six (6) months, or within three (3) months, or within one (1) month of realizing the deficit. The timing for depositing an allotment into the recycle content inventory, applying an allotment (or credit) to a composition to make a r-composition, and cracking r-pyoil, need not be simultaneous or in any particular order. In one embodiment or in combination with any mentioned embodiments, the step of cracking a particular volume of r-pyoil occurs after the recycle content value or allotment from that volume of r-pyoil is deposited into a recycle content inventory. Further, the allotments or recycle content values withdrawn from the recycle content inventory need not be traceable to r-pyoil or cracking r-pyoil, but rather can be obtained from any waste recycle stream, and from any method of processing the recycle waste stream. Desirably, at least a portion of the recycle content value in the recycle content inventory is obtained from r-pyoil, and optionally at least a portion of r-pyoil, are processed in the one or more cracking processes as described herein, optionally within a year of each other and optionally at least a portion of the volume of r-pyoil from which a recycle content value is deposited into the recycle content inventory is also processed by any or more of the cracking processes described herein.
The determination of whether an r-composition is derived directly or indirectly from recycled waste is not on the basis of whether intermediate steps or entities do or do not exist in the supply chain, but rather whether at least a portion of the r-composition that is fed to the reactor for making an end product such as an olefin or an aldehyde or an oxo alcohol or an oxo plasticizer can be traced to an r-composition made from recycled waste.
The determination of whether a pr-composition is derived directly or indirectly from the pyrolysis of recycled waste (e.g., from the cracking of r-pyoil or from r-pygas) is not on the basis of whether intermediate steps or entities do or do not exist in the supply chain, but rather whether at least a portion of the pr-composition that is fed to the reactor for making an end product such as an olefin or an aldehyde or an oxo alcohol or an oxo plasticizer can be traced to an pr-composition made from the pyrolysis of recycled waste.
As noted above, the end product is considered to be directly derived from recycled waste if at least a portion of the reactant feedstock used to make the product can be traced back, optionally through one or more intermediate steps or entities, to at least a portion of an r-composition produced from recycled waste (e.g., during the cracking of r-pyoil fed to a cracking furnace or as an effluent from the cracking furnace).
The r-composition as an effluent may be in crude form that requires refining to isolate the particular r-composition. The r-composition manufacturer can, typically after refining and/or purification and compression to produce the desired grade of the particular r-composition, sell such r-composition to an intermediary entity who then sells the r-composition, or one or more derivatives thereof, to another intermediary for making an intermediate product or directly to the product manufacturer. Any number of intermediaries and intermediate derivates can be made before the final product is made.
The actual r-composition volume, whether condensed as a liquid, supercritical, or stored as a gas, can remain at the facility where it is made, or can be shipped to a different location, or held at an off-site storage facility before utilized by the intermediary or product manufacturer. For purposes of tracing, once r-composition made from recycled waste (e.g., by cracking r-pyoil or from r-pygas) is mixed with another volume of the composition (e.g. r-propylene mixed with non-recycle propylene), for example in a storage tank, salt dome, or cavern, then the entire tank, dome, or cavern at that point becomes an r-composition source, and for purposes of tracing, withdrawal from such storage facility is withdrawing from an r-composition source until such time as when the entire volume or inventory of the storage facility is turned over or withdrawn and/or replaced with non-recycle compositions after the r-composition feed to the tank stops. Likewise, this applies also to any downstream storage facilities for storing the derivatives of the r-compositions, such as r-Et and pr-Et compositions.
An r-composition is considered to be indirectly derived from recycled waste or pyrolysis of recycled waste or cracking of r-pyoil if it has associated with it a recycle content allotment and may or may not contain a physical component that is traceable to an r-composition at least a portion of which is obtained from recycled waste/pyrolysis of recycled waste/cracking of r-pyoil. For example, the (i) manufacturer of the product can operate within a legal framework, or an association framework, or an industry recognized framework for making a claim to a recycle content through, for example, a system of credits transferred to the product manufacturer regardless of where or from whom the r-composition, or derivatives thereof, or reactant feedstocks to make the product, is purchased or transferred, or (ii) a supplier of the r-composition or a derivate thereof (“supplier”) operates within an allotment framework that allows for associating or applying a recycle content value or pr-value to a portion or all of an olefin-containing effluent or a compound within an olefin-containing effluent or derivate thereof to make an r-composition, and to transfer the recycle content value or allotment to the manufacturer of the product or any intermediary who obtains a supply of r-composition, or its derivatives, from the supplier. In this system, one need not trace the source of r-olefin, r-aldehyde, r-oxo alcohol or r-oxo plasticizer volume back to the manufacture of r-composition from recycled waste/pyrolyzed recycled waste, but rather can use any olefin, aldehyde, or oxo alcohol composition made by any process and have associated with such olefin, aldehyde, or oxo alcohol composition a recycle content allotment.
Examples of how a propylene composition for making an aldehyde can obtain recycle content include:
Similarly, examples of how an olefin composition for making an oxo alcohol or an oxo plasticizer can obtain recycle content include:
As discussed above, the recycle content can be a pyrolysis recycle content that is directly or indirectly derived from the pyrolysis of recycled waste (e.g., from cracking r-pyoil or from r-pygas).
In one embodiment or in combination with any of the mentioned embodiments, the recycle content input or creation (recycle content feedstock or allotments) can be to or at a first Site, and recycle content values from said inputs are transferred to a second Site and applied to one or more compositions made at a second Site. The recycle content values can be applied symmetrically or asymmetrically to the compositions at the second Site. A recycle content value that is directly or indirectly “derived from cracking r-pyoil”, or a recycle content value that is “obtained from cracking r-pyoil” or originating in cracking r-pyoil does not imply the timing of when the recycle content value or allotment is taken, captured, deposited into a recycle content inventory, or transferred. The timing of depositing the allotment or recycle content value into a recycle content inventory, or realizing, recognizing, capturing, or transferring it, is flexible and can occur as early as receipt of r-pyoil onto the site within a Family of Entities, possessing it, or bringing the r-pyoil into inventory by the entity or person, or within the Family of Entities, owning or operating the cracker facility. Thus, an allotment or recycle content value on a volume of r-pyoil can be obtained, captured, deposited into an inventory, or transferred to a product without having yet fed that volume to cracker furnace and cracked. The allotment can also be obtained during feeding r-pyoil to a cracker, during cracking, or when an r-composition is made. An allotment taken when r-pyoil is owned, possessed, or received and deposited into a recycle content inventory is an allotment that is associated with, obtained from, or originates from cracking r-pyoil even though, at the time of taking or depositing the allotment, the r-pyoil has not yet been cracked, provided that the r-pyoil is at some future point in time cracked.
The terms “recycled waste,” “waste stream,” and “recycled waste stream” are used interchangeably to mean any type of waste or waste-containing stream that is reused in a production process, rather than being permanently disposed of (e.g., in a landfill or incinerator). The recycled waste stream is a flow or accumulation of recycled waste from industrial and consumer sources that is at least in part recovered.
A recycled waste stream includes materials, products, and articles (collectively “material(s)” when used alone). Recycled waste materials can be solid or liquid. Examples of a solid recycled waste stream include plastics, rubber (including tires), textiles, wood, biowaste, modified celluloses, wet laid products, and any other material capable of being pyrolyzed. Examples of liquid waste streams include industrial sludge, oils (including those derived from plants and petroleum), recovered lube oil, or vegetable oil or animal oil, and any other chemical streams from industrial plants.
In one embodiment or in combination with any of the mentioned embodiments, the recycled waste stream that is pyrolyzed includes a stream containing at least in part post-industrial, or post-consumer, or both a post-industrial and post-consumer materials. In one embodiment or in combination with any of the mentioned embodiments, a post-consumer material is one that has been used at least once for its intended application for any duration of time regardless of wear, or has been sold to an end use customer, or which is discarded into a recycle bin by any person or entity other than a manufacturer or business engaged in the manufacture or sale of the material.
In one embodiment or in combination with any of the mentioned embodiments, a post-industrial material is one which has been created and has not been used for its intended application, or has not been sold to the end use customer, or discarded by a manufacturer or any other entity engaged in the sale of the material. Examples of post-industrial materials include rework, regrind, scrap, trim, out of specification materials, and finished materials transferred from a manufacturer to any downstream customer (e.g. manufacturer to wholesaler to distributor) but not yet used or sold to the end use customer.
The form of the recycled waste stream, which can be fed to a pyrolysis unit, is not limited, and can include any of the forms of articles, products, materials, or portions thereof. A portion of an article can take the form of sheets, extruded shapes, moldings, films, laminates, foam pieces, chips, flakes, particles, fibers, agglomerates, briquettes, powder, shredded pieces, long strips, or randomly shaped pieces having a wide variety of shapes, or any other form other than the original form of the article and adapted to feed a pyrolysis unit.
In one embodiment or in combination with any of the mentioned embodiments, the recycled waste material is size reduced. Size reduction can occur through any means, including chopping, shredding, harrowing, confrication, pulverizing, cutting a feedstock, molding, compression, or dissolution in a solvent.
Recycled waste plastics can be isolated as one type of polymer stream or may be a stream of mixed recycled waste plastics. The plastics can be any organic synthetic polymer that is solid at 25° C. at 1 atm. The plastics can be thermosetting, thermoplastic, or elastomeric plastics. Examples of plastics include high density polyethylene and copolymers thereof, low density polyethylene and copolymers thereof, polypropylene and copolymers thereof, other polyolefins, polystyrene, polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), polyesters including polyethylene terephthalate, copolyesters and terephthalate copolyesters (e.g. containing residues of TMCD, CHDM, propylene glycol, or NPG monomers), polyethylene terephthalate, polyamides, poly(methyl methacrylate), polytetrafluoroethylene, acrylobutadienestyrene (ABS), polyurethanes, cellulosics and derivates thereof such as cellulose acetate, cellulose diacetate, cellulose triacetate, cellulose propionate, cellulose butyrate; regenerated cellulosics such as viscose and rayons, epoxy, polyamides, phenolic resins, polyacetal, polycarbonates, polyphenylene-based alloys, polypropylene and copolymers thereof, polystyrene, styrenic compounds, vinyl based compounds, styrene acrylonitrile, thermoplastic elastomers, and urea based polymers and melamine containing polymers.
Suitable recycled waste plastics also include any of those having a resin ID code numbered 1-7 within the chasing arrow triangle established by the SPI. In one embodiment or in combination with any of the mentioned embodiments, the r-pyoil is made from a recycled waste stream at least a portion of which contains plastics that are not generally recycled. These would include plastics having numbers 3 (polyvinyl chloride), 5 (polypropylene), 6 (polystyrene), and 7 (other). In one embodiment or in combination with any of the mentioned embodiments, the recycled waste stream that is pyrolyzed contains less than 10 weight percent, or not more than 5 weight percent, or not more than 3 weight percent, or not more than 2 weight percent, or not more than 1 weight percent, or not more than 0.5 weight percent, or not more than 0.2 weight percent, or not more than 0.1 weight percent, or not more and 0.05 weight percent plastics with a number 3 designation (polyvinyl chloride), or optionally plastics with a number 3 and 6 designation, or optionally with a number 3, 6 and 7 designation.
Examples of recycled rubber include natural and synthetic rubber. The form of the rubber is not limited, and includes tires.
Examples of recycled waste wood include soft and hard woods, chipped, pulped, or as finished articles. The source of much recycled waste wood is industrial, construction, or demolition.
Examples of recycled biorecycled waste includes household biorecycled waste (e.g. food), green or garden biorecycled waste, and biorecycled waste from the industrial food processing industry.
Examples of recycled textiles includes natural and/or synthetic fibers, rovings, yarns, nonwoven webs, cloth, fabrics and products made from or containing any of the aforementioned items. Textiles can be woven, knitted, knotted, stitched, tufted, pressing of fibers together such as would be done in a felting operation, embroidered, laced, crocheted, braided, or nonwoven webs and materials. Textiles include fabrics, and fibers separated from a textile or other product containing fibers, scrap or off spec fibers or yarns or fabrics, or any other source of loose fibers and yarns. A textile also includes staple fibers, continuous fibers, threads, tow bands, twisted and/or spun yarns, grey fabrics made from yarns, finished fabrics produced by wet processing gray fabrics, and garments made from the finished fabrics or any other fabrics. Textiles include apparels, interior furnishings, and industrial types of textiles.
Examples of recycled textiles in the apparel category (things humans wear or made for the body) include sports coats, suits, trousers and casual or work pants, shirts, socks, sportswear, dresses, intimate apparel, outerwear such as rain jackets, cold temperature jackets and coats, sweaters, protective clothing, uniforms, and accessories such as scarves, hats, and gloves. Examples of textiles in the interior furnishing category include furniture upholstery and slipcovers, carpets and rugs, curtains, bedding such as sheets, pillow covers, duvets, comforters, mattress covers; linens, table cloths, towels, washcloths, and blankets. Examples of industrial textiles include transportation (auto, airplanes, trains, buses) seats, floor mats, trunk liners, and headliners; outdoor furniture and cushions, tents, backpacks, luggage, ropes, conveyor belts, calendar roll felts, polishing cloths, rags, soil erosion fabrics and geotextiles, agricultural mats and screens, personal protective equipment, bullet proof vests, medical bandages, sutures, tapes, and the like.
The recycled nonwoven webs can also be dry laid nonwoven webs. Examples of suitable articles that may be formed from dry laid nonwoven webs as described herein can include those for personal, consumer, industrial, food service, medical, and other types of end uses. Specific examples can include, but are not limited to, baby wipes, flushable wipes, disposable diapers, training pants, feminine hygiene products such as sanitary napkins and tampons, adult incontinence pads, underwear, or briefs, and pet training pads. Other examples include a variety of different dry or wet wipes, including those for consumer (such as personal care or household) and industrial (such as food service, health care, or specialty) use. Nonwoven webs can also be used as padding for pillows, mattresses, and upholstery, batting for quilts and comforters. In the medical and industrial fields, nonwoven webs of the present invention may be used for medical and industrial face masks, protective clothing, caps, and shoe covers, disposable sheets, surgical gowns, drapes, bandages, and medical dressings. Additionally, nonwoven webs may be used for environmental fabrics such as geotextiles and tarps, oil and chemical absorbent pads, as well as building materials such as acoustic or thermal insulation, tents, lumber and soil covers and sheeting. Nonwoven webs may also be used for other consumer end use applications, such as for, carpet backing, packaging for consumer, industrial, and agricultural goods, thermal or acoustic insulation, and in various types of apparel. The dry laid nonwoven webs may also be used for a variety of filtration applications, including transportation (e.g., automotive or aeronautical), commercial, residential, industrial, or other specialty applications. Examples can include filter elements for consumer or industrial air or liquid filters (e.g., gasoline, oil, water), including nanofiber webs used for microfiltration, as well as end uses like tea bags, coffee filters, and dryer sheets. Further, nonwoven webs may be used to form a variety of components for use in automobiles, including, but not limited to, brake pads, trunk liners, carpet tufting, and under padding.
The recycled textiles can include single type or multiple type of natural fibers and/or single type or multiple type of synthetic fibers. Examples of textile fiber combinations include all natural, all synthetic, two or more type of natural fibers, two or more types of synthetic fibers, one type of natural fiber and one type of synthetic fiber, one type of natural fibers and two or more types of synthetic fibers, two or more types of natural fibers and one type of synthetic fibers, and two or more types of natural fibers and two or more types of synthetic fibers.
Examples of recycled wet laid products include cardboard, office paper, newsprint and magazine, printing and writing paper, sanitary, tissue/toweling, packaging/container board, specialty papers, apparel, bleached board, corrugated medium, wet laid molded products, unbleached Kraft, decorative laminates, security paper and currency, grand scale graphics, specialty products, and food and drink products.
Examples of modified cellulose include cellulose acetate, cellulose diacetate, cellulose triacetate, regenerated cellulose such a viscose, rayon, and Lyocel™ products, in any form, such as tow bands, staple fibers, continuous fibers, films, sheets, molded or stamped products, and contained in or on any article such as cigarette filter rods, ophthalmic products, screwdrivers handles, optical films, and coatings.
Examples of recycled vegetable oil or animal oil include the oils recovered from animal processing facilities and recycled waste from restaurants.
The source for obtaining recycled post-consumer or post-industrial recycled waste is not limited, and can include recycled waste present in and/or separated from municipal solid recycled waste streams (“MSW”). For example, an MSW stream can be processed and sorted to several discrete components, including textiles, fibers, papers, wood, glass, metals, etc. Other sources of textiles include those obtained by collection agencies, or by or for or on behalf of textile brand owners or consortiums or organizations, or from brokers, or from postindustrial sources such as scrap from mills or commercial production facilities, unsold fabrics from wholesalers or dealers, from mechanical and/or chemical sorting or separation facilities, from landfills, or stranded on docks or ships.
In one embodiment or in combination with any of the mentioned embodiments, the feed to the pyrolysis unit can comprise at least 30, or at least 35, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 99, in each case weight percent of at least one, or at least two, or at least three, or at least four, or at least five, or at least six different kinds of recycled waste. Reference to a “kind” is determined by resin ID code 1-7. In one embodiment or in combination with any of the mentioned embodiments, the feed to the pyrolysis unit contains less than 25, or not more than 20, or not more than 15, or not more than 10, or not more than 5, or not more than 1, in each case weight percent of polyvinyl chloride and/or polyethylene terephthalate. In one embodiment or in combination with any of the mentioned embodiments, the recycled waste stream contains at least one, two, or three kinds of plasticized plastics.
As shown in
In an embodiment or in combination with any of the embodiments mentioned herein, the waste plastics can include one or more post-consumer waste plastic such as, for example, high density polyethylene, low density polyethylene, polypropylene, other polyolefins, polystyrene, polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), polyethylene terephthalate, polyamides, poly(methyl methacrylate), polytetrafluoroethylene, or combinations thereof. In an embodiment or in combination with any of the embodiments mentioned herein, the waste plastics may include high density polyethylene, low density polyethylene, polypropylene, or combinations thereof. As used herein, “post-consumer” refers to non-virgin plastics that have been previously introduced into the consumer market.
In an embodiment or in combination with any of the embodiments mentioned herein, a waste plastic-containing feed may be supplied from the plastic source 112. In an embodiment or in combination with any of the embodiments mentioned herein, the waste plastic-containing feed can comprise, consist essentially of, or consist of high density polyethylene, low density polyethylene, polypropylene, other polyolefins, polystyrene, polyvinyl chloride (PVC), polyvinylidene chloride (PVDC), polyethylene terephthalate, polyamides, poly(methyl methacrylate), polytetrafluoroethylene, or combinations thereof.
In an embodiment or in combination with any of the embodiments mentioned herein, the waste plastic-containing feed can comprise at least 30, or at least 35, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 99, in each case weight percent of at least one, two, three, or four different kinds of waste plastic. In an embodiment or in combination with any of the embodiments mentioned herein, the plastic waste may comprise not more than 25, or not more than 20, or not more than 15, or not more than 10, or not more than 5, or not more than 1, in each case weight percent of polyvinyl chloride and/or polyethylene terephthalate. In an embodiment or in combination with any of the embodiments mentioned herein, the waste plastic-containing feed can comprise at least one, two, or three kinds of plasticized plastics. Reference to a “kind” is determined by resin ID code 1-7.
As depicted in
Next, the pretreated plastic feed can be introduced into a plastic feed system 116. The plastic feed system 116 may be configured to introduce the plastic feed into the pyrolysis reactor 118. The plastic feed system 116 can comprise any system known in the art that is capable of feeding the solid plastic feed into the pyrolysis reactor 118. In an embodiment or in combination with any of the embodiments mentioned herein, the plastic feed system 116 can comprise a screw feeder, a hopper, a pneumatic conveyance system, a mechanic metal train or chain, or combinations thereof.
While in the pyrolysis reactor 118, at least a portion of the plastic feed may be subjected to a pyrolysis reaction that produces a pyrolysis effluent comprising a pyrolysis oil (e.g., r-pyoil) and a pyrolysis gas (e.g., r-pyrolysis gas). The pyrolysis reactor 118 can be, for example, an extruder, a tubular reactor, a tank, a stirred tank reactor, a riser reactor, a fixed bed reactor, a fluidized bed reactor, a rotary kiln, a vacuum reactor, a microwave reactor, an ultrasonic or supersonic reactor, or an autoclave, or a combination of these reactors.
Generally, pyrolysis is a process that involves the chemical and thermal decomposition of the introduced feed. Although all pyrolysis processes may be generally characterized by a reaction environment that is substantially free of oxygen, pyrolysis processes may be further defined, for example, by 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.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis reaction can involve heating and converting the plastic feed in an atmosphere that is substantially free of oxygen or in an atmosphere that contains less oxygen relative to ambient air. In an embodiment or in combination with any of the embodiments mentioned herein, the atmosphere within the pyrolysis reactor 118 may comprise not more than 5, or not more than 4, or not more than 3, or not more than 2, or not more than 1, or not more than 0.5, in each case weight percent of oxygen gas.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis process may be carried out in the presence of an inert gas, such as nitrogen, carbon dioxide, and/or steam. Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis process can be carried out in the presence of a reducing gas, such as hydrogen and/or carbon monoxide.
In an embodiment or in combination with any of the embodiments mentioned herein, the temperature in the pyrolysis reactor 118 can be adjusted to as to facilitate the production of certain end products. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis temperature in the pyrolysis reactor 118 can be at least 325° C., or at least 350° C., or at least 375° C., or at least 400° C., or at least 425° C., or at least 450° C., or at least 475° C., or at least 500° C., or at least 525° C., or at least 550° C., or at least 575° C., or at least 600° C., or at least 625° C., or at least 650° C., or at least 675° C., or at least 700° C., or at least 725° C., or at least 750° C., or at least 775° C., or at least 800° C. Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis temperature in the pyrolysis reactor 118 can be not more than 1,100° C., or not more than 1,050° C., or not more than 1,000° C., or not more than 950° C., or not more than 900° C., or not more than 850° C., or not more than 800° C., or not more than 750° C., or 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. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis temperature in the pyrolysis reactor 118 can range from 325 to 1,100° C., 350 to 900° C., 350 to 700° C., 350 to 550° C., 350 to 475° C., 500 to 1,100° C., 600 to 1,100° C., or 650 to 1,000° C.
In an embodiment or in combination with any of the embodiments mentioned herein, the residence times of the pyrolysis reaction can be at least 1, or at least 2, or at least 3, or at least 4, in each case seconds, or at least 10, or at least 20, or at least 30, or at least 45, or at least 60, or at least 75, or at least 90, in each case minutes. Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the residence times of the pyrolysis reaction can be not more than 6 hours, or not more than 5, or not more than 4, or not more than 3, or not more than 2, or not more than 1, or not more than 0.5, in each case hours. In an embodiment or in combination with any of the embodiments mentioned herein, the residence times of the pyrolysis reaction can range from 30 minutes to 4 hours, or 30 minutes to 3 hours, or 1 hour to 3 hours, or 1 hour to 2 hours.
In an embodiment or in combination with any of the embodiments mentioned herein, the pressure within the pyrolysis reactor 118 can be maintained at a pressure of at least 0.1, or at least 0.2, or at least 0.3, in each case bar 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, in each case bar. In an embodiment or in combination with any of the embodiments mentioned herein, the pressure within the pyrolysis reactor 18 can be maintained at about atmospheric pressure or within the range of 0.1 to 100 bar, or 0.1 to 60 bar, or 0.1 to 30 bar, or 0.1 to 10 bar, or 1.5 bar, 0.2 to 1.5 bar, or 0.3 to 1.1 bar.
In an embodiment or in combination with any of the embodiments mentioned herein, a pyrolysis catalyst may be introduced into the plastic feed prior to introduction into the pyrolysis reactor 118 and/or introduced directly into the pyrolysis reactor 118 to produce an r-catalytic pyoil, or an r-pyoil made by a catalytic pyrolysis process. In an embodiment or in combination with any embodiment mentioned herein or in combination with any of the embodiments mentioned herein, the catalyst can comprise: (i) a solid acid, such as a zeolite (e.g., ZSM-5, Mordenite, Beta, Ferrierite, and/or zeolite-Y); (ii) a super acid, such as sulfonated, phosphated, or fluorinated forms of zirconia, titania, alumina, silica-alumina, and/or clays; (iii) a solid base, such as metal oxides, mixed metal oxides, metal hydroxides, and/or metal carbonates, particularly those of alkali metals, alkaline earth metals, transition metals, and/or rare earth metals; (iv) hydrotalcite and other clays; (v) a metal hydride, particularly those of alkali metals, alkaline earth metals, transition metals, and/or rare earth metals; (vi) an alumina and/or a silica-alumina; (vii) a homogeneous catalyst, such as a Lewis acid, a metal tetrachloroaluminate, or an organic ionic liquid; (viii) activated carbon; or (ix) combinations thereof.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis reaction in the pyrolysis reactor 118 occurs in the substantial absence of a catalyst, particularly the above-referenced catalysts. In such embodiments, a non-catalytic, heat-retaining inert additive may still be introduced into the pyrolysis reactor 118, such as sand, in order to facilitate the heat transfer within the reactor 118.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis reaction in the pyrolysis reactor 118 may occur in the substantial absence of a pyrolysis catalyst, at a temperature in the range of 350 to 550° C., at a pressure ranging from 0.1 to 60 bar, and at a residence time of 0.2 seconds to 4 hours, or 0.5 hours to 3 hours.
Referring again to
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis effluent 120 may comprise at least 20, or at least 25, or at least 30, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least or at least 80, in each case weight percent of the pyrolysis vapors, which may be subsequently condensed into the resulting pyrolysis oil (e.g., r-pyoil). Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis effluent 120 may comprise not more than 99, or not more than 95, or not more than 90, or not more than 85, or not more than 80, or not more than 75, or not more than 70, or not more than 65, or not more than 60, or not more than 55, or not more than 50, or not more than 45, or not more than 40, or not more than 35, or not more than 30, in each case weight percent of the pyrolysis vapors. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis effluent 120 may comprise in the range of 20 to 99 weight percent, 40 to 90 weight percent, or 55 to 90 weight percent of the pyrolysis vapors.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis effluent 120 may comprise at least 1, or at least 5, or at least 6, or at least 7, or at least 8, or at least 9, or at least 10, or at least 11, or at least 12, in each case weight percent of the pyrolysis gas (e.g., r-pyrolysis gas). As used herein, a “pyrolysis gas” refers to a composition that is produced via pyrolysis and is a gas at standard temperature and pressure (STP). Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis effluent 20 may comprise not more than 90, or not more than 85, or not more than 80, or not more than 75, or not more than 70, or not more than 65, or not more than 60, or not more than 55, or not more than 50, or not more than 45, or not more than 40, or not more than 35, or not more than 30, or not more than 25, or not more than 20, or not more than 15, in each case weight percent of the pyrolysis gas. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis effluent 120 may comprise 1 to 90 weight percent, or 5 to 60 weight percent, or 10 to 60 weight percent, or 10 to 30 weight percent, or 5 to 30 weight percent of the pyrolysis gas.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis effluent 120 may comprise not more than 15, or not more than 10, or not more than 9, or not more than 8, or not more than 7, or not more than 6, or not more than 5, or not more than 4 or not more than 3, in each case weight percent of the residual solids.
In one embodiment or in combination of any mentioned embodiments, there is provided a cracker feed stock composition containing pyrolysis oil (r-pyoil), and the r-pyoil composition contains recycle content catalytic pyrolysis oil (r-catalytic pyoil) and a recycle content thermal pyrolysis oil (r-thermal pyoil). An r-thermal pyoil is pyoil made without the addition of a pyrolysis catalyst. The cracker feedstock can include at least 5, 10, 15, or 20 weight percent r-catalytic pyoil, optionally that has been hydrotreated. The r-pyoil containing r-thermal pyoil and r-catalytic pyoil can be cracked according to any of the processes described herein to provide an olefin-containing effluent stream. The r-catalytic pyoil can be blended with r-thermal pyoil to form a blended stream cracked in the cracker unit. Optionally, the blended stream can contain not more than 10, 5, 3, 2, 1 weight percent of r-catalytic pyoil that has not been hydrotreated.
In one embodiment or in combination with any mentioned embodiment, the r-pyoil does not contain r-catalytic pyoil.
As depicted in
Turning back to
In an embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the pyrolysis oil vapor stream 136 may be introduced into a quench unit 138 in order to at least partially quench the pyrolysis vapors into their liquid form (i.e., the pyrolysis oil). The quench unit 138 may comprise any suitable quench system known in the art, such as a quench tower. The resulting liquid pyrolysis oil stream 140 may be removed from the system 110 and utilized in the other downstream applications described herein. In an embodiment or in combination with any of the embodiments mentioned herein, the liquid pyrolysis oil stream 140 may not be subjected to any additional treatments, such as hydrotreatment and/or hydrogenation, prior to being utilized in any of the downstream applications described herein.
In an embodiment or in combination with any embodiment mentioned herein or in combination with any of the embodiments mentioned herein, at least a portion of the pyrolysis oil vapor stream 136 may be introduced into a hydroprocessing unit 142 for further refinement. The hydroprocessing unit 142 may comprise a hydrocracker, a catalytic cracker operating with a hydrogen feed stream, a hydrotreatment unit, and/or a hydrogenation unit. While in the hydroprocessing unit 142, the pyrolysis oil vapor stream 136 may be treated with hydrogen and/or other reducing gases to further saturate the hydrocarbons in the pyrolysis oil and remove undesirable byproducts from the pyrolysis oil. The resulting hydroprocessed pyrolysis oil vapor stream 144 may be removed and introduced into the quench unit 138. Alternatively, the pyrolysis oil vapor may be cooled, liquified, and then treated with hydrogen and/or other reducing gases to further saturate the hydrocarbons in the pyrolysis oil. In this case, the hydrogenation or hydrotreating is performed in a liquid phase pyrolysis oil. No quench step is required in this embodiment post-hydrogenation or post-hydrotreating.
The pyrolysis system 110 described herein may produce a pyrolysis oil (e.g., r-pyoil) and pyrolysis gases (e.g., r-pyrolysis gas) that may be directly used in various downstream applications based on their desirable formulations. The various characteristics and properties of the pyrolysis oils and pyrolysis gases are described below. It should be noted that, while all of the following characteristics and properties may be listed separately, it is envisioned that each of the following characteristics and/or properties of the pyrolysis oils or pyrolysis gases are not mutually exclusive and may be combined and present in any combination.
The pyrolysis oil may predominantly comprise hydrocarbons having from 4 to 30 carbon atoms per molecule (e.g., C4 to C30 hydrocarbons). As used herein, the term “Cx” or “Cx hydrocarbon,” refers to a hydrocarbon compound including x total carbons per molecule, and encompasses all olefins, paraffins, aromatics, 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.”
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil fed to the cracking furnace may have a C4-C30 hydrocarbon content of at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, in each case weight percent based on the weight of the pyrolysis oil.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil fed to the furnace can predominantly comprise C5-C25, C5-C22, or C5-C20hydrocarbons, or may comprise at least about 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, in each case weight percent of C5-C25, C5-C22, or C5-C20hydrocarbons, based on the weight of the pyrolysis oil.
The gas furnace can tolerate a wide variety of hydrocarbon numbers in the pyrolysis oil feedstock, thereby avoiding the necessity for subjecting a pyrolysis oil feedstock to separation techniques to deliver a smaller or lighter hydrocarbon cut to the cracker furnace. In one embodiment or in any of the mentioned embodiments, the pyrolysis oil after delivery from a pyrolysis manufacturer is not subjected a separation process for separating a heavy hydrocarbon cut from a lighter hydrocarbon cut, relative to each other, prior to feeding the pyrolysis oil to a cracker furnace. The feed of pyrolysis oil to a gas furnace allows one to employ a pyrolysis oil that contains heavy tail ends or higher carbon numbers at or above 12. In one embodiment or in any of the mentioned embodiments, the pyrolysis oil fed to a cracker furnace is a C5 to C25 hydrocarbon stream containing at least 3 wt. %, or at least 5 wt. %, or at least 8 wt. %, or at least 10 wt. %, or at least 12 wt. %, or at least 15 wt. %, or at least 18 wt. %, or at least 20 wt. %, or at least 25 wt. % or at least 30 wt. %, or at least 35 wt. %, or at least 40 wt. %, or at least 45 wt. %, or at least 50 wt. %, or at least 55 wt. %, or at least 60 wt. % hydrocarbons within a range from C12 to C25, inclusive, or within a range of C14 to C25, inclusive, or within a range of C16 to C25, inclusive.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a C6 to C12 hydrocarbon content of at least 10, or at least 15, or at least 20, or at least 25, or at least 30, or at least 35, or at least 40, or at least 45, or at least 50, or at least 55, in each case weight percent, based on the weight of the pyrolysis oil. Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a C6-C12 hydrocarbon content of not more than 95, or not more than 90, or not more than 85, or not more than 80, or not more than 75, or not more than 70, or not more than 65, or not more than 60, in each case weight percent. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a C6-C12 hydrocarbon content in the range of 10 to 95 weight percent, 20 to 80 weight percent, or 35 to 80 weight percent.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a C13 to C23 hydrocarbon content of at least 1, or at least 5, or at least 10, or at least 15, or at least 20, or at least 25, or at least 30, in each case weight percent. Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a C13 to C23 hydrocarbon content of not more than 80, or not more than 75, or not more than 70, or not more than 65, or not more than 60, or not more than 55, or not more than 50, or not more than 45, or not more than 40, in each case weight percent. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a C13 to C23 hydrocarbon content in the range of 1 to 80 weight percent, 5 to 65 weight percent, or 10 to 60 weight percent.
In an embodiment or in combination with any of the embodiments mentioned herein, the r-pyrolysis oil, or r-pyoil fed to a cracker furnace, or r-pyoil fed to a cracker furnace that, prior to feeding-pyoil, accepts a predominately C2-C4 feedstock (and the mention of r-pyoil or pyrolysis oil throughout includes any of these embodiments), may have a C24+ hydrocarbon content of at least 1, or at least 2, or at least 3, or at least 4, or at least 5, in each case weight percent. Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a C24+ hydrocarbon content of not more than 15, or not more than 10, or not more than 9, or not more than 8, or not more than 7, or not more than 6, in each case weight percent. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a C24+ hydrocarbon content in the range of 1 to 15 weight percent, 3 to 15 weight percent, 2 to 5 weight percent, or 5 to 10 weight percent.
The pyrolysis oil may also include various amounts of olefins, aromatics, and other compounds. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil includes at least 1, or at least 2, or at least 5, or at least 10, or at least 15, or at least 20, in each case weight percent olefins and/or aromatics. Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may include not more than 50, or not more than 45, or not more than 40, or not more than 35, or not more than 30, or not more than 25, or not more than 20, or not more than 15, or not more than 10, or not more than 5, or not more than 2, or not more than 1, in each case weight percent olefins and/or aromatics.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have an aromatic content of not more than 25, or not more than 20, or not more than 15, or not more than 14, or not more than 13, or not more than 12, or not more than 11, or not more than 10, or not more than 9, or not more than 8, or not more than 7, or not more than 6, or not more than 5, or not more than 4, or not more than 3, or not more than 2, or not more than 1, in each case weight percent. In one embodiment or in combination with any mentioned embodiments, the pyrolysis oil has an aromatic content that is not higher than 15, or not more than 10, or not more than 8, or not more than 6, in each case weight percent.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a naphthene content of at least 1, or at least 2, or at least 3, or at least 4, or at least 5, or at least 6, or at least 7, or at least 8, or at least 9, or at least 10, or at least 11, or at least 12, or at least 13, or at least 14, or at least 15, in each case weight percent. Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a naphthene content of not more than 50, or not more than 45, or not more than 40, or not more than 35, or not more than 30, or not more than 25, or not more than 20, or not more than 10, or not more than 5, or not more than 2, or not more than 1, or not more than 0.5, or no detectable amount, in each case weight percent. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a naphthene content of not more than 5, or not more than 2, or not more than 1 wt. %, or no detectable amount, or naphthenes. Alternatively, the pyrolysis oil may contain in the range of 1 to 50 weight percent, 5 to 50 weight percent, or 10 to 45 weight percent naphthenes, especially if the r-pyoil was subjected to a hydrotreating process.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a paraffin content of at least 25, or at least 30, or at least 35, or at least 40, or at least 45, or at least 50, in each case weight percent. Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a paraffin content of not more than 90, or not more than 85, or not more than 80, or not more than 75, or not more than 70, or not more than 65, or not more than 60, or not more than 55, in each case weight percent. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a paraffin content in the range of 25 to 90 weight percent, 35 to 90 weight percent, or 40 to 80, or 40-70, or 40-65 weight percent.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have an n-paraffin content of at least 5, or at least 10, or at least 15, or at least 25, or at least 30, or at least 35, or at least 40, or at least 45, or at least 50, in each case weight percent. Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have an n-paraffin content of not more than 90, or not more than 85, or not more than 80, or not more than 75, or not more than 70, or not more than 65, or not more than 60, or not more than 55, in each case weight percent. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have an n-paraffin content in the range of 25 to 90 weight percent, 35 to 90 weight percent, or 40-70, or 40-65, or 50 to 80 weight percent.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a paraffin to olefin weight ratio of at least 0.2:1, or at least 0.3:1, or at least 0.4:1, or at least 0.5:1, or at least 0.6:1, or at least 0.7:1, or at least 0.8:1, or at least 0.9:1, or at least 1:1. Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a paraffin to olefin weight ratio not more than 3:1, or not more than 2.5:1, or not more than 2:1, or not more than 1.5:1, or not more than 1.4:1, or not more than 1.3:1. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a paraffin to olefin weight ratio in the range of 0.2:1 to 5:1, or 1:1 to 4.5:1, or 1.5:1 to 5:1, or 1.5:1:4.5:1, or 0.2:1 to 4:1, or 0.2:1 to 3:1, 0.5:1 to 3:1, or 1:1 to 3:1.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have an n-paraffin to i-paraffin weight ratio of at least 0.001:1, or at least 0.1:1, or at least 0.2:1, or at least 0.5:1, or at least 1:1, or at least 2:1, or at least 3:1, or at least 4:1, or at least 5:1, or at least 6:1, or at least 7:1, or at least 8:1, or at least 9:1, or at least 10:1, or at least 15:1, or at least 20:1. Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have an n-paraffin to i-paraffin weight ratio of not more than 100:1, 7 or not more than 5:1, or not more than 50:1, or not more than 40:1, or not more than 30:1. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have an n-paraffin to i-paraffin weight ratio in the range of 1:1 to 100:1, 4:1 to 100:1, or 15:1 to 100:1.
It should be noted that all of the above-referenced hydrocarbon weight percentages may be determined using gas chromatography-mass spectrometry (GC-MS).
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may exhibit a density at 15° C. of at least 0.6 g/cm3, or at least 0.65 g/cm3, or at least 0.7 g/cm3. Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may exhibit a density at 15° C. of not more than 1 g/cm3, or not more than 0.95 g/cm3, or not more than 0.9 g/cm3, or not more than 0.85 g/cm3. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil exhibits a density at 15° C. at a range of 0.6 to 1 g/cm3, 0.65 to 0.95 g/cm3, or 0.7 to 0.9 g/cm3.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may exhibit an API gravity at 15° C. of at least 28, or at least 29, or at least 30, or at least 31, or at least 32, or at least 33. Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may exhibit an API gravity at 15° C. of not more than 50, or not more than 49, or not more than 48, or not more than 47, or not more than 46, or not more than 45, or not more than 44. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil exhibits an API gravity at 15° C. at a range of 28 to 50, 29 to 58, or 30 to 44.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a mid-boiling point of at least 75° C., or at least 80° C., or at least 85° C., or at least 90° C., or at least 95° C., or at least 100° C., or at least 105° C., or at least 110° C., or at least 115° C. The values can be measured according to the procedures described in either according to ASTM D-2887, or in the working examples. A mid-boiling point having the stated value are satisfied if the value is obtained under either method. Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a mid-boiling point of not more than 250° C., or not more than 245° C., or not more than 240° C., or not more than 235° C., or not more than 230° C., or not more than 225° C., or not more than 220° C., or not more than 215° C., or not more than 210° C., or not more than 205° C., or not more than 200° C., or not more than 195° C., or not more than 190° C., or not more than 185° C., or not more than 180° C., or not more than 175° C., or not more than 170° C., or not more than 165° C., or not more than 160° C., 1 or not more than 55° C., or not more than 150° C., or not more than 145° C., or not more than 140° C., or not more than 135° C., or not more than 130° C., or not more than 125° C., or not more than 120° C. The values can be measured according to the procedures described in either according to ASTM D-2887, or in the working examples. A mid-boiling point having the stated value are satisfied if the value is obtained under either method. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a mid-boiling point in the range of 75 to 250° C., 90 to 225° C., or 115 to 190° C. As used herein, “mid-boiling point” refers to the median boiling point temperature of the pyrolysis oil when 50 weight percent of the pyrolysis oil boils above the mid-boiling point and 50 weight percent boils below the mid-boiling point.
In an embodiment or in combination with any of the embodiments mentioned herein, the boiling point range of the pyrolysis oil may be such that not more than 10 percent of the pyrolysis oil has a final boiling point (FBP) of 250° C., 280° C., 290° C., 300° C., or 310° C., to determine the FBP, the procedures described in either according to ASTM D-2887, or in the working examples, can be employed and a FBP having the stated values are satisfied if the value is obtained under either method.
Turning to the pyrolysis gas, the pyrolysis gas can have a methane content of at least 1, or at least 2, or at least 5, or at least 10, or at least 11, or at least 12, or at least 13, or at least 14, or at least 15, or at least 16, or at least 17, or at least 18, or at least 19, or at least 20 weight percent. Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis gas can have a methane content of not more than 50, or not more than 45, or not more than 40, or not more than 35, or not more than 30, or not more than 25, in each case weight percent. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis gas can have a methane content in the range of 1 to 50 weight percent, 5 to 50 weight percent, or 15 to 45 weight percent.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis gas can have a C3 hydrocarbon content of at least 1, or at least 2, or at least 3, or at least 4, or at least 5, or at least 6, or at least 7, or at least 8, or at least 9, or at least 10, or at least 15, or at least 20, or at least 25, in each case weight percent. Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis gas can have a C3 hydrocarbon content of not more than 50, or not more than 45, or not more than 40, or not more than 35, or not more than 30, in each case weight percent. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis gas can have a C3 hydrocarbon content in the range of 1 to 50 weight percent, 5 to 50 weight percent, or 20 to 50 weight percent.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis gas can have a C4 hydrocarbon content of at least 1, or at least 2, or at least 3, or at least 4, or at least 5, or at least 6, or at least 7, or at least 8, or at least 9, or at least 10, or at least 11, or at least 12, or at least 13, or at least 14, or at least 15, or at least 16, or at least 17, or at least 18, or at least 19, or at least 20, in each case weight percent. Additionally, or alternatively, in an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis gas can have a C4 hydrocarbon content of not more than 50, or not more than 45, or not more than 40, or not more than 35, or not more than 30, or not more than 25, in each case weight percent. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis gas can have a C4 hydrocarbon content in the range of 1 to 50 weight percent, 5 to 50 weight percent, or 20 to 50 weight percent.
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oils of the present invention may be a recycle content pyrolysis oil composition (r-pyoil).
Various downstream applications that may utilize the above-disclosed pyrolysis oils and/or the pyrolysis gases are described in greater detail below. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may be subjected to one or more treatment steps prior to being introduced into downstream units, such as a cracking furnace. Examples of suitable treatment steps can include, but are not limited to, separation of less desirable components (e.g., nitrogen-containing compounds, oxygenates, and/or olefins and aromatics), distillation to provide specific pyrolysis oil compositions, and preheating.
Turning now to
As shown in the treatment zone 220 illustrated in
In an embodiment or in combination with any of the embodiments mentioned herein, the heavy fraction may have a C4 to C7 content or a C8+ content of at least 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, or 85 weight percent. The light fraction may include at least about 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, or 85 percent of C3 and lighter (C3−) or C7 and lighter (C7−) content. In some embodiments, separator may concentrate desired components into the heavy fraction, such that the heavy fraction may have a C4 to C7 content or a C8+ content that is at least 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 7, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, or 150% greater than the C4 to C7 content or the C8+ content of the pyrolysis oil withdrawn from the pyrolysis zone. As shown in
In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil is hydrotreated in a treatment zone, while, in other embodiments, the pyrolysis oil is not hydrotreated prior to entering downstream units, such as a cracking furnace. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil is not pretreated at all before any downstream applications and may be sent directly from the pyrolysis oil source. The temperature of the pyrolysis oil exiting the pre-treatment zone can be in the range of 15 to 55° C., 30 to 55° C., 49 to 40° C., 15 to 50° C., 20 to 45° C., or 25 to 40° C.
In an embodiment or in combination with any of the embodiments mentioned herein, the r-pyoil may be combined with the non-recycle cracker stream in order to minimize the amount of less desirable compounds present in the combined cracker feed. For example, when the r-pyoil has a concentration of less desirable compounds (such as, for example, impurities like oxygen-containing compounds, aromatics, or others described herein), the r-pyoil may be combined with a cracker feedstock in an amount such that the total concentration of the less desirable compound in the combined stream is at least 40, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 percent less than the original content of the compound in the r-pyoil stream (calculated as the difference between the r-pyoil and combined streams, divided by the r-pyoil content, expressed as a percentage). In some cases, the amount of non-recycle cracker feed to combine with the r-pyoil stream may be determined by comparing the measured amount of the one or more less desirable compounds present in the r-pyoil with a target value for the compound or compounds to determine a difference and, then, based on that difference, determining the amount of non-recycle hydrocarbon to add to the r-pyoil stream. The amounts of r-pyoil and non-recycle hydrocarbon can be within one or more ranges described herein.
At least a portion of the r-ethylene can be derived directly or indirectly from the cracking of r-pyoil. The process for obtaining r-olefins from cracking (r-pyoil) can be as follows and as described in
Turning now to
A pyrolysis unit producing r-pyoil can be co-located with the production facility. In other embodiments, the r-pyoil can be sourced from a remote pyrolysis unit and transported to the production facility.
In an embodiment or in combination with any of the embodiments mentioned herein, the r-pyoil containing feed stream may contain r-pyoil in an amount of at least 1, or at least 5, or at least 10, or at least 15, or at least 20, or at least 25, or at least 30, or at least 35, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 97, or at least 98, or at least 99, or at least or 100, in each case weight percent and/or not more than 95, or not more than 90, or not more than 85, or not more than 80, or not more than 75, or not more than 70, or not more than 65, or not more than 60, or not more than 55, or not more than 50, or not more than 45, or not more than 40, or not more than 35, or not more than 30, or not more than 25, or not more than 20, in each case weight percent, based on the total weight of the r-pyoil containing feed stream.
In an embodiment or in combination with any of the embodiments mentioned herein, at least 1, or at least 5, or at least 10, or at least 15, or at least 20, or at least 25, or at least 30, or at least 35, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90 or at least 97, or at least 98, or at least 99, or 100, in each case weight percent and/or not more than 95, or not more than 90, or not more than 85, or not more than 80, or not more than 75, or not more than 70, or not more than 65, or not more than 60, or not more than 55, or not more than 50, or not more than 45, or not more than 40, or not more than 35, or not more than 30, or not more than 25, or not more than 20, or not more than 15 or not more than 10, in each case weight percent of the r-pyoil is obtained from the pyrolysis of a waste stream. In an embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the r-pyoil is obtained from pyrolysis of a feedstock comprising plastic waste. Desirably, at least 90, or at least 95, or at least 97, or at least 98, or at least 99, or at least or 100, in each case wt. %, of the r-pyoil is obtained from pyrolysis of a feedstock comprising plastic waste, or a feedstock comprising at least 50 wt. % plastic waste, or a feedstock comprising at least 80 wt. % plastic waste, or a feedstock comprising at least 90 wt. % plastic waste, or a feedstock comprising at least 95 wt. % plastic waste.
In an embodiment or in combination with any of the embodiments mentioned herein, the r-pyoil can have any one or combination of the compositional characteristics described above with respect to pyrolysis oil.
In an embodiment or in combination with any of the embodiments mentioned herein, the r-pyoil may comprise at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, in each case weight percent of C4-C30 hydrocarbons, and as used herein, hydrocarbons include aliphatic, cycloaliphatic, aromatic, and heterocyclic compounds. In an embodiment or in combination with any of the embodiments mentioned herein, the r-pyoil can predominantly comprise C5-C25, C5-C22, or C5-C20 hydrocarbons, or may comprise at least 55, 60, 65, 70, 75, 80, 85, 90, or 95 weight percent of C5-C25, C5-C22, or C5-C20 hydrocarbons.
In an embodiment or in combination with any embodiment mentioned herein, the r-pyoil composition can comprise C4-C12 aliphatic compounds (branched or unbranched alkanes and alkenes including diolefins, and alicyclics) and C13-C22 aliphatic compounds in a weight ratio of more than 1:1, or at least 1.25:1, or at least 1.5:1, or at least 2:1, or at least 2.5:1, or at least 3:1, or at least 4:1, or at least 5:1, or at least 6:1, or at least 7:1, 10:1, 20:1, or at least 40:1, each by weight and based on the weight of the r-pyoil.
In an embodiment or in combination with any embodiment mentioned herein, the r-pyoil composition can comprise C13-C22 aliphatic compounds (branched or unbranched alkanes and alkenes including diolefins, and alicyclics) and C4-C12 aliphatic compounds in a weight ratio of more than 1:1, or at least 1.25:1, or at least 1.5:1, or at least 2:1, or at least 2.5:1, or at least 3:1, or at least 4:1, or at least 5:1, or at least 6:1, or at least 7:1, 10:1, 20:1, or at least 40:1, each by weight and based on the weight of the r-pyoil.
In an embodiment, the two aliphatic hydrocarbons (branched or unbranched alkanes and alkenes, and alicyclics) having the highest concentration in the r-pyoil are in a range of C5-C18, or C5-C16, or C5-C14, or C5-C10, or C5-C8, inclusive.
The r-pyoil can include one or more of paraffins, naphthenes or cyclic aliphatic hydrocarbons, aromatics, aromatic containing compounds, olefins, oxygenated compounds and polymers, heteroatom compounds or polymers, and other compounds or polymers.
For example, in an embodiment or in combination with any of the embodiments mentioned herein, the r-pyoil may comprise at least 5, or at least 10, or at least 15, or at least 20, or at least 25, or at least 30, or at least 35, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, in each case weight percent and/or not more than 99, or not more than 97, or not more than 95, or not more than 93, or not more than 90, or not more than 87, or not more than 85, or not more than 83, or not more than 80, or not more than 78, or not more than 75, or not more than 70, or not more than 65, or not more than 60, or not more than 55, or not more than 50, or not more than 45, or not more than 40, or not more than 35, or not more than 30, or not more than 25, or not more than 20, or not more than 15, in each case weight percent of paraffins (or linear or branched alkanes), based on the total weight of the r-pyoil. In an embodiment or in combination with any of the embodiments mentioned herein, the pyrolysis oil may have a paraffin content in the range of 25 to 90, 35 to 90, or 40 to 80, or 40-70, or 40-65 weight percent, or 5-50, or 5 to 40, or 5 to 35, or 10- to 35, or 10 to 30, or 5 to 25, or 5 to 20, in each case as wt. % based on the weight of the r-pyoil composition.
In an embodiment or in combination with any of the embodiments mentioned herein, the r-pyoil can include naphthenes or cyclic aliphatic hydrocarbons in amount of zero, or at least 1, or at least 2, or at least 5, or at least 8, or at least 10, or at least 15, or at least 20, in each case weight percent and/or not more than 50, or not more than 45, or not more than 40, or not more than 35, or not more than 30, or not more than 25, or not more than 20, or not more than 15, or not more than 10, or not more than 5, or not more than 2, or not more than 1, or not more than 0.5, or no detectable amount, in each case weight percent. In an embodiment or in combination with any of the embodiments mentioned herein, the r-pyoil may have a naphthene content of not more than 5, or not more than 2, or not more than 1 wt. %, or no detectable amount, or naphthenes. Examples of ranges for the amount of naphthenes (or cyclic aliphatic hydrocarbons) contained in the r-pyoil is from 0-35, or 0-30, or 0-25, or 2-20, or 2-15, or 2-10, or 1-10, in each case as wt. % based on the weight of the r-pyoil composition.
In one embodiment or in combination with any of the mentioned embodiments, the r-pyoil comprises not more than 30, or not more than 25, or not more than 20, or not more than 15, 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, in each case weight percent of aromatics, based on the total weight of the r-pyoil. As used herein, the term “aromatics” refers to the total amount (in weight) of benzene, toluene, xylene, and styrene. The r-pyoil may include at least 1, or at least 2, or at least 5, or at least 8, or at least 10, in each case weight percent of aromatics, based on the total weight of the r-pyoil.
In one embodiment or in combination with any of the mentioned embodiments or in combination with any of the embodiments mentioned herein, the r-pyoil can include aromatic containing compounds in an amount of not more than 30, or not more than 25, or not more than 20, or not more than 15, 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, in each case weight, or not detectable, based on the total weight of the r-pyoil. Aromatic containing compounds includes the above-mentioned aromatics and any compounds containing an aromatic moiety, such as terephthalate residues and fused ring aromatics such as the naphthalenes and tetrahydronaphthalene.
In an embodiment or in combination with any of the embodiments mentioned herein, the r-pyoil can include olefins in amount of at least 1, or at least 2, or at least 5, or at least 8, or at least 10, or at least 15, or at least 20, or at least 30, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least or at least 65, in each case weight percent olefins and/or not more than 85, or not more than 80, or not more than 75, or not more than 70, or not more than 65, or not more than 60, or not more than 55, or not more than 50, or not more than 45, or not more than 40, or not more than 35, or not more than 30, or not more than 25, or not more than 20, or not more than 15, or not more than 10, in each case weight percent, based on the weight of a r-pyoil. Olefins include mono- and di-olefins. Examples of suitable ranges include olefins present in an amount ranging from 5 to 45, or 10-35, or 15 to 30, or 40-85, or 45-85, or 50-85, or 55-85, or 60-85, or 65-85, or 40-80, or 45-80, or 50-80, or 55-80, or 60-80, or 65-80, 45-80, or 50-80, or 55-80, or 60-80, or 65-80, or 40-75, or 45-75, or 50-75, or 55-75, or 60-75, or 65-75, or 40-70, or 45-70, or 50-70, or 55-70, or 60-70, or 65-70, or 40-65, or 45-65, or 50-65, or 55-65, in each case as wt. % based on the weight of the r-pyoil.
In an embodiment or in combination with any of the embodiments mentioned herein, the r-pyoil can include oxygenated compounds or polymers in amount of zero or at least 0.01, or at least 0.1, or at least 1, or at least 2, or at least 5, in each case weight percent and/or not more than 20, or not more than 15, or not more than 10, or not more than 8, or not more than 6, or not more than 5, or not more than 3, or not more than 2, in each case weight percent oxygenated compounds or polymers, based on the weight of a r-pyoil. Oxygenated compounds and polymers are those containing an oxygen atom. Examples of suitable ranges include oxygenated compounds present in an amount ranging from 0-20, or 0-15, or 0-10, or 0.01-10, or 1-10, or 2-10, or 0.01-8, or 0.1-6, or 1-6, or 0.01-5, in each case as wt. % based on the weight of the r-pyoil.
In an embodiment or in combination with any embodiment mentioned herein, the amount of oxygen atoms in the r-pyoil can be not more than 10, or not more than 8, or not more than 5, or not more than 4, or not more than 3, or not more than 2.75, or not more than 2.5, or not more than 2.25, or not more than 2, or not more than 1.75, or not more than 1.5, or not more than 1.25, or not more than 1, or not more than 0.75, or not more than 0.5, or not more than 0.25, or not more than 0.1, or not more than 0.05, in each case wt. %, based on the weight of the r-pyoil. Examples of the amount of oxygen in the r-pyoil can be from 0-8, or 0-5, or 0-3, or 0-2.5 or 0-2, or 0.001-5, or 0.001-4, or 0.001-3, or 0.001-2.75, or 0.001-2.5, or 0.001-2, or 0.001-1.5, or 0.001-1, or 0.001-0.5, or 0.001-0.1, in each case as wt. % based on the weight of the r-pyoil.
In an embodiment or in combination with any of the embodiments mentioned herein, the r-pyoil can include heteroatom compounds or polymers in amount of at least 1, or at least 2, or at least 5, or at least 8, or at least 10, or at least 15, or at least 20, in each case weight percent and/or not more than 25, or not more than 20, or not more than 15, or not more than 10, or not more than 8, or not more than 6, or not more than 5, or not more than 3, or not more than 2, in each case weight percent, based on the weight of a r-pyoil. A heterocompound or polymer is defined in this paragraph as any compound or polymer containing nitrogen, sulfur, or phosphorus. Any other atom is not regarded as a heteroatom for purposes of determining the quantity of heteroatoms, heterocompounds, or heteropolymers present in the r-pyoil. The r-pyoil can contain heteroatoms present in an amount of not more than 5, or not more than 4, or not more than 3, or not more than 2.75, or not more than 2.5, or not more than 2.25, or not more than 2, or not more than 1.75, or not more than 1.5, or not more than 1.25, or not more than 1, or not more than 0.75, or not more than 0.5, or not more than 0.25, or not more than 0.1, or not more than 0.075, or not more than 0.05, or not more than 0.03, or not more than 0.02, or not more than 0.01, or not more than 0.008, or not more than 0.006, or not more than 0.005, or not more than 0.003, or not more than 0.002, in each case wt. %, based on the weight of the r-pyoil.
In an embodiment or in combination with any embodiment mentioned herein or in combination with any of the embodiments mentioned herein, the solubility of water in the r-pyoil at 1 atm and 25° C. is less than 2 wt. %, water, or not more than 1.5, or not more than 1, or not more than 0.5, or not more than 0.1, or not more than 0.075, or not more than 0.05, or not more than 0.025, or not more than 0.01, or not more than 0.005, in each case wt. % water based on the weight of the r-pyoil. Desirably, the solubility of water in the r-pyoil is not more than 0.1 wt. % based on the weight of the r-pyoil. In an embodiment or in combination with any embodiment mentioned herein or in combination with any of the embodiments mentioned herein, the r-pyoil contains not more than 2 wt. %, water, or not more than 1.5, or not more than 1, or not more than 0.5, desirably or not more than 0.1, or not more than 0.075, or not more than 0.05, or not more than 0.025, or not more than 0.01, or not more than 0.005, in each case wt. % water based on the weight of the r-pyoil.
In an embodiment or in combination with any embodiment mentioned herein or in combination with any of the embodiments mentioned herein, the solids content in the r-pyoil does not exceed 1, or is not more than 0.75, or not more than 0.5, or not more than 0.25, or not more than 0.2, or not more than 0.15, or not more than 0.1, or not more than 0.05, or not more than 0.025, or not more than 0.01, or not more than 0.005, or does not exceed 0.001, in each case wt. % solids based on the weight of the r-pyoil.
In an embodiment or in combination with any embodiment mentioned herein or in combination with any of the embodiments mentioned herein the sulfur content of the r-pyoil does not exceed 2.5 wt. %, or is not more than 2, or not more than 1.75, or not more than 1.5, or not more than 1.25, or not more than 1, or not more than 0.75, or not more than 0.5, or not more than 0.25, or not more than 0.1, or not more than 0.05, desirably or not more than 0.03, or not more than 0.02, or not more than 0.01, or not more than 0.008, or not more than 0.006, or not more than 0.004, or not more than 0.002, or is not more than 0.001, in each case wt. % based on the weight of the r-pyoil.
In an embodiment or in combination with any embodiment mentioned herein or in combination with any of the embodiments mentioned herein, the r-pyoil can have the following compositional content:
In an embodiment or in combination with any embodiment mentioned herein, the amount of hydrogen atoms in the r-pyoil can be in a range of from 10-20, or 10-18, or 11-17, or 12-16 or 13-16, or 13-15, or 12-15, in each case as wt. % based on the weight of the r-pyoil.
In an embodiment or in combination with any embodiment mentioned herein or in combination with any of the embodiments mentioned herein, the metal content of the r-pyoil is desirably low, for example, not more than 2 wt. %, or not more than 1, or not more than 0.75, or not more than 0.5, or not more than 0.25, or not more than 0.2, or not more than 0.15, or not more than 0.1, or not more than 0.05, in each case wt. % based on the weight of the r-pyoil.
In one embodiment or in combination with any of the mentioned embodiments or in combination with any of the embodiments mentioned herein, the weight ratio of paraffin to naphthene in the r-pyoil can be at least 1:1, or at least 1.5:1, or at least 2:1, or at least 2.2:1, or at least 2.5:1, or at least 2.7:1, or at least 3:1, or at least 3.3:1, or at least 3.5:1, or at least 3.75:1, or at least 4:1, or at least 4.25:1, or at least 4.5:1, or at least 4.75:1, or at least 5:1, or at least 6:1, or at least 7:1, or at least 8:1, or at least 9:1, or at least 10:1, or at least 13:1, or at least 15:1, or at least 17:1, based on the weight of the r-pyoil.
In an embodiment or in combination with any embodiment mentioned herein or in combination with any of the embodiments mentioned herein, the weight ratio of paraffin and naphthene combined to aromatics can be at least 1:1, or at least 1.5:1, or at least 2:1, or at least 2.5:1, or at least 2.7:1, or at least 3:1, or at least 3.3:1, or at least 3.5:1, or at least 3.75:1, or at least 4:1, or at least 4.5:1, or at least 5:1, or at least 7:1, or at least 10:1, or at least 15:1, or at least 20:1, or at least 25:1, or at least 30:1, or at least 35:1, or at least 40:1, based on the weight of the r-pyoil. In an embodiment or in combination with any embodiment mentioned herein, the ratio of paraffin and naphthene combined to aromatics in the r-pyoil can be in a range of from 50:1-1:1, or 40:1-1:1, or 30:1-1:1, or 20:1-1:1, or 30:1-3:1, or 20:1-1:1, or 20:1-5:1, or 50:1-5:1, or 30:1-5:1, or 1:1-7:1, or 1:1-5:1, 1:1-4:1, or 1:1-3:1.
In an embodiment or in combination with any of the embodiments mentioned herein, the r-pyoil may have a boiling point curve defined by one or more of its 10%, its 50%, and its 90% boiling points, as defined below. As used herein, “boiling point” refers to the boiling point of a composition as determined by ASTM D2887 or according to the procedure described in the working examples. A boiling point having the stated values are satisfied if the value is obtained under either method. Additionally, as used herein, an “x % boiling point,” refers to a boiling point at which x percent by weight of the composition boils per either of these methods.
As used throughout, an x % boiling at a stated temperature means at least x % of the composition boils at the stated temperature. In an embodiment or in combination with any of the embodiments mentioned herein, the 90% boiling point of the cracker feed stream or composition can be not more than 350, or not more than 325, or not more than 300, or not more than 295, or not more than 290, or not more than 285, or not more than 280, or not more than 275, or not more than 270, or not more than 265, or not more than 260, or not more than 255, or not more than 250, or not more than 245, or not more than 240, or not more than 235, or not more than 230, or not more than 225, or not more than 220, or not more than 215, not more than 200, not more than 190, not more than 180, not more than 170, not more than 160, not more than 150, or not more than 140, in each case ° C. and/or at least 200, or at least 205, or at least 210, or at least 215, or at least 220, or at least 225, or at least 230, in each case ° C. and/or not more than 25, 20, 15, 10, 5, or 2 weight percent of the r-pyoil may have a boiling point of 300° C. or higher.
Referring again to
In an embodiment or in combination with any of the embodiments mentioned herein, the cracker feed stream may comprise a predominantly C2-C4 hydrocarbon containing composition, or a predominantly C5-C22hydrocarbon containing composition. As used herein, the term “predominantly C2-C4 hydrocarbon,” refers to a stream or composition containing at least 50 weight percent of C2-C4 hydrocarbon components. Examples of specific types of C2-C4 hydrocarbon streams or compositions include propane, ethane, butane, and LPG. In an embodiment or in combination with any of the embodiments mentioned herein, the cracker feed may comprise at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, in each case wt. % based on the total weight of the feed, and/or not more than 100, or not more than 99, or not more than 95, or not more than 92, or not more than 90, or not more than 85, or not more than 80, or not more than 75, or not more than 70, or not more than 65, or not more than 60, in each case weight percent C2-C4 hydrocarbons or linear alkanes, based on the total weight of the feed. The cracker feed can comprise predominantly propane, predominantly ethane, predominantly butane, or a combination of two or more of these components. These components may be non-recycle components. The cracker feed can comprise predominantly propane, or at least 50 mole % propane, or at least 80 mole % propane, or at least 90 mole % propane, or at least 93 mole % propane, or at least 95 mole % propane (inclusive of any recycle streams combined with virgin feed). The cracker feed can comprise HD5 quality propane as a virgin or fresh feed. The cracker can comprise at more than 50 mole % ethane, or at least 80 mole % ethane, or at least 90 mole % ethane, or at least 95 mole % ethane. These components may be non-recycle components.
In an embodiment or in combination with any of the embodiments mentioned herein, the cracker feed stream may comprise a predominantly C5-C22 hydrocarbon containing composition. As used herein, “predominantly C5-C22 hydrocarbon” refers to a stream or composition comprising at least 50 weight percent of C5-C22 hydrocarbon components. Examples include gasoline, naphtha, middle distillates, diesel, kerosene. In an embodiment or in combination with any of the embodiments mentioned herein, the cracker feed stream or composition may comprise at least 20, or at least 25, or at least 30, or at least 35, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, in each case wt. % and/or not more than 100, or not more than 99, or not more than 95, or not more than 92, or not more than 90, or not more than 85, or not more than 80, or not more than 75, or not more than 70, or not more than 65, or not more than 60, in each case weight percent C5-C22, or C5-C20 hydrocarbons, based on the total weight of the stream or composition. In an embodiment or in combination with any of the embodiments mentioned herein, the cracker feed may have a Cis and heavier (Cis+) content of at least 0.5, or at least 1, or at least 2, or at least 5, in each case weight percent and/or not more than 40, or not more than 35, or not more than 30, or not more than 25, or not more than 20, or not more than 18, or not more than 15, or not more than 12, or not more than 10, or not more than 5, or not more than 3, in each case weight percent, based on the total weight of the feed.
The cracker feed may have a boiling point curve defined by one or more of its 10%, its 50%, and its 90% boiling points, the boiling point being obtained by the methods described above Additionally, as used herein, an “x % boiling point,” refers to a boiling point at which x percent by weight of the composition boils per the methods described above. In an embodiment or in combination with any of the embodiments mentioned herein, the 90% boiling point of the cracker feed stream or composition can be not more than 360, or not more than 355, or not more than 350, or not more than 345, or not more than 340, or not more than 335, or not more than 330, or not more than 325, or not more than 320, or not more than 315, or not more than 300, or not more than 295, or not more than 290, or not more than 285, or not more than 280, or not more than 275, or not more than 270, or not more than 265, or not more than 260, or not more than 255, or not more than 250, or not more than 245, or not more than 240, or not more than 235, or not more than 230, or not more than 225, or not more than 220, or not more than 215, in each case ° C. and/or at least 200, or at least 205, or at least 210, or at least 215, or at least 220, or at least 225, or at least 230, in each case ° C.
In an embodiment or in combination with any of the embodiments mentioned herein, the 10% boiling point of the cracker feed stream or composition can be at least 40, at least 50, at least 60, at least 70, at least 80, at least 90, at least 100, at least 110, at least 120, at least 130, at least 140, at least 150, or at least 155, in each case ° C. and/or not more than 250, not more than 240, not more than 230, not more than 220, not more than 210, not more than 200, not more than 190, not more than 180, or not more than 170 in each case ° C.
In an embodiment or in combination with any of the embodiments mentioned herein, the 50% boiling point of the cracker feed stream or composition can be 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 100, at least 110, at least 120, at least 130, at least 140, at least 150, at least 160, at least 170, at least 180, at least 190, at least 200, at least 210, at least 220, or at least 230, in each case ° C., and/or not more than 300, not more than 290, not more than 280, not more than 270, not more than 260, not more than 250, not more than 240, not more than 230, not more than 220, not more than 210, not more than 200, not more than 190, not more than 180, not more than 170, not more than 160, not more than 150, or not more than 145° C. The 50% boiling point of the cracker feed stream or composition can be in the range of 65 to 160, 70 to 150, 80 to 145, 85 to 140, 85 to 230, 90 to 220, 95 to 200, 100 to 190, 110 to 180, 200 to 300, 210 to 290, 220 to 280, 230 to 270, in each case in ° C.
In an embodiment or in combination with any of the embodiments mentioned herein, the 90% boiling point of the cracker feedstock or stream or composition can be at least 350° C., the 10% boiling point can be at least 60° C.; and the 50% boiling point can be in the range of from 95° C. to 200° C. In an embodiment or in combination with any of the embodiments mentioned herein, the 90% boiling point of the cracker feedstock or stream or composition can be at least 150° C., the 10% boiling point can be at least 60° C., and the 50% boiling point can be in the range of from 80 to 145° C. In an embodiment or in combination with any of the embodiments mentioned herein, the cracker feedstock or stream has a 90% boiling point of at least 350° C., a 10% boiling point of at least 150° C., and a 50% boiling point in the range of from 220 to 280° C.
In an embodiment or in combination with any embodiment mentioned herein or in combination with any of the embodiments mentioned herein, the r-pyoil is cracked in a gas furnace. A gas furnace is a furnace having at least one coil which receives (or operated to receive), at the inlet of the coil at the entrance to the convection zone, a predominately vapor-phase feed (more than 50% of the weight of the feed is vapor) (“gas coil”). In an embodiment or in combination with any embodiment mentioned herein, the gas coil can receive a predominately C2-C4 feedstock, or a predominately a C2-C3 feedstock to the inlet of the coil in the convection section, or alternatively, having at least one coil receiving more than 50 wt. % ethane and/or more than 50% propane and/or more than 50% LPG, or in any one of these cases at least 60 wt. %, or at least 70 wt. %, or at least 80 wt. %, based on the weight of the cracker feed to the coil, or alternatively based on the weight of the cracker feed to the convection zone. The gas furnace may have more than one gas coil. In an embodiment or in combination with any embodiment mentioned herein, at least 25% of the coils, or at least 50% of the coils, or at least 60% of the coils, or all the coils in the convection zone or within a convection box of the furnace are gas coils. In an embodiment or in combination with any embodiment mentioned herein, the gas coil receives, at the inlet of the coil at the entrance to the convection zone, a vapor-phase feed in which at least 60 wt. %, or at least 70 wt. %, or at least 80 wt. %, or at least 90 wt. %, or at least 95 wt. %, or at least 97 wt. %, or at least 98 wt. %, or at least 99 wt. %, or at least 99.5 wt. %, or at least 99.9 wt. % of feed is vapor.
In an embodiment or in combination with any embodiment mentioned herein, the r-pyoil is cracked in a split furnace. A split furnace is a type of gas furnace. A split furnace contains at least one gas coil and at least one liquid coil within the same furnace, or within the same convection zone, or within the same convection box. A liquid coil is a coil which receives, at the inlet of coil at the entrance to the convection zone, a predominately liquid phase feed (more than 50% of the weight of the feed is liquid) (“liquid coil”). In an embodiment or in combination with any embodiment mentioned herein, the liquid coil can receive a predominately C5+ feedstock to the inlet of the coil at the entrance of the convection section (“liquid coil”). In an embodiment or in combination with any embodiment mentioned herein, the liquid coil can receive a predominately C6-C22 feedstock, or a predominately a C7-C16 feedstock to the inlet of the coil in the convection section, or alternatively, having at least one coil receiving more than 50 wt. % naphtha, and/or more than 50% natural gasoline, and/or more than 50% diesel, and/or more than JP-4, and/or more than 50% Stoddard Solvent, and/or more than 50% kerosene, and/or more than 50% fresh creosote, and/or more than 50% JP-8 or Jet-A, and/or more than 50% heating oil, and/or more than 50% heavy fuel oil, and/or more than 50% bunker C, and/or more than 50% lubricating oil, or in any one of these cases at least 60 wt. %, or at least 70 wt. %, or at least 80 wt. %, or at least 90 wt. %, or at least 95 wt. %, or at least 98 wt. %, or at least 99 wt. %, based on the weight of the cracker feed to the liquid coil, or alternatively based on the weight of the cracker feed to the convection zone. In an embodiment or in combination with any embodiment mentioned herein, at least one coil and not more than 75% of the coils, or not more than 50% of the coils, or not more than at least 40% of the coils in the convection zone or within a convection box of the furnace are liquid coils. In an embodiment or in combination with any embodiment mentioned herein, the liquid coil receives, at the inlet of the coil at the entrance to the convection zone, a liquid-phase feed in which at least 60 wt. %, or at least 70 wt. %, or at least 80 wt. %, or at least 90 wt. %, or at least 95 wt. %, or at least 97 wt. %, or at least 98 wt. %, or at least 99 wt. %, or at least 99.5 wt. %, or at least 99.9 wt. % of feed is liquid.
In an embodiment or in combination with any embodiment mentioned herein, the r-pyoil is cracked in a thermal gas cracker.
In an embodiment or in combination with any embodiment mentioned herein, the r-pyoil is cracked in a thermal steam gas cracker in the presence of steam.
Steam cracking refers to the high-temperature cracking (decomposition) of hydrocarbons in the presence of steam.
In an embodiment or in combination with any embodiment mentioned herein, the r-composition is derived directly or indirectly from cracking r-pyoil in a gas furnace. The coils in the gas furnace can consist entirely of gas coils or the gas furnace can be a split furnace.
When the r-pyoil containing feed stream is combined with the non-recycle cracker feed, such a combination may occur upstream of, or within, the cracking furnace or within a single coil or tube. Alternatively, the r-pyoil containing feed stream and non-recycle cracker feed may be introduced separately into the furnace, and may pass through a portion, or all, of the furnace simultaneously while being isolated from one another by feeding into separate tubes within the same furnace (e.g., a split furnace). Ways of introducing the r-pyoil containing feed stream and the non-recycle cracker feed into the cracking furnace according to an embodiment or in combination with any of the embodiments mentioned herein are described in further detail below.
Turning now to
In an embodiment or in combination with any embodiment mentioned herein, although not shown, a vaporizer can be provided to vaporize a condensed feedstock of C2-C5 hydrocarbons 350 to ensure that the feed to the inlet of the coils in the convection box 312, or the inlet of the convection zone 310, is a predominately vapor phase feed.
The cracking furnace shown in
As hot combustion gases ascend upwardly through the furnace stack, the gases may pass through the convection section 310, wherein at least a portion of the waste heat may be recovered and used to heat the cracker stream passing through the convection section 310. In an embodiment or in combination with any of the embodiments mentioned herein, the cracking furnace 300 may have a single convection (preheat) section 310 and a single radiant 320 section, while, in other embodiments, the furnace may include two or more radiant sections sharing a common convection section. At least one induced draft (I.D.) fan 316 near the stack may control the flow of hot flue gas and heating profile through the furnace, and one or more heat exchangers 340 may be used to cool the furnace effluent 370. In an embodiment or in combination with any of the embodiments mentioned herein (not shown), a liquid quench may be used in addition to, or alternatively with, the exchanger (e.g., transfer line heat exchanger or TLE) shown in
The furnace 300 also includes at least one furnace coil 324 through which the cracker streams pass through the furnace. The furnace coils 324 may be formed of any material inert to the cracker stream and suitable for withstanding high temperatures and thermal stresses within the furnace. The coils may have any suitable shape and can, for example, have a circular or oval cross-sectional shape.
The coils in the convection section 310, or tubes within the coil, may have a diameter of at least 1, or at least 1.5, or at least 2, or at least 2.5, or at least 3, or at least 3.5, or at least 4, or at least 4.5, or at least 5, or at least 5.5, or at least 6, or at least 6.5, or at least 7, or at least 7.5, or at least 8, or at least 8.5, or at least 9, or at least 9.5, or at least 10, or at least 10.5, in each case cm and/or not more than 12, or not more than 11.5, or not more than 11, 1 or not more than 0.5, or not more than 10, or not more than 9.5, or not more than 9, or not more than 8.5, or not more than 8, or not more than 7.5, or not more than 7, or not more than 6.5, in each case cm. All or a portion of one or more coils can be substantially straight, or one or more of the coils may include a helical, twisted, or spiral segment. One or more of the coils may also have a U-tube or split U-tube design. In an embodiment or in combination with any of the embodiments mentioned herein, the interior of the tubes may be smooth or substantially smooth, or a portion (or all) may be roughened in order to minimize coking. Alternatively, or in addition, the inner portion of the tube may include inserts or fins and/or surface metal additives to prevent coke build up.
In an embodiment or in combination with any of the embodiments mentioned herein, all or a portion of the furnace coil or coils 324 passing through in the convection section 310 may be oriented horizontally, while all, or at least a portion of, the portion of the furnace coil passing through the radiant section 322 may be oriented vertically. In an embodiment or in combination with any of the embodiments mentioned herein, a single furnace coil may run through both the convection and radiant section. Alternatively, at least one coil may split into two or more tubes at one or more points within the furnace, so that cracker stream may pass along multiple paths in parallel. For example, the cracker stream (including r-pyoil) 350 may be introduced into multiple coil inlets in the convection zone 310, or into multiple tube inlets in the radiant 320 or cross-over sections 330. When introduced into multiple coil or tube inlets simultaneously, or nearly simultaneously, the amount of r-pyoil introduced into each coil or tube may not be regulated. In an embodiment or in combination with any of the embodiments mentioned herein, the r-pyoil and/or cracker stream may be introduced into a common header, which then channels the r-pyoil into multiple coil or tube inlets.
A single furnace can have at least 1, or at least 2, or at least 3, or at least 4, or at least 5, or at least 6, or at least 7, or at least 8 or more, in each case coils. Each coil can be from 5 to 100, 10 to 75, or 20 to 50 meters in length and can include at least 1, or at least 2, or at least 3, or at least 4, or at least 5, or at least 6, or at least 7, or at least 8, or at least 10, or at least 12, or at least 14 or more tubes. Tubes of a single coil may be arranged in many configurations and in an embodiment or in combination with any of the embodiments mentioned herein may be connected by one or more 180° (“U”) bends. One example of a furnace coil 410 having multiple tubes 420 is shown in
An olefin plant can have a single cracking furnace, or it can have at least 2, or at least 3, or at least 4, or at least 5, or at least 6, or at least 7, or at least 8 or more cracking furnaces operated in parallel. Any one or each furnace(s) may be gas cracker, or a liquid cracker, or a split furnace. In an embodiment or in combination with any embodiment mentioned herein, the furnace is a gas cracker receiving a cracker feed stream containing at least 50 wt. %, or at least 75 wt. %, or at least 85 wt. % or at least 90 wt. % ethane, propane, LPG, or a combination thereof through the furnace, or through at least one coil in a furnace, or through at least one tube in the furnace, based on the weight of all cracker feed to the furnace. In an embodiment or in combination with any embodiment mentioned herein, the furnace is a liquid or naphtha cracker receiving a cracker feed stream containing at least 50 wt. %, or at least 75 wt. %, or at least 85 wt. % liquid (when measured at 25° C. and 1 atm) hydrocarbons having a carbon number from C5-C22. through the furnace, or through at least one coil in a furnace, or through at least one tube in the furnace, based on the weight of all cracker feed to the furnace. In an embodiment or in combination with any embodiment mentioned herein, the cracker is a split furnace receiving a cracker feed stream containing at least 50 wt. %, or at least 75 wt. %, or at least 85 wt. % or at least 90 wt. % ethane, propane, LPG, or a combination thereof through the furnace, or through at least one coil in a furnace, or through at least one tube in the furnace, and receiving a cracker feed stream containing at least 0.5 wt. %, or at least 0.1 wt. %, or at least 1 wt. %, or at least 2 wt. %, or at least 5 wt. %, or at least 7 wt. %, or at least 10 wt. %, or at least 13 wt. %, or at least 15 wt. %, or at least 20 wt. % liquid and/or r-pyoil (when measured at 25° C. and 1 atm), each based on the weight of all cracker feed to the furnace.
Turning now to
In an embodiment or in combination with any of the embodiments mentioned herein, an r-pyoil containing feed stream 550 may be combined with the non-recycle cracker feed 552 upstream of the convection section to form a combined cracker feed stream 554, which may then be introduced into the convection section 510 of the furnace. Alternatively, or in addition, the r-pyoil containing feed 550 may be introduced into a first furnace coil, while the non-recycle cracker feed 552 is introduced into a separate or second furnace coil, within the same furnace, or within the same convection zone. Both streams may then travel in parallel with one another through the convection section 510 within a convection box 512, cross-over 530, and radiant section 520 within a radiant box 522, such that each stream is substantially fluidly isolated from the other over most, or all, of the travel path from the inlet to the outlet of the furnace. The pyoil stream introduced into any heating zone within the convection section 510 can flow through the convection section 510 and flow through as a vaporized stream 514b into the radiant box 522. In other embodiments, the r-pyoil containing feed stream 550 may be introduced into the non-recycle cracker stream 552 as it passes through a furnace coil in the convection section 510 flowing into the cross-over section 530 of the furnace to form a combined cracker stream 514a, as also shown in
In an embodiment or in combination with any embodiment mentioned herein, the r-pyoil 550 may be introduced into the first furnace coil, or an additional amount introduced into the second furnace coil, at either a first heating zone or a second heating zone as shown in
The non-recycle cracker feed stream may be mostly liquid and have a vapor fraction of less than 0.25 by volume, or less than 0.25 by weight, or it may be mostly vapor and have a vapor fraction of at least 0.75 by volume, or at least 0.75 by weight, when introduced into the furnace and/or when combined with the r-pyoil containing feed. Similarly, the r-pyoil containing feed may be mostly vapor or mostly liquid when introduced into the furnace and/or when combined with the non-recycle cracker stream.
Turning back to
The heated cracker stream, which usually has a temperature of at least 500, or at least 510, or at least 520, or at least 530, or at least 540, or at least 550, or at least 560, or at least 570, or at least 580, or at least 590, or at least 600, or at least 610, or at least 620, or at least 630, or at least 640, or at least 650, or at least 660, or at least 670, or at least 680, in each case ° C. and/or not more than 850, or not more than 840, or not more than 830, or not more than 820, or not more than 810, or not more than 800, or not more than 790, or not more than 780, or not more than 770, or not more than 760, or not more than 750, or not more than 740, or not more than 730, or not more than 720, or not more than 710, or not more than 705, or not more than 700, or not more than 695, or not more than 690, or not more than 685, or not more than 680, or not more than 675, or not more than 670, or not more than 665, or not more than 660, or not more than 655, or not more than 650, in each case ° C., or in the range of from 500 to 710° C., 620 to 740° C., 560 to 670° C., or 510 to 650° C., may then pass from the convection section of the furnace to the radiant section via the cross-over zone.
In one embodiment or in combination with any of the mentioned embodiments or in combination with any of the embodiments mentioned herein, the r-pyoil containing feed stream may be added to the cracker stream at the cross-over zone. When introduced into the furnace in the cross-over zone, the r-pyoil may be at least partially vaporized or atomized prior to being combined with the cracker stream at the cross-over.
In an embodiment or in combination with any of the embodiments mentioned herein, the vapor-liquid separator 640 may comprise a flash drum, while in other embodiments it may comprise a fractionator. As the stream 614 passes through the vapor-liquid separator 640, a gas stream impinges on a tray and flows through the tray, as the liquid from the tray fall to an underflow 642. The vapor-liquid separator may further comprise a demister or chevron or other device located near the vapor outlet for preventing liquid carry-over into the gas outlet from the vapor-liquid separator 640.
Within the convection section 610, the temperature of the cracker stream may increase by at least 50, 75, 100, 150, 175, 200, 225, 250, 275, or 300° C. and/or not more than about 650, 600, 575, 550, 525, 500, 475, 450, 425, 400, 375, 350, 325, 300, or 275° C., so that the passing of the heated cracker stream exiting the convection section 610 through the vapor-liquid separator 640 may be performed at a temperature of least 400, 425, 450, 475, 500, 525, 550, 575, 600, 625, 650° C. and/or not more than 800, 775, 750, 725, 700, 675, 650, 625° C. When heavier components are present, at least a portion or nearly all of the heavy components may be removed in the heavy fraction as an underflow 642. At least a portion of the light fraction 644 from the separator 640 may be introduced into the cross-over section or the radiant zone tubes 624 after the separation, alone or in combination with one or more other cracker streams, such as, for example, a predominantly C5-C22 hydrocarbon stream or a C2-C4 hydrocarbon stream.
Referencing
The heated cracker stream, which usually has a temperature of at least 500, or at least 510, or at least 520, or at least 530, or at least 540, or at least 550, or at least 560, or at least 570, or at least 580, or at least 590, or at least 600, or at least 610, or at least 620, or at least 630, or at least 640, or at least 650, or at least 660, or at least 670, or at least 680, in each case ° C. and/or not more than 850, or not more than 840, or not more than 830, or not more than 820, or not more than 810, or not more than 800, or not more than 790, or not more than 780, or not more than 770, or not more than 760, or not more than 750, or not more than 740, or not more than 730, or not more than 720, or not more than 710, or not more than 705, or not more than 700, or not more than 695, or not more than 690, or not more than 685, or not more than 680, or not more than 675, or not more than 670, or not more than 665, or not more than 660, or not more than 655, or not more than 650, in each case ° C., or in the range of from 500 to 710° C., 620 to 740° C., 560 to 670° C., or 510 to 650° C., may then pass from the convection section 610 of the furnace to the radiant section 620 via the cross-over section 630. In an embodiment or in combination with any of the embodiments mentioned herein, the r-pyoil containing feed stream 550 may be added to the cracker stream at the cross-over section 530 as shown in
The resulting cracker feed stream then passes through the radiant section, wherein the r-pyoil containing feed stream is thermally cracked to form lighter hydrocarbons, including olefins such as ethylene, propylene, and/or butadiene. The residence time of the cracker feed stream in the radiant section can be at least 0.1, or at least 0.15, or at least 0.2, or at least 0.25, or at least 0.3, or at least 0.35, or at least 0.4, or at least 0.45, in each case seconds and/or not more than 2, or not more than 1.75, or not more than 1.5, or not more than 1.25, or not more than 1, or not more than 0.9, or not more than 0.8, or not more than 0.75, or not more than 0.7, or not more than 0.65, or not more than 0.6, or not more than 0.5, in each case seconds. The temperature at the inlet of the furnace coil is at least 500, or at least 510, or at least 520, or at least 530, or at least 540, or at least 550, or at least 560, or at least 570, or at least 580, or at least 590, or at least 600, or at least 610, or at least 620, or at least 630, or at least 640, or at least 650, or at least 660, or at least 670, or at least 680, in each case ° C. and/or not more than 850, or not more than 840, or not more than 830, or not more than 820, or not more than 810, or not more than 800, or not more than 790, or not more than 780, or not more than 770, or not more than 760, or not more than 750, or not more than 740, or not more than 730, or not more than 720, or not more than 710, or not more than 705, or not more than 700, or not more than 695, or not more than 690, or not more than 685, or not more than 680, or not more than 675, or not more than 670, or not more than 665, or not more than 660, or not more than 655, or not more than 650, in each case ° C., or in the range of from 550 to 710° C., 560 to 680° C., or 590 to 650° C., or 580 to 750° C., 620 to 720° C., or 650 to 710° C.
The coil outlet temperature can be at least 640, or at least 650, or at least 660, or at least 670, or at least 680, or at least 690, or at least 700, or at least 720, or at least 730, or at least 740, or at least 750, or at least 760, or at least 770, or at least 780, or at least 790, or at least 800, or at least 810, or at least 820, in each case ° C. and/or not more than 1000, or not more than 990, or not more than 980, or not more than 970, or not more than 960, or not more than 950, or not more than 940, or not more than 930, or not more than 920, or not more than 910, or not more than 900, or not more than 890, or not more than 880, or not more than 875, or not more than 870, or not more than 860, or not more than 850, or not more than 840, or not more than 830, in each case ° C., in the range of from 730 to 900° C., 750 to 875° C., or 750 to 850° C. In an embodiment or in combination with any of the embodiments mentioned herein, the mass velocity of the cracker feed stream through at least one, or at least two radiant coils (for clarity as determine across the entire coil as opposed to a tube within a coil) is in the range of 60 to 165 kilograms per second (kg/s) per square meter (m2) of cross-sectional area (kg/s/m2), 60 to 130 (kg/s/m2), 60 to 110 (kg/s/m2), 70 to 110 (kg/s/m2), or 80 to 100 (kg/s/m2). When steam is present, the mass velocity is based on the total flow of hydrocarbon and steam.
In one embodiment or in combination with any of the mentioned embodiments or in combination with any of the embodiments mentioned herein, the burners in the radiant zone provide an average heat flux into the coil in the range of from 60 to 160 kW/m2 or 70 to 145 kW/m2 or 75 to 130 kW/m2. The maximum (hottest) coil surface temperature is in the range of 1035 to 1150° C. or 1060 to 1180° C. The pressure at the inlet of the furnace coil in the radiant section is in the range of 1.5 to 8 bar absolute (bara), or 2.5 to 7 bara, while the outlet pressure of the furnace coil in the radiant section is in the range of from 15 to 40 psia, or 15 to 30 psia. The pressure drop across the furnace coil in the radiant section can be from 1.5 to 5 bara, or 1.75 to 3.5 bara, or 1.5 to 3 bara, or 1.5 to 3.5 bara.
In one embodiment or in combination with any of the mentioned embodiments or in combination with any of the embodiments mentioned herein, the yield of olefin—ethylene, propylene, butadiene, or combinations thereof—can be at least 15, or at least 20, or at least 25, or at least 30, or at least 35, or at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, in each case percent. As used herein, the term “yield” refers to the mass of product/mass of feedstock×100%. The olefin-containing effluent stream comprises at least about 30, or at least 40, or at least 50, or at least 60, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 97, or at least 99, in each case weight percent of ethylene, propylene, or ethylene and propylene, based on the total weight of the effluent stream.
In one embodiment or in combination with any of the mentioned embodiments, the olefin-containing effluent stream comprises MAPD (methyl acetylene and propadiene). The amount of MAPD can be at least 2 ppm, or at least 5 ppm, or at least 10 ppm, or at least 20 ppm, or at least 50 ppm, or at least 100 ppm, or at least 500 ppm, or at least 1000 ppm, or at least 5000 ppm, or at least 10,000 ppm, based on the total weight of the effluent stream from the furnace.
In one embodiment or in combination with any of the mentioned embodiments, the olefin-containing effluent stream comprises acetylene. The amount of acetylene can be at least 2000 ppm, or at least 5000 ppm, or at least 8000 ppm, or at least 10,000 ppm, based on the total weight of the effluent stream from the furnace.
Turning now to
As shown in
The resulting cooled effluent stream is then vapor liquid separated and the vapor is compressed in a compression zone 720, such as in a gas compressor having, for example, between 1 and 5 compression stages with optional inter-stage cooling and liquid removal. The pressure of the gas stream at the outlet of the first set of compression stages is in the range of from 7 to 20 bar gauge (barg), 8.5 to 18 psig (0.6-1.3 barg), or 9.5 to 14 barg.
The resulting compressed stream is then treated in an acid gas removal zone 722 for removal of acid gases, including CO, CO2, and H2S by contact with an acid gas removal agent. Examples of acid gas removal agents can include, but are not limited to, caustic and various types of amines. In an embodiment or in combination with any of the embodiments mentioned herein, a single contactor may be used, while, in other embodiments, a dual column absorber-stripper configuration may be employed.
The treated compressed olefin-containing stream may then be further compressed in another compression zone 724 via a compressor, optionally with inter-stage cooling and liquid separation. The resulting compressed stream, which has a pressure in the range of 20 to 50 barg, 25 to 45 barg, or 30 to 40 barg. Any suitable moisture removal method can be used including, for example, molecular sieves or other similar process to dry the gas in a drying zone 726. The resulting stream 730 may then be passed to the fractionation section, wherein the olefins and other components may be separated in to various high-purity product or intermediate streams.
Turning now to
As shown in
As shown in
The bottoms stream from the ethane-ethylene fractionator 824 may include at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 98, in each case weight percent ethane, based on the total weight of the bottoms stream. All or a portion of the recovered ethane may be recycled to the cracker furnace as additional feedstock, alone or in combination with the r-pyoil containing feed stream, as discussed previously.
The liquid bottoms stream 818 withdrawn from the deethanizer column, which may be enriched in C3 and heavier components, may be separated in a depropanizer 840, as shown in
The overhead stream 826 from the depropanizer 840 are introduced into a propane-propylene fractionator (propylene fractionator) 860, wherein the propylene and any lighter components are removed in the overhead stream 832, while the propane and any heavier components exit the column in the bottoms stream 834. The propylene fractionator 860 may be operated at an overhead temperature of at least 20, or at least 25, or at least 30, or at least 35, in each case ° C. and/or not more than 55, 50, 45, 40° C., and an overhead pressure of at least 12, or at least 15, or at least 17, or at least 20, in each case barg and/or not more than 20, or not more than 17, or not more than 15, or not more than 12, in each case barg. The overhead stream 860, which is enriched in propylene, can include at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 97, or at least 98, or at least 99, in each case weight percent propylene, based on the total weight of the stream and may be sent to downstream processing unit for further processing, storage, or sale. The overhead propylene stream produced during the cracking of a cracker feedstock containing r-pyoil is a r-propylene composition or stream. In an embodiment or in combination with any of the embodiments mentioned herein, the stream may be used to make one or more petrochemicals.
The bottoms stream 834 from the propane-propylene fractionator 860 may include at least 40, or at least 45, or at least 50, or at least 55, or at least 60, or at least 65, or at least 70, or at least 75, or at least 80, or at least 85, or at least 90, or at least 95, or at least 98, in each case weight percent propane, based on the total weight of the bottoms stream 834. All or a portion of the recovered propane may be recycled to the cracker furnace as additional feedstock, alone or in combination with r-pyoil, as discussed previously.
Referring again to
The overhead stream 836 from the debutanizer, or the C4s, can be subjected to any conventional separation methods such as extraction or distillation processes to recover a more concentrated stream of butadiene.
Production of r-Aldehydes, r-Oxo Alcohols, and r-Oxo Plasticizers and their Use
In one embodiment or in combination with any of the mentioned embodiments, there is now provided a method for processing recycle content olefin including, for example, recycle content propylene, by feeding the r-olefin to a reactor in which is made r-aldehydes, which are subsequently hydrogenated to form oxo alcohols. In some embodiments, the r-aldehydes may include r-butyraldehyde, which can be further condensed in an Aldol condensation reactor to form an α,β-aldehyde such as 2-ethylhexenal and/or 2-ethylhexanal. These α,β-aldehyde can then be hydrogenated to form various oxo alcohols, including, for example 2-ethylhexanol, which itself can be used to form a variety of other compounds, including oxo plasticizers.
In one embodiment or in combination with any of the mentioned embodiments, the concentration of r-olefin, introduced into a reactor vessel is at least 90 wt. %, or at least 95 wt. %, or at least 97 wt. %, or at least 99 wt. %, based on the weight of the olefin composition fed to the aldehyde reactor.
Similarly, in one embodiment or in combination with any of the mentioned embodiments, the concentration of r-aldehyde, introduced into a reactor vessel for hydrogenating aldehyde to form an oxo alcohol is at least 90 wt. %, or at least 95 wt. %, or at least 97 wt. %, or at least 99 wt. %, based on the weight of the aldehyde composition fed to the oxo alcohol reactor.
In one embodiment or in combination with any of the mentioned embodiments, the olefin or aldehyde fed to the reaction vessel does not contain recycle content. In another embodiment, at least a portion of the olefin or aldehyde composition fed to the reaction vessel is derived directly or indirectly from the cracking of r-pyoil or obtained from r-pygas. For example, at least 0.005 wt. %, or at least 0.01 wt. %, or at least 0.05 wt. %, or at least 0.1 wt. %, or at least 0.15 wt. %, or at least 0.2 wt. %, or at least 0.25 wt. %, or at least 0.3 wt. %, or at least 0.35 wt. %, or at least 0.4 wt. %, or at least 0.45 wt. %, or at least 0.5 wt. %, or at least 0.6 wt. %, or at least 0.7 wt. %, or at least 0.8 wt. %, or at least 0.9 wt. %, or at least 1 wt. %, or at least 2 wt. %, or at least 3 wt. %, or at least 4 wt. %, or at least 5 wt. %, or at least 6 wt. %, or at least 7 wt. %, or at least 8 wt. %, or at least 9 wt. %, or at least 10 wt. %, or at least 11 wt. %, or at least 13 wt. %, or at least 15 wt. %, or at least 20 wt. %, or at least 25 wt. %, or at least 30 wt. %, or at least 35 wt. %, or at least 40 wt. %, or at least 45 wt. %, or at least 50 wt. %, or at least 55 wt. %, or at least 60 wt. %, or at least 70 wt. %, or at least 80 wt. %, or at least 90 wt. %, or at least 95 wt. %, or at least 98 wt. %, or at least 99 wt. %, or 100 wt. % of the olefin composition is r-olefin or pr-olefin or r-aldehyde, or pr-aldehyde.
In addition, or in the alternative, up to 100 wt. %, or up to 98 wt. %, or up to 95 wt. %, or up to 90 wt. %, or up to 80 wt. %, or up to 75 wt. %, or up to 70 wt. %, or up to 60 wt. %, or up to 50 wt. %, or up to 40 wt. %, or up to 30 wt. %, or up to 20 wt. %, or up to 10 wt. %, or up to 8 wt. %, or up to 5 wt. %, or up to 4 wt. %, or up to 3 wt. %, or up to 2 wt. %, or up to 1 wt. %, or up to 0.8 wt. %, or up to 0.7 wt. %, or up to 0.6 wt. %, or up to 0.5 wt. %, or up to 0.4 wt. %, or up to 0.3 wt. %, or up to 0.2 wt. %, or up to 0.1 wt. %, or up to 0.09 wt. %, or up to 0.07 wt. %, or up to 0.05 wt. %, or up to 0.03 wt. %, or up to 0.02 wt. %, or up to 0.01 wt. % of the olefin composition is pr-olefin, based on the weight the olefin composition fed to the reaction vessel.
Alternatively, or in addition, at least 0.005 wt. %, or at least 0.01 wt. %, or at least 0.05 wt. %, or at least 0.1 wt. %, or at least 0.15 wt. %, or at least 0.2 wt. %, or at least 0.25 wt. %, or at least 0.3 wt. %, or at least 0.35 wt. %, or at least 0.4 wt. %, or at least 0.45 wt. %, or at least 0.5 wt. %, or at least 0.6 wt. %, or at least 0.7 wt. %, or at least 0.8 wt. %, or at least 0.9 wt. %, or at least 1 wt. %, or at least 2 wt. %, or at least 3 wt. %, or at least 4 wt. %, or at least 5 wt. %, or at least 6 wt. %, or at least 7 wt. %, or at least 8 wt. %, or at least 9 wt. %, or at least 10 wt. %, or at least 11 wt. %, or at least 13 wt. %, or at least 15 wt. %, or at least 20 wt. %, or at least 25 wt. %, or at least 30 wt. %, or at least 35 wt. %, or at least 40 wt. %, or at least 45 wt. %, or at least 50 wt. %, or at least 55 wt. %, or at least 60 wt. %, or at least 70 wt. %, or at least 80 wt. %, or at least 90 wt. %, or at least 95 wt. %, or at least 98 wt. %, or at least 99 wt. %, or 100 wt. % of the aldehyde composition is r-aldehyde or pr-aldehyde.
In addition, or in the alternative, up to 100 wt. %, or up to 98 wt. %, or up to 95 wt. %, or up to 90 wt. %, or up to 80 wt. %, or up to 75 wt. %, or up to 70 wt. %, or up to 60 wt. %, or up to 50 wt. %, or up to 40 wt. %, or up to 30 wt. %, or up to 20 wt. %, or up to 10 wt. %, or up to 8 wt. %, or up to 5 wt. %, or up to 4 wt. %, or up to 3 wt. %, or up to 2 wt. %, or up to 1 wt. %, or up to 0.8 wt. %, or up to 0.7 wt. %, or up to 0.6 wt. %, or up to 0.5 wt. %, or up to 0.4 wt. %, or up to 0.3 wt. %, or up to 0.2 wt. %, or up to 0.1 wt. %, or up to 0.09 wt. %, or up to 0.07 wt. %, or up to 0.05 wt. %, or up to 0.03 wt. %, or up to 0.02 wt. %, or up to 0.01 wt. % of the aldehyde composition is r-aldehyde or pr-aldehyde, based on the weight the composition fed to the reaction vessel.
In each case, the stated amounts are also applicable to not only olefin or aldehyde as fed into the reactor, but alternatively or in addition, to the pr-olefin or pr-aldehyde stock supplied to a manufacturer of the oxo alcohol, or can be used as a basis for associating or calculating the amount of recycle content in pr-olefin or pr-aldehyde, such as when blending a source of pr-olefin or pr-aldehyde with non-recycle content olefin or aldehyde to make an olefin or aldehyde composition having pr-olefin or pr-aldehyde in quantities mentioned above.
In one embodiment or in combination with any of the mentioned embodiments, the oxo alcohol or oxo plasticizer composition has associated with it, or contains, or is labelled, advertised, or certified as containing recycle content in an amount of at least 0.01 wt. %, or at least 0.05 wt. %, or at least 0.1 wt. %, or at least 0.5 wt. %, or at least 0.75 wt. %, or at least 1 wt. %, or at least 1.25 wt. %, or at least 1.5 wt. %, or at least 1.75 wt. %, or at least 2 wt. %, or at least 2.25 wt. %, or at least 2.5 wt. %, or at least 2.75 wt. %, or at least 3 wt. %, or at least 3.5 wt. %, or at least 4 wt. %, or at least 4.5 wt. %, or at least 5 wt. %, or at least 6 wt. %, or at least 7 wt. %, or at least 10 wt. %, or at least 15 wt. %, or at least 20 wt. %, or at least 25 wt. %, or at least 30 wt. %, or at least 35 wt. %, or at least 40 wt. %, or at least 45 wt. %, or at least 50 wt. %, or at least 55 wt. %, or at least 60 wt. %, or at least 65 wt. % and/or the amount can be up to 100 wt. %, or up to 95 wt. %, or up to 90 wt. %, or up to 80 wt. %, or up to 70 wt. %, or up to 60 wt. %, or up to 50 wt. %, or up to 40 wt. %, or up to 30 wt. %, or up to 25 wt. %, or up to 22 wt. %, or up to 20 wt. %, or up to 18 wt. %, or up to 16 wt. %, or up to 15 wt. %, or up to 14 wt. %, or up to 13 wt. %, or up to 11 wt. %, or up to 10 wt. %, or up to 8 wt. %, or up to 6 wt. %, or up to 5 wt. %, or up to 4 wt. %, or up to 3 wt. %, or up to 2 wt. %, or up to 1 wt. %, or up to 0.9 wt. %, or up to 0.8 wt. %, or up to 0.7 wt. %, based on the weight of the oxo alcohol or oxo plasticizer composition.
The recycle content associated with the oxo alcohol or oxo plasticizer can be established by applying a recycle content value to the oxo alcohol or oxo plasticizer, such as through deducting the recycle content value from a recycle inventory populated with allotments (credit or allocation) or by reacting an r-olefin or r-aldehyde or r-oxo alcohol feedstock to make r-oxo alcohol or r-oxo plasticizer, respectively (meaning olefin and/or aldehyde as feeds to make oxo-alcohol and oxo-alcohol as a feed to make oxo-plasticizers). The allotment can be contained in a recycle inventory created, maintained or operated by or for the oxo alcohol or oxo plasticizer manufacturer. The allotments are obtained from any source along any manufacturing chain of products. In one embodiment, the origin of the allotment is derived indirectly from pyrolyzing recycled waste, or from cracking r-pyoil or from r-pygas.
The amount of recycle content in an r-olefin or r-aldehyde raw material fed to an oxo alcohol reactor, or the amount of recycle content applied to the r-oxo alcohol, or the amount of r-olefin or r-aldehyde needed to feed the reactor to claim a desired amount of recycle content in the oxo alcohol in the event that all the recycle content from the r-olefin or r-aldehyde is applied to the oxo alcohol, or the amount of recycle content in an r-oxo alcohol raw material fed to an oxo plasticizer reactor, or the amount of recycle content applied to the r-oxo plasticizer, or the amount of r-oxo alcohol needed to feed the reactor to claim a desired amount of recycle content in the oxo plasticizer in the event that all the recycle content from the r-oxo alcohol is applied to the oxo plasticizer can be determined or calculated by any of the following methods:
Satisfying any one of the methods (i)-(iv) is sufficient to establish the portion of r-olefin or r-aldehyde that is derived directly or indirectly from recycled waste, the pyrolysis of recycled waste, pyrolysis gas produced from the pyrolysis of recycled waste, and/or the cracking of r-pyoil produced from the pyrolysis of recycled waste. In the event that an r-olefin or r-aldehyde feed is blended with a recycle feed from other recycle sources, a pro-rata approach to the mass of r-olefin or r-aldehyde directly or indirectly obtained from recycled waste, the pyrolysis of recycled waste, pyrolysis gas produced from the pyrolysis of recycled waste, and/or the cracking of r-pyoil produced from the pyrolysis of recycled waste to the mass of recycle olefin or aldehyde from other sources is adopted to determine the percentage in the declaration attributable to r-olefin or r-aldehyde obtained directly or indirectly from recycled waste, the pyrolysis of recycled waste, pyrolysis gas produced from the pyrolysis of recycled waste, and/or the cracking of r-pyoil produced from the pyrolysis of recycled waste.
Methods (i) and (ii) need no calculation since they are determined based on what the olefin or aldehyde manufacturer or oxo alcohol manufacturer or suppliers declare, claim, or otherwise communicate to each other or the public. Methods (iii) and (iv) are calculated.
In one embodiment or in combination with any of the mentioned embodiments, the minimum amount of recycle content olefin or aldehyde fed to the reactor can be determined by knowing the amount of recycle content associated with the end product oxo alcohol and assuming that the entire recycle content in the oxo alcohol is attributable to the r-olefin or r-aldehyde fed to the reactor and none to any other components in the reaction zone.
The minimum portion of r-olefin or r-aldehyde content derived directly or indirectly from recycled waste, the pyrolysis of recycled waste, pyrolysis gas produced from the pyrolysis of recycled waste, and/or the cracking of r-pyoil produced from the pyrolysis of recycled waste, to make an oxo alcohol product associated with a particular amount of recycle content, can be calculated as:
where P means the minimum portion of r-olefin or r-aldehyde derived directly or indirectly recycled waste, the pyrolysis of recycled waste, pyrolysis gas produced from the pyrolysis of recycled waste, and/or the cracking of r-pyoil produced from the pyrolysis of recycled waste, and
The amount of recycle content in the r-olefin or r-aldehyde feed can be greater than the minimum, resulting in excess recycle content left over if for a given designation of recycle content in the oxo alcohol. In such a case, the remainder of recycle content available may be reserved in a recycle inventory. The excess recycle content may be stored in a recycle inventory and applied to other oxo alcohol products that either are not made with r-olefin or r-aldehyde or with a deficient amount of r-olefin or r-aldehyde recycle content relative to the amount of recycle content one desires to apply to the oxo alcohol. However, whether or not the r-olefin or r-aldehyde feedstock actually was designated by the manufacturer of the oxo alcohol as containing the minimum amount of recycle content, an r-oxo alcohol designated as containing a certain recycle content is nevertheless deemed to have been made from an r-olefin or r-aldehyde feedstock containing the minimum recycle content by the calculation method described above.
In the case of a pro-rata mass approach in method (iv), the portion of r-olefin or r-aldehyde derived directly or indirectly from recycled waste, the pyrolysis of recycled waste, pyrolysis gas produced from the pyrolysis of recycled waste, and/or the cracking of r-pyoil produced from the pyrolysis of recycled waste would be calculated on the basis of the mass of recycle content available to the oxo alcohol manufacturer by way of purchase or transfer or created in case the olefin or aldehyde is integrated into r-olefin or r-aldehyde production, that is attributed to the feedstock on a daily run divided by the mass of the r-olefin or r-aldehyde feedstock, or:
For example, if an oxo alcohol manufacturer has available 1000 kg of a recycle allocation or credit that has its origin in pyrolyzing recycled waste, and the oxo alcohol manufacturer elects to attribute 10 kg of the recycle allocation to an olefin or aldehyde feedstock used to make the oxo alcohol, and the olefin or aldehyde feedstock employs 100 kg per day to make oxo alcohol, the portion P of the r-olefin or r-aldehyde feedstock derived directly or indirectly from cracking pyoil would be 10 kg/100 kg, or 10 wt %. The olefin or aldehyde feedstock composition would be considered to be an r-olefin or r-aldehyde composition because a portion of the recycle allocation is applied to the olefin or aldehyde feedstock used to make the oxo alcohol.
The same methodologies and principles would be applied to calculate the recycle content in an oxo plasticizer, adjusting the formulas to the g/mole weights appropriate for oxo plasticizer moieties.
In another embodiment, there is provided a variety of methods for apportioning the recycle content among the various products made by an oxo alcohol manufacturer or an oxo plasticizer manufacturer or the products made by any one entity or a combinations of entities among the Family of Entities of which the oxo plasticizer manufacturer is a part. For example, the oxo alcohol manufacturer or oxo plasticizer manufacturer, of any combination or the entirety of its Family of Entities, or a Site, can:
Both the symmetric distribution and the asymmetric distribution of recycle content can be proportional on a site wide basis, or on a multi-site basis. In one embodiment or in combination with any of the mentioned embodiments, the recycle content input (recycle content feedstock or allotments) can be to a Site, and recycle content values from said inputs are applied to one or more products made at the same Site, and at least one of the products made at the Site is oxo alcohol or oxo plasticizer, and optionally at least a portion of the recycle content value is applied to the oxo alcohol or oxo plasticizer products, respectively. The recycle content values can be applied symmetrically or asymmetrically to the products at the Site. The recycle content values can be applied across different oxo alcohol or oxo plasticizer volumes symmetrically or asymmetrically, or applied across a combination of oxo alcohol and other products made at the Site or oxo plasticizer and other products made at the Site. For example, a recycle content value is transferred to a recycle inventory at a Site, created at a Site, or a feedstock containing recycle content value is reacted at a Site (collectively the “a recycle input”), and recycle content values obtained from said inputs are:
In one embodiment or in combination with any of the mentioned embodiments, the recycle content input or creation (recycle content feedstock or allotments) can be to or at a first Site, and recycle content values from said inputs are transferred to a second Site and applied to one or more products made at a second Site, and at least one of the products made at the second Site is oxo plasticizer, and optionally at least a portion of the recycle content value is applied to oxo alcohol or oxo plasticizer products made at the second Site. The recycle content values can be applied symmetrically or asymmetrically to the products at the second Site. The recycle content values can be applied across different oxo alcohol or oxo plasticizer volumes symmetrically or asymmetrically, or applied across a combination of oxo plasticizer and other products made at the second Site. For example, a recycle content value is transferred to a recycle inventory at a first Site, created at a first Site, or a feedstock containing recycle content value is reacted at a first Site (collectively the “a recycle input”), and recycle content values obtained from said inputs are:
In one embodiment or in combination with any of the mentioned embodiments, the oxo alcohol manufacturer, or one among its Family of Entities, can make oxo alcohol, or process an olefin or aldehyde, or process olefin or aldehyde and make an r-oxo alcohol, or make r-oxo alcohol, by obtaining any source of an olefin or aldehyde composition from a supplier, whether or not such olefin or aldehyde composition has any direct or indirect recycle content, and either:
The allotment in (i) is obtained from an olefin or aldehyde supplier, and the olefin or aldehyde supplier also supplies olefin or aldehyde to the oxo alcohol manufacturer or within its Family of Entities. The circumstance described in (i) allows an oxo alcohol manufacturer to obtain a supply of an olefin or aldehyde composition that is a non-recycle content olefin or aldehyde, yet obtain a recycle content allotment from the olefin or aldehyde supplier. In one embodiment or in combination with any of the mentioned embodiments, the olefin or aldehyde supplier transfers a recycle content allotment to the oxo alcohol manufacturer and a supply of olefin or aldehyde to the oxo alcohol manufacturer, where the recycle content allotment is not associated with the olefin or aldehyde supplied, or even not associated with any olefin or aldehyde made by the olefin or aldehyde supplier. The recycle content allotment does not have to be tied to an amount of recycle content in an olefin or aldehyde composition or to any compound used to make oxo alcohol, but rather the recycle content allotment transferred by the olefin or aldehyde supplier can be associated with other products derived directly or indirectly from recycled waste, the pyrolysis of recycled waste, pyrolysis gas produced from the pyrolysis of recycled waste, and/or the cracking of r-pyoil produced from the pyrolysis of recycled waste or the recycle content of any downstream compounds obtained from the pyrolysis of recycled waste, such as r-ethylene, r-propylene, r-butadiene, r-aldehydes, r-alcohols, r-benzene, etc. For example, the olefin or aldehyde supplier can transfer to the oxo alcohol manufacturer a recycle content associated with r-olefin or r-aldehyde and also supply a quantity of olefin or aldehyde even though r-olefin or r-aldehyde was not used in the synthesis of the olefin or aldehyde. This allows flexibility among the olefin or aldehyde supplier and oxo alcohol manufacturer to apportion a recycle content among the variety of products they each make.
In one embodiment or in combination with any of the mentioned embodiments, the olefin or aldehyde or oxo-alcohol supplier transfers a recycle content allotment to the oxo alcohol or oxo plasticizer manufacturer and a supply of olefin or aldehyde or oxo-alcohol to the oxo alcohol or oxo plasticizer manufacturer, where the recycle content allotment is associated with the olefin or aldehyde or oxo-alcohol. In this case, the olefin or aldehyde or oxo-alcohol transferred does not have to be an r-olefin or r-aldehyde or r-oxo alcohol (one that is derived directly or indirectly from the pyrolysis of recycled waste); rather the olefin or aldehyde or oxo-alcohol supplied by the supplier can be any olefin or aldehyde or oxo-alcohol such as a non-recycle content olefin or aldehyde or oxo-alcohol, so long as the allocation supplied is associated with a manufacture of olefin or aldehyde or oxo-alcohol. Optionally, the olefin or aldehyde or oxo-alcohol being supplied can r-olefin or r-aldehyde or r-oxo-alcohol and at least a portion of the recycle content allotment being transferred can be the recycle content in the r-olefin or r-aldehyde or r-oxo-alcohol. The recycle content allotment transferred to the oxo alcohol or oxo-plasticizer manufacturer can be up front with the olefin or aldehyde or oxo-alcohol supplied in installments, or with each olefin or aldehyde or oxo-alcohol installment, or apportioned as desired among the parties.
The allotment in (ii) is obtained by the oxo alcohol or oxo-plasticizer manufacturer (or its Family of Entities) from any person or entity without obtaining a supply of olefin or aldehyde from the person or entity. The person or entity can be an olefin or aldehyde or oxo-alcohol manufacturer that does not supply olefin or aldehyde or oxo-alcohol to the oxo alcohol or oxo-plasticizer manufacturer or its Family of Entities, respectively, or the person or entity can be a manufacturer that does not make olefin or aldehyde or oxo-alcohol.
In either case, the circumstances of (ii) allows an oxo alcohol or oxo-plasticizer manufacturer to obtain a recycle content allotment without having to purchase any olefin or aldehyde or oxo-alcohol from the entity supplying the recycle content allotment. For example, the person or entity may transfer a recycle content allotment through a buy/sell model or contract to the oxo alcohol or oxo-plasticizer manufacturer or its Family of Entities without requiring purchase or sale of an allotment (e.g. as a product swap of products that are not olefin or aldehyde), or the person or entity may outright sell the allotment to the oxo alcohol or oxo-plasticizer manufacturer or one among its Family of Entities. Alternatively, the person or entity may transfer a product, other than olefin or aldehyde or oxo-alcohol feedstocks, along with its associated recycle content allotment to the oxo alcohol or oxo-plasticizer manufacturer. This can be attractive to an oxo alcohol or oxo-plasticizer manufacturer that has a diversified business making a variety of products other than oxo alcohol or oxo-plasticizer requiring raw materials other than olefin or aldehyde that the person or entity can supply to the oxo alcohol or oxo-plasticizer manufacturer.
The oxo alcohol manufacturer or oxo plasticizer manufacturer can deposit the allotment into a recycle inventory. The oxo alcohol manufacturer also makes oxo alcohol, whether or not a recycle content is applied to the oxo alcohol so made and whether or not a recycle content value, if applied to the oxo alcohol, is drawn from the recycle inventory. For example, the oxo alcohol manufacturer or oxo plasticizer manufacturer, or any entity among its Family of Entities may:
If desired, however, from that recycle inventory, any allotment can be deducted and applied to the oxo alcohol product or oxo plasticizer product in any amount and at any time up to the point of sale or transfer of the oxo alcohol or oxo plasticizer product to a third party. Thus, the recycle content allotment applied to the oxo alcohol or oxo plasticizer product can be derived directly or indirectly from pyrolyzing recycled waste, or the recycle content allotment applied to the oxo alcohol or oxo plasticizer product is not derived directly or indirectly from the pyrolysis of recycled waste.
For example, a recycle inventory of allotments can be generated having a variety of sources for creating the allotments. Some recycle content allotments (credits) can have their origin in methanolysis of recycled waste, or from gasification of recycled waste, or from mechanical recycling of waste plastic or metal recycling, and/or from pyrolyzing recycled waste, or from any other chemical or mechanical recycling technology. The recycle inventory may or may not track the origin or basis of obtaining a recycle content, or the recycle inventory may not allow one to associate the origin or basis of an allocation to the allocation applied to oxo alcohol. Thus, in this embodiment, it is sufficient that a recycle content value is deducted from recycle inventory and applied to oxo alcohol or oxo plasticizer product regardless of the source or origin of the recycle content value, provided that an allotment derived from pyrolyzing recycled waste is also obtained by the oxo alcohol manufacturer or oxo plasticizer manufacturer as specified in step (i) or step (ii), whether or not that allotment is actually deposited into the recycle inventory. In one embodiment or in combination with any of the mentioned embodiments, the allotment obtained in step (i) or (ii) is deposited into a recycle inventory of allotments. In one embodiment or in combination with any of the mentioned embodiments, the recycle content value deducted from the recycle inventory and applied to the oxo alcohol or oxo plasticizer product originates from pyrolyzing recycled waste.
As used throughout, the recycle inventory of allotments can be owned by the oxo alcohol manufacturer, operated by the oxo alcohol manufacturer, owned or operated by other than the oxo alcohol manufacturer but at least in part for the oxo alcohol manufacturer, or licensed by the oxo alcohol manufacturer, or by the oxo plasticizer manufacturer, operated by the oxo plasticizer manufacturer, owned or operated by other than the oxo plasticizer manufacturer but at least in part for the oxo plasticizer manufacturer, or licensed by the oxo plasticizer manufacturer. Also, as used throughout, the oxo alcohol or oxo plasticizer manufacturer may also include its Family of Entities. For example, while the oxo alcohol or oxo plasticizer manufacturer may not own or operate the recycle inventory, one among its Family of Entities may own such a platform, or license it from an independent vendor, or operate it for the oxo alcohol or oxo plasticizer manufacturer. Alternatively, an independent entity may own and/or operate the recycle inventory and for a service fee operate and/or manage at least a portion of the recycle inventory for the oxo alcohol manufacturer.
In one embodiment or in combination with any of the mentioned embodiments, the oxo alcohol or oxo-plasticizer manufacturer obtains a supply of olefin or aldehyde or oxo-alcohol from a supplier, and also obtains an allotment from either (i) the supplier or (ii) from any other person or entity, where such allotment is derived from recycled waste, the pyrolysis of recycled waste, pyrolysis gas produced from the pyrolysis of recycled waste, and/or the cracking of r-pyoil produced from the pyrolysis of recycled waste, and optionally the allotment is obtained from the olefin or aldehyde or oxo-alcohol supplier and can even be an allotment by virtue of obtaining an r-olefin or r-aldehyde or r-oxo-alcohol from the supplier. The oxo alcohol or oxo-plasticizer manufacturer is deemed to obtain the supply of olefin or aldehyde or oxo-alcohol from a supplier if the supply is obtained by a person or entity within the Family of Entities of the oxo alcohol or oxo-plasticizer manufacturer. The oxo alcohol or oxo-plasticizer manufacturer then carries out one or more of the following steps:
It is not necessary in all embodiments that r-olefin or r-aldehyde is used to make the r-oxo alcohol composition or that r-oxo alcohol is used to make the r-oxo plasticizer or that the r-oxo alcohol or r-oxo plasticizer was obtained from a recycle content allotment associated with an olefin or aldehyde composition. Further, it is not necessary that an allotment be applied to the feedstock for making the oxo alcohol or oxo plasticizer to which recycle content is applied. Rather, as noted above, the allotment, even if associated with an olefin or aldehyde or oxo-alcohol composition when the olefin or aldehyde or oxo-alcohol composition is obtained from a supplier, can be deposited into an electronic recycle inventory. In one embodiment or in combination with any of the mentioned embodiments, however, r-olefin or r-aldehyde or r-oxo alcohol is used to make the r-oxo alcohol or r-oxo plasticizer composition, respectively. In one embodiment or in combination with any of the mentioned embodiments, at least a portion of r-olefin or r-aldehyde allotments are applied to oxo alcohol to make an r-oxo alcohol.
The oxo alcohol or oxo plasticizer composition can be made from any source of an olefin or aldehyde or oxo-alcohol composition, whether or not the olefin or aldehyde or oxo-alcohol composition is an r-olefin or r-aldehyde or r-oxo-alcohol, and whether or not the olefin or aldehyde or oxo-alcohol is obtained from a supplier or made by the oxo alcohol or oxo plasticizer manufacturer or within its Family of Entities. Once an oxo alcohol or oxo plasticizer composition is made, it can be designated as having recycle content based on and derived from at least a portion of the allotment, again whether or not the r-olefin or r-aldehyde or r-oxo alcohol is used to make the r-oxo alcohol or r-oxo plasticizer composition and regardless of the source of olefin or aldehyde or oxo-alcohol used to make the oxo alcohol or oxo plasticizer, respectively. The allocation can be withdrawn or deducted from recycle inventory. The amount of the deduction and/or applied to the oxo alcohol or oxo plasticizer can correspond to any of the methods described above, e.g. a mass balance approach.
In one embodiment or in combination with any of the mentioned embodiments, a recycle content oxo alcohol or oxo plasticizer composition can be made by reacting an olefin or aldehyde or oxo-alcohol composition obtained from any source in a synthetic process to make an oxo alcohol or oxo plasticizer, respectively, and a recycle content value can be applied to at least a portion of the oxo alcohol or oxo plasticizer to thereby obtain r-oxo alcohol or r-oxo plasticizer. Optionally, a recycle content value can be obtained by deducting from a recycle inventory. The entire amount of recycle content value in the oxo alcohol or oxo plasticizer can correspond to the recycle content value deducted from the recycle inventory. Recycle content value deducted from the recycle inventory can be applied to both oxo alcohol or oxo plasticizer and products or compositions other than oxo alcohol or oxo plasticizer made by the oxo alcohol or oxo plasticizer manufacturer or a person or entity among its Family of Entities.
The olefin or aldehyde or oxo-alcohol composition can be obtained from a third party, or made by the oxo alcohol or oxo plasticizer manufacturer, or made by a person or entity amount the Family of Entities of the oxo alcohol or oxo plasticizer manufacturer and transferred to the oxo alcohol or oxo plasticizer manufacturer. In another example, the oxo alcohol manufacturer or oxo plasticizer or its Family of Entities can have a first facility for making olefin or aldehyde or oxo-alcohol within a first Site, and a second facility within the first Site or a second facility within a second Site where the second facility makes oxo alcohol or oxo plasticizer, and transfer the olefin or aldehyde or oxo-alcohol from the first facility or first Site to the second facility or second Site. The facilities or Sites can be in direct or indirect, continuous or discontinuous, fluid communication or pipe communication with each other. A recycle content value is then applied to (e.g. assigned to, designate to correspond to, attributed to, or associated with) the oxo alcohol or oxo plasticizer to make an r-oxo alcohol or r-oxo plasticizer. At least a portion of the recycle content value applied to the oxo alcohol or oxo plasticizer is obtained from a recycle inventory.
Optionally, one may communicate to a third party that the r-oxo alcohol or r-oxo plasticizer has recycle content or is obtained or derived from recycled waste. In one embodiment or in combination with any of the mentioned embodiments, one may communicate recycle content information about the oxo alcohol or oxo plasticizer to a third party where such recycle content information is based on or derived from at least a portion of the allocation or credit. The third party may be a customer of the oxo alcohol or oxo plasticizer manufacturer or supplier, or may be any other person or entity or governmental organization other than the entity owning the oxo alcohol. The communication may electronic, by document, by advertisement, or any other means of communication.
In one embodiment or in combination with any of the mentioned embodiments, a recycle content oxo alcohol or oxo plasticizer composition is obtained by either making a first r-oxo alcohol or r-oxo plasticizer or by merely possessing (e.g. by way of purchase, transfer, or otherwise) a first r-oxo alcohol or r-oxo plasticizer already having a recycle content, and transferring a recycle content value between a recycle inventory and the first r-oxo alcohol or r-oxo plasticizer to obtain a second r-oxo alcohol or r-oxo plasticizer having different recycle content value than the first r-oxo alcohol or r-oxo plasticizer.
In one embodiment or in combination with any of the mentioned embodiments, the transferred recycle content value described above is deducted from the recycle inventory and applied to the first r-oxo alcohol or r-oxo plasticizer to obtain a second r-oxo alcohol or r-oxo plasticizer having a second recycle content value higher than the first r-oxo alcohol or r-oxo plasticizer contains, to thereby increase the recycle content in first r-oxo alcohol or r-oxo plasticizer, respectively.
The recycle content in the first r-oxo alcohol or r-oxo plasticizer need not be obtained from a recycle inventory, but rather can be attributed to oxo alcohol or oxo plasticizer by any of the methods described herein (e.g. by virtue of using an r-olefin or r-aldehyde as a reactant feed), and the oxo alcohol or oxo plasticizer manufacturer may seek to further increase the recycle content in the first r-oxo alcohol or r-oxo plasticizer so made, respectively. In another example, an oxo alcohol or oxo plasticizer distributor may have r-oxo alcohol or r-oxo plasticizer in its inventory and seek to increase the recycle content value of the first r-oxo alcohol or r-oxo plasticizer in its possession. The recycle content in the first r-oxo alcohol or r-oxo plasticizer can be increased by applying a recycle content value withdrawn from a recycle inventory.
The recycle content value quantity that is deducted from recycle inventory is flexible and will depend on the amount of recycle content applied to the oxo alcohol or r-oxo plasticizer. In one embodiment or in combination with any of the mentioned embodiments, it is at least sufficient to correspond with at least a portion of the recycle content in the r-oxo alcohol or r-oxo plasticizer. This is useful if, as noted above, a portion of the oxo alcohol or r-oxo plasticizer was made with r-olefin or r-aldehyde where the recycle content value in the r-olefin or r-aldehyde was not deposited into a recycle inventory, resulting in an r-oxo alcohol and one desires to increase the recycle content in the r-oxo alcohol by applying a recycle content value withdrawn from a recycle inventory; or where one possesses r-oxo alcohol (by way of purchase, transfer, or otherwise) and desires to increase its recycle content value. Alternatively, the entire recycle content in the r-oxo alcohol or r-oxo plasticizer can be obtained by applying a recycle content value to the oxo alcohol or oxo plasticizer obtained from a recycle inventory.
The method for calculating the recycle content value is not limited, and can include the mass balance approach or the methods of calculation described above. The recycle inventory can be established on any basis and be a mix of bases. Examples of the origin for obtaining allotments deposited into a recycle inventory can be from pyrolyzing recycled waste, gasification of recycled waste, depolymerization of recycled waste such as through hydrolysis or methanolysis, and so on. In one embodiment or in combination with any of the mentioned embodiments, at least a portion of the allocations deposited into the recycle inventory is attributable to pyrolyzing recycled waste (e.g. obtained from cracking r-pyoil or obtained from r-pygas). The recycle inventory may or may not track the origin of recycle content value deposited into the recycle inventory. In one embodiment or in combination with any of the mentioned embodiments, the recycle inventory distinguishes between a recycle content value obtained from pyrolyzing recycled waste (i.e., pyrolysis recycle content value) and recycle content values having their origin in other technologies (i.e., recycle content value). This may be accomplished simply by assigning distinguishing units of measure to the recycle content values having is origin in pyrolyzing recycled waste, or tracking the origin of the allocation by assigning or placing the allocation into a unique module, unique spreadsheet, unique column or row, unique database, unique taggants associated with a unit of measure, and the like to as to distinguish the:
Origin of technology used to create the allotment, or
The type of compound having recycle content from which the allocation is obtained, or
The supplier or Site identity, or
A combination thereof.
The recycle content value applied to the oxo alcohol or oxo plasticizer from the recycle inventory does not have to be obtained from allotments having their origin in pyrolyzing recycled waste. The recycle content values deducted from the recycle inventory and/or applied to the oxo alcohol or oxo plasticizer can be derived from any technology used to generate allocations from recycled waste, such as through methanolysis or gasification of recycled waste. In one embodiment or in combination with any of the mentioned embodiments, however, the recycle content value applied to the oxo alcohol or oxo plasticizer or withdrawn/deducted from the recycle inventory have their origins or are derived from allotments obtained from pyrolyzing recycled waste.
The following are examples of applying (designating, assigning, or declaring a recycle content) a recycle content value or allotment to oxo alcohol or oxo plasticizer or to an olefin or aldehyde composition:
As used throughout, the step of deducting an allocation from a recycle inventory does not require its application to an oxo alcohol or oxo plasticizer product. The deduction also does not mean that the quantity of the deduction disappears or is removed from the inventory logs. A deduction can be an adjustment of an entry, a withdrawal, an addition of an entry as a debit, or any other algorithm that adjusts inputs and outputs based on an amount of recycle content associated with a product and one or a cumulative amount of allocations on deposit in the recycle inventory. For example, a deduction can be a simple step of a reducing/debit entry from one column and an addition/credit to another column within the same program or books, or an algorithm that automates the deductions and entries/additions and/or applications or designations to a product slate. The step of applying a recycle content value to an oxo alcohol or oxo plasticizer product also does not require the recycle content value or allocation to be applied physically to an oxo alcohol product or to any document issued in association with the oxo alcohol product sold. For example, an oxo alcohol or oxo plasticizer manufacturer may ship oxo alcohol or oxo plasticizer product to a customer and satisfy the “application” of the recycle content value to the oxo alcohol or oxo plasticizer product by electronically transferring a recycle content credit or certification document to the customer, or by applying a recycle content value to a package or container containing the oxo alcohol or oxo plasticizer.
Some oxo alcohol or oxo-plasticizer manufacturers may be integrated into making downstream products using oxo alcohol as a raw material, such as making oxo plasticizers, as described below. The integrated oxo alcohol or oxo-plasticizer manufacturers, and other non-integrated oxo alcohol or oxo-plasticizer manufacturers, can also offer to sell or sell oxo alcohol or oxo-plasticizer on the market as containing or obtained with an amount of recycle content. The recycle content designation can also be found on or in association with the downstream product made with the oxo alcohol or oxo-plasticizer.
In one embodiment or in combination with any of the mentioned embodiments, the amount of recycle content in the r-olefin or r-aldehyde or in the r-oxo alcohol or r-oxo plasticizer will be based on the allocation or credit obtained by the manufacturer of the oxo alcohol or oxo plasticizer composition or the amount available in the oxo alcohol or oxo plasticizer manufacturer's recycle inventory. A portion or all of the recycle content value in an allocation or credit obtained by or in the possession of a manufacturer of oxo alcohol or oxo plasticizer can be designated and assigned to an r-oxo alcohol or r-oxo plasticizer on a mass balance basis. The assigned value of the recycle content to the r-oxo alcohol or r-oxo plasticizer should not exceed the total amount of all allocations and/or credits available to the manufacturer of the oxo alcohol or oxo plasticizer or other entity authorized to assign a recycle content value to the oxo alcohol.
There is now also provided a method of introducing or establishing a recycle content in an oxo alcohol without necessarily using an r-olefin or r-aldehyde feedstock. In this method,
In this method, the oxo alcohol manufacturer need not purchase r-olefin or r-aldehyde from any entity or from the supplier of olefin or aldehyde, and does not require the oxo alcohol manufacturer to purchase olefin or aldehyde, r-olefin or r-aldehyde, or olefin or aldehyde from a particular source or supplier, and does not require the oxo alcohol manufacturer to use or purchase an olefin or aldehyde composition having r-olefin or r-aldehyde in order to successfully establish a recycle content in the oxo alcohol composition. The olefin or aldehyde manufacturer may use any source of olefin or aldehyde and apply at least a portion of the allocation or credit to at least a portion of the olefin or aldehyde feedstock or to at least a portion of the oxo alcohol product. When the allocation or credit is applied to the feedstock olefin or aldehyde, this would be an example of an r-olefin or r-aldehyde feedstock indirectly derived from the cracking of r-pyoil or obtained from r-pygas. The association by the oxo alcohol manufacturer may come in any form, whether by on in its recycle inventory, internal accounting methods, or declarations or claims made to a third party or the public.
In another embodiment, an exchanged recycle content value is deducted from a first r-oxo alcohol or r-oxo plasticizer and added to the recycle inventory to obtain a second r-oxo alcohol or r-oxo plasticizer having a second recycle content value lower than the first r-oxo alcohol or r-oxo plasticizer contains, to thereby decrease the recycle content in first r-oxo alcohol or r-oxo plasticizer. This embodiment, the above description concerning adding a recycle content value from a recycle inventory to a first r-oxo alcohol or r-oxo plasticizer applies in reverse to deducting a recycle content from first r-oxo alcohol or r-oxo plasticizer and adding it to a recycle inventory.
The allotment can be obtained from a variety of sources in the manufacturing chain starting from pyrolyzing recycled waste up to making and selling an r-olefin or r-aldehyde or r-oxo alcohol feedstocks. The recycle content value applied to oxo alcohol or oxo plasticizer or the allocation deposited into the recycle inventory need not be associated with r-olefin or r-aldehyde or r-oxo alcohol feedstocks. In one embodiment or in combination with any of the mentioned embodiments, the process for making r-oxo alcohol or r-oxo plasticizer can be flexible and allow for obtaining an allocation anywhere along the manufacturing chain to make oxo alcohol or r-oxo plasticizer starting from pyrolyzing recycled waste. For example, one can make r-oxo alcohol by:
In one embodiment or in combination with any of the mentioned embodiments, there is also provided a comprehensive process for making recycle content oxo alcohols or oxo plasticizers by:
In this embodiment, all steps a)-d) can be practiced by and within a Family of Entities, or optionally on the same Site.
In another method, the direct method, a recycle content can be introduced or established in oxo alcohol by:
obtaining recycle olefin composition at least a portion of which is indirectly derived from cracking r-pyoil or indirectly obtained from r-pygas (“r-olefin”),
making an aldehyde composition from a feedstock comprising r-olefin,
making an oxo alcohol composition from a feedstock comprising r-aldehyde,
applying a recycle content value to at least a portion of any oxo alcohol composition made by the same entity that made the oxo alcohol composition in step c), and the recycle content value is based at least partly on the amount of recycle content contained in the r-olefin or r-aldehyde.
In another more detailed direct method, a recycle content can be introduced or established in oxo alcohol by:
In these direct methods, the r-olefin or r-aldehyde content used to make the oxo alcohol would be traceable to the olefin or aldehyde made by a supplier by cracking r-pyoil or obtained from r-pygas. Not all of the amount of r-olefin or r-aldehyde used to make the olefin or aldehyde need be designated or associated with the olefin or aldehyde. For example, if 1000 kg of r-olefin or r-aldehyde is used to make r-oxo alcohol, the olefin or aldehyde manufacturer can designate less than 1000 kg of recycle content toward a particular batch of feedstock used to make the olefin or aldehyde and may instead spread out the 1000 kg recycle content amount over various productions runs to make olefin or aldehyde. The olefin or aldehyde manufacturer may elect to offer for sale its dr-oxo alcohol and in doing so may also elect to represent the r-oxo alcohol that is sold as containing, or obtained with sources that contain, a recycle content.
There is also provided a use for an olefin or aldehyde or oxo-alcohol derived directly or indirectly from cracking r-pyoil or obtained from r-pygas, the use including converting r-olefin or r-aldehyde or r-oxoalcohol in any synthetic process to make oxo alcohols or oxo-plasticizer, respectively.
There is also provided a use for an r-olefin or r-aldehyde or r-oxo alcohol allotment or an r-olefin or r-aldehyde or r-oxo alcohol allotment that includes converting an olefin or aldehyde or oxo alcohol in a synthetic process to make oxo alcohols or oxo-plasticizers, respectively, and applying at least a portion of an r-olefin or r-aldehyde or r-oxo alcohol allotment to the oxo alcohol or oxo alcohol. An r-olefin or r-aldehyde or r-oxo alcohol allotment is an allotment that is created by pyrolyzing recycled waste. Desirably, the allotments originate from the cracking of r-pyoil, or cracking of r-pyoil in a gas furnace, or from r-pygas.
There is also provided a use for an oxo alcohol formed by hydroformylating olefin to form an aldehyde, then condensing the aldehyde to form an α,β-aldehyde, which can be hydrogenated to form an oxo alcohol. The oxo alcohol can be reacted with an esterifying agent to provide an oxo plasticizer. At least a portion of the recycle content allotment can be applied to at least a portion of the oxo alcohol to make an r-oxo alcohol. At least a portion of the recycle inventory from which the recycle content allotment is applied to the oxo alcohol are allotments originating from pyrolyzing recycled waste. Desirably, the allotments originate from the cracking of r-pyoil, or cracking of r-pyoil in a gas furnace, or from r-pygas. Also, the allotment applied to the oxo alcohol can be a recycle content allotment originating from pyrolyzing recycled waste.
In one embodiment or in combination with any of the mentioned embodiments, there is also provided a use of a recycle inventory by converting any olefin or aldehyde or oxo alcohol composition in a synthetic process to make an oxo alcohol or oxo plasticizer composition; deducting a recycle content value from the recycle inventory and applying at least a portion of the deducted recycle content value to the oxo alcohol or r-oxo plasticizer, respectively, and at least a portion of the inventory contains a recycle content allotment. The recycle content allotment can be present in the inventory at the time of deducting a recycle content value from the recycle inventory, or a recycle content allotment deposit is made into the recycle inventory before deducting a recycle content value (but need not be present or accounted for when a deduction is made), or it can be present within a year from the deduction, or within the same calendar year as the deduction, or within the same month as the deduction, or within the same week as the deduction. In one embodiment or in combination with any of the mentioned embodiments, the recycle content deduction is withdrawn against a recycle content allotment.
In one embodiment or in combination with any of the mentioned embodiments, there is provided an oxo alcohol or r-oxo plasticizer composition that is obtained by any of the methods described above.
The same operator, owner, of Family of Entities may practice each of these steps, or one or more steps may be practiced among different operators, owners, or Family of Entities.
The olefin or aldehyde or oxo-alcohol can be stored in a storage vessel and transferred to an oxo alcohol or r-oxo plasticizer manufacturing facility by way of truck, pipe, or ship, or as further described below, the olefin or aldehyde or oxo-alcohol production facility can be integrated with the oxo alcohol or r-oxo plasticizer facility, respectively. The olefin or aldehyde or oxo-alcohol may be shipped or transferred to the operator or facility that makes the oxo alcohol or r-oxo plasticizer, respectively.
In one embodiment or in combination with any of the mentioned embodiments, one may integrate two or more facilities and make r-oxo alcohol. The facilities to make r-oxo plasticizer, r-oxo alcohol, the r-olefin or r-aldehyde, and the r-pyoil and/or r-pygas, can be stand-alone facilities or facilities integrated to each other. For example, one may establish a system of producing and consuming a recycle olefin or aldehyde composition at least a portion of which is obtained from directly or indirectly from cracking r-pyoil or obtaining r-pygas; or a method of making r-oxo alcohol, as follows:
The feeding in step c) can be a supply system providing fluid communication between these two facilities and capable of supplying an olefin or aldehyde composition from the olefin or aldehyde manufacturing facility to the oxo alcohol manufacturing facility, such as a piping system that has a continuous or discontinuous flow.
The oxo alcohol manufacturing facility can make r-oxo alcohol, and can make the r-oxo alcohol directly or indirectly from the pyrolysis of recycled waste or the cracking of r-pyoil or from r-pygas. For example, in a direct method, the oxo alcohol manufacturing facility can make r-oxo alcohol by accepting r-olefin or r-aldehyde from the olefin or aldehyde manufacturing facility and feeding the r-olefin or r-aldehyde as a feed stream to a reactor to make oxo alcohol. Alternatively, the oxo alcohol manufacturing facility can make r-oxo alcohol by accepting any olefin or aldehyde composition from the olefin or aldehyde manufacturing facility and applying a recycle content to oxo alcohol made with the olefin or aldehyde composition by deducting recycle content value from its recycle inventory and applying them to the oxo alcohol, optionally in amounts using the methods described above. The allotments obtained and stored in recycle inventory can be obtained by any of the methods described above, and need not necessarily be allotments associated with r-olefin or r-aldehyde.
In one embodiment or in combination with any of the mentioned embodiments, there is also provided a system for producing r-oxo alcohol as follows:
The oxo alcohol manufacturing facility can make r-oxo alcohol, and can make the r-oxo alcohol directly or indirectly from the pyrolysis of recycled waste. In this system, the olefin or aldehyde manufacturing facility can have its output in fluid communication with the olefin or aldehyde manufacturing facility which in turn can have its output in fluid communication with the oxo alcohol manufacturing facility. Alternatively, the manufacturing facilities of a) and b) alone can be in fluid communication. In the latter case, the oxo alcohol manufacturing facility can make r-oxo alcohol directly by having the r-olefin or r-aldehyde or r-olefin or r-aldehyde produced in the olefin or aldehyde manufacturing facility converted all the way to oxo alcohol, or indirectly by accepting any olefin or aldehyde composition from the olefin or aldehyde manufacturing facility and applying a recycle content to oxo alcohol by deducting allotments from its recycle inventory and applying them to the oxo alcohol, optionally in amounts using the methods described above. The allotments obtained and stored in recycle inventory can be obtained by any of the methods described above, and need not necessarily be allotments associated with r-olefin or r-aldehyde. For example, the allotments can be obtained from any facility or source, so long as they originate from the pyrolysis of recycled waste, or the cracking r-pyoil or obtained from r-pygas.
The fluid communication can be gaseous, or liquid if compressed. The fluid communication need not be continuous and can be interrupted by storage tanks, valves, or other purification or treatment facilities, so long as the fluid can be transported from one facility to the subsequent facility through, for example, an interconnecting pipe network and without the use of truck, train, ship, or airplane. For example, one or more storage vessels may be placed in the supply system so that the r-olefin or r-aldehyde or r-oxo alcohol facility feeds r-olefin or r-aldehyde or r-oxo alcohol to a storage facility and r-olefin or r-aldehyde or r-oxo alcohol can be withdrawn from the storage facility as needed by the oxo alcohol or oxo plasticizer manufacturing facility, with valving and pumps and compressors utilized an in line with the piping network as needed. Further, the facilities may share the same site, or in other words, one site may contain two or more of the facilities. Additionally, the facilities may also share storage tank sites, or storage tanks for ancillary chemicals, or may also share utilities, steam or other heat sources, etc., yet also be considered as discrete facilities since their unit operations are separate. A facility will typically be bounded by a battery limit.
In one embodiment or in combination with any of the mentioned embodiments, the integrated process includes at least two facilities co-located within 5, or within 3, or within 2, or within 1 mile of each other (measured as a straight line). In one embodiment or in combination with any of the mentioned embodiments, at least two facilities are owned by the same Family of Entities.
In one embodiment or in combination with any of the mentioned embodiments, there is also provided an integrated r-olefin or r-aldehyde and r-oxo alcohol generating and consumption system. This system includes:
The system does not necessarily require a fluid communication between the two facilities, although fluid communication is desirable. In this system, olefin or aldehyde or olefin or aldehyde made at the olefin or aldehyde manufacturing facility can be delivered to the olefin or aldehyde facility through the interconnecting piping network that can be interrupted by other processing equipment, such as treatment, purification, pumps, compression, or equipment adapted to combine streams, or storage facilities, all containing optional metering, valving, or interlock equipment. The equipment can be a fixed to the ground or fixed to structures that are fixed to the ground. The interconnecting piping does not need to connect to the olefin or aldehyde reactor or the cracker, but rather to a delivery and receiving point at the respective facilities. The same concept applies between the olefin or aldehyde facility and the oxo alcohol facility. The interconnecting pipework need not connect all three facilities to each other, but rather the interconnecting pipework can be between facilities a)-b), or b)-c), or between a)-b)-c).
There can now also be provided a package or a combination of an oxo alcohol or oxo plasticizer and a recycle content identifier associated with oxo alcohol or oxo plasticizer, where the identifier is or contains a representation that the oxo alcohol or oxo plasticizer contains, or is sourced from or associated with a recycle content. The package can be any suitable package for containing an oxo alcohol, such as a plastic or metal drum, railroad car, isotainer, totes, polytotes, IBC totes, bottles, jerricans, and polybags.
The identifier can be a certificate document, a product specification stating the recycle content, a label, a logo or certification mark from a certification agency representing that the article or package contains contents or the oxo alcohol contains, or is made from sources or associated with recycle content, or it can be electronic statements by the oxo alcohol manufacturer that accompany a purchase order or the product, or posted on a website as a statement, representation, or a logo representing that the oxo alcohol contains or is made from sources that are associated with or contain recycle content, or it can be an advertisement transmitted electronically, by or in a website, by email, or by television, or through a tradeshow, in each case that is associated with oxo alcohol. The identifier need not state or represent that the recycle content is derived directly or indirectly from cracking r-pyoil or obtained from r-pygas. Rather, it is sufficient that the oxo alcohol is directly or indirectly obtained at least in part from the cracking of r-pyoil, and the identifier can merely convey or communicate that the oxo alcohol or oxo plasticizer has or is sourced from a recycle content, regardless of the source.
In one embodiment or in combination with any of the mentioned embodiments, there is provided a system or package comprising:
The system can be a physical combination, such as a package having at least some oxo alcohol or oxo plasticizer as its contents and the package has a label, such as a logo, that the contents such as the oxo alcohol or oxo plasticizer has or is sourced from a recycle content. Alternatively, the label or certification can be issued to a third party or customer as part of a standard operating procedure of an entity whenever it transfers or sells oxo alcohol or oxo plasticizer having or sourced from recycle content. The identifier does not have to be physically on the oxo alcohol or oxo plasticizer or on a package, and does not have to be on any physical document that accompanies or is associated with the oxo alcohol or oxo plasticizer. For example, the identifier can be an electronic credit or certification or representation transferred electronically by the oxo alcohol or oxo plasticizer manufacturer to a customer in connection with the sale or transfer of the oxo alcohol or oxo plasticizer product, respectively, and by sole virtue of being a credit, it is a representation that the oxo alcohol or oxo plasticizer has recycle content. The identifier, such as a label (such as a logo) or certification need not state or represent that the recycle content is derived directly or indirectly from cracking r-pyoil or obtained from r-pygas.
Rather, it is sufficient that the oxo alcohol or oxo plasticizer is directly or indirectly obtained at least in part either (i) from pyrolyzing recycled waste or (ii) from a recycle inventory into which at least a portion of the deposits or credits in the recycle inventory have their origin in pyrolyzing recycled waste. The identifier itself need only convey or communicate that the oxo alcohol or oxo plasticizer has or is sourced from a recycle content, regardless of the source. In one embodiment or in combination with any of the mentioned embodiments, articles made with, containing, or from the oxo alcohol or oxo plasticizer may have the identifier, such as a stamp or logo embedded or adhered to the article. In one embodiment or in combination with any of the mentioned embodiments, the identifier is an electronic recycle content credit from any source. In one embodiment or in combination with any of the mentioned embodiments, the identifier is an electronic recycle content credit derived directly or indirectly from pyrolyzing recycled waste.
In one embodiment or in combination with any of the mentioned embodiments, the r-oxo alcohol, or r-oxo plasticizer or articles made thereby, can be offered for sale or sold as oxo alcohol or oxo plasticizer containing or obtained with, or an article containing or obtained with, recycle content. The sale or offer for sale can be accompanied with a certification or representation of the recycle content claim made in association with the oxo alcohol or oxo plasticizer or article made with the oxo alcohol or oxo plasticizer.
The obtaining of an allocation and designating (whether internally such as through a bookkeeping or a recycle inventory tracking software program or externally by way of declaration, certification, advertising, representing, etc.) can be by the oxo alcohol or oxo plasticizer manufacturer or within the oxo alcohol or oxo plasticizer manufacturer Family of Entities. The designation of at least a portion of the oxo alcohol or oxo plasticizer as corresponding to at least a portion of the allotment (e.g. allocation or credit) can occur through a variety of means and according to the system employed by the oxo alcohol manufacturer, which can vary from manufacturer to manufacturer. For example, the designation can occur internally merely through a log entry in the books or files of the oxo alcohol or oxo plasticizer manufacturer or other inventory software program, or through an advertisement or statement on a specification, on a package, on the product, by way of a logo associated with the product, by way of a certification declaration sheet associated with a product sold, or through formulas that compute the amount deducted from recycle inventory relative to the amount of recycle content applied to a product.
Optionally, the oxo alcohol or oxo plasticizer can be sold. In one embodiment or in combination with any of the mentioned embodiments, there is provided a method of offering to sell or selling oxo alcohols or oxo plasticizer by:
An oxo alcohol or oxo plasticizer manufacturer or its Family of Entities can obtain a recycle content allocation, and the allocation can be obtained by any of the means described herein and can be deposited into recycle inventory, the recycle content allocation derived directly or indirectly from the pyrolysis of recycled waste. The olefin or aldehyde or oxo-alcohol converted in a synthetic process to make an oxo alcohol or oxo plasticizer composition can be any olefin or aldehyde or oxo alcohol composition obtained from any source, including a non-recycle olefin or non-recycle aldehyde or non-recycle oxo alcohol composition, or it can be an r-olefin or r-aldehyde or r-oxo alcohol composition. The r-oxo alcohol or r-oxo plasticizer sold or offered for sale can be designated (e.g. labelled or certified or otherwise associated) as having a recycle content value. In one embodiment or in combination with any of the mentioned embodiments, at least a portion of the recycle content value associated with the r-oxo alcohol or r-oxo plasticizer can be drawn from a recycle inventory. In another embodiment, at least a portion of the recycle content value in the oxo alcohol or oxo plasticizer is obtained by converting r-olefin or r-aldehyde or r-oxo alcohol. The recycle content value deducted from the recycle inventory can be a non-pyrolysis recycle content value or can be a pyrolysis recycle content allocation; i.e. a recycle content value that has its origin in pyrolysis of recycled waste.
The recycle inventory can optionally contain at least one entry that is an allocation derived directly or indirectly from pyrolysis of recycled waste. The designation can be the amount of allocation deducted from recycle inventory, or the amount of recycle content declared or determined by the oxo alcohol manufacturer in its accounts. The amount of recycle content does not necessarily have to be applied to the oxo alcohol product in a physical fashion. The designation can be an internal designation to or by the oxo alcohol or oxo plasticizer manufacturer or its Family of Entities or a service provider in contractual relationship to the oxo alcohol or oxo plasticizer manufacturer or its Family of Entities. The amount of recycle content represented as contained in the oxo alcohol or oxo plasticizer sold or offered for sale has a relationship or linkage to the designation. The amount of recycle content can be a 1:1 relationship in the amount of recycle content declared on an oxo alcohol offered for sale or sold and the amount of recycle content assigned or designated to the oxo alcohol by the oxo alcohol or oxo plasticizer manufacturer.
The steps described need not be sequential, and can be independent from each other. For example, the steps a) and b) can be simultaneous, such as would be the case if employs an r-olefin or r-aldehyde composition to make the oxo alcohol since the r-olefin or r-aldehyde is both an olefin or aldehyde composition and has a recycle content allocation associated with it; or where the process of making oxo alcohol is continuous and the application of the oxo alcohol application of the recycle content value occurs during the manufacture of oxo alcohol.
As discussed herein, oxo alcohols may be formed by the hydroformylation of olefins with synthesis gas, the resulting aldehydes having one more carbon atom per molecule than the starting olefin. For example, when the starting olefin comprises propylene, the aldehyde formed by hydroformylation is a butyraldehyde. The resulting aldehyde may then be subjected to an aldol condensation reaction, during which larger-chain, α,β-aldehydes may be formed. These α,β-aldehydes, which may include, for example 2-ethylhexenal and/or 2-ethylhexanal, can then be hydrogenated to form an oxo alcohol, such as 2-ethylhexanol.
2-Ethylhexenal is an unsaturated aldehyde formed from the aldol condensation of n-butyraldehyde, which itself is formed by hydroformylation of propylene with syngas (carbon monoxide and hydrogen). In some cases, 2-ethylhexenal can be partially hydrogenated to form a saturated aldehyde, 2-ethylhexanal, or further hydrogenated to form the corresponding alcohol, 2-ethylhexanol. 2-Ethylhexanol may be used as an intermediate compound for forming a variety of chemical compounds, including, but not limited to various types of plasticizers as discussed in detail below. The process of forming alcohols from alkenes is commonly referred to as an “oxo process” or “oxo synthesis,” while the process for forming α,β-aldehydes from lower carbon aldehydes is called aldol condensation.
One example of a system suitable for forming a recycle content α,β-aldehyde (r-α,β-aldehyde) and/or a recycle content oxo alcohol (r-oxo alcohol) from a recycle content olefin or alkene (r-olefin or r-alkene) is shown in
The pyrolysis units and cracking units may include those that were previously described in the present disclosure. In certain embodiments, the pyrolysis unit/facility, the cracking unit/facility, and the hydroformylation unit/facility may be in fluid communication. In some cases, the pyrolysis unit and cracking unit may be separately located and/or operated, while, in other cases, the pyrolysis and cracking units may be co-located as described herein.
As shown in
In an embodiment or in combination with any of the embodiments mentioned herein, at least 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 percent of the total weight of the hydroformylation feed stream can comprise olefin, including r-olefin such as r-propylene. In some cases, the r-olefin can comprise, consist essentially of, or consist of r-propylene, or the total amount of r-olefin may include at least about 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 weight percent of r-propylene, based on the total weight or r-olefin in the feed stream. The total amount of r-olefin in the feed stream to the hydroformylation unit can be at least 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 weight percent, based on the total weight of the hydroformylation feed stream. Additionally or alternatively, in certain embodiments, the feed stream going into the hydroformylation reactor may comprise not more than 99, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, or 1 weight percent of the r-propylene.
In certain embodiments, at least 5, 10, 15, 02, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 99 percent of the total amount of propylene fed into the hydroformylation zone comprises r-propylene, with the balance (if any) being non-recycle content propylene. In certain embodiments, the feed stream going into the hydroformylation reactor may comprise an propylene to r-propylene weight ratio of at least 0.1:1, 0.5:1, 1:1, 2:1, 3:1, or 4:1. Additionally or alternatively, in certain embodiments, the feed going into the hydroformylation reactor may comprise an propylene to r-propylene weight ratio of not more than 100:1, 50:1, 25:1, 10:1, 5:1, 4:1, 3:1, 2:1, 1:1, 0.5:1, or 0.1:1.
The propylene (including r-propylene) may be reacted with syngas in the presence of a catalyst in a hydroformylation reactor within the hydroformylation zone. In an embodiment or in combination with any of the embodiments mentioned herein, the syngas stream introduced into the hydroformylation reactor can comprise at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, or 70 and/or not more than 90, 85, 80, 75, 70, 65, 60, 55, 50, or 45 weight percent of hydrogen and/or carbon monoxide. The molar ratio of carbon monoxide to hydrogen can be at least 0.5:1, 0.75:1, 1:1, 1.25:1 or 1.5:1 and/or not more than 5:1, 3.5:1, 2.5:1, 2:1, 1.75:1, 1.5:1 or 1:1. The syngas stream may include at least 1, 2, 5, 10, or 15 and/or not more than 45, 40, 35, 30, 25, 20, 15, or 10 weight percent of one or more other components, such as, for example, carbon dioxide, based on the total weight of the stream.
Although it is not essential, an inert solvent can be employed as a hydroformylation reaction medium diluent. A variety of solvents can be used, including ketones such as acetone, methyl ethyl ketone, methyl isobutyl ketone, acetophenone, and cyclohexanone; aromatics such as benzene, toluene and xylenes; halogenated aromatics including orthodichlorobenzene; ethers such as tetrahydrofuran, dimethoxyethane and dioxane; halogenated paraffins including methylene chloride; paraffinic hydrocarbons such as heptane; or combinations thereof.
As shown in
In certain embodiments, the hydroformylation process may occur at a temperature in the range of 40 to 200° C., 50 to 150° C., or 60 to 120° C., or even 80 to 105° C.
In certain embodiments, the hydroformylation process may occur at a pressure in the range of 0.01 to 35 MPa, 0.1 to 12 MPa, or 1 to 7 MPa.
Additionally, the hydroformylation unit/facility may further include one or more separators (not shown) for purifying the effluent stream withdrawn from the hydroformylation reactor. For example, in certain embodiments, the effluent stream from the hydroformylation reactor may comprise at least 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 and/or not more than 99, 95, 90, 85, 80, 75, 70, 65, or 60 weight percent of C4 aldehydes such as, for example, normal and isobutyl aldehydes. In some cases, the amount of normal butyl aldehyde (n-butyraldehyde) can be at least 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, or 80 percent and/or not more than 99, 95, 90, 85, 80, 75, 70, 65, or 60 percent of the total amount of C4 aldehydes present in the reactor effluent stream with the balance being, for example, isobutyraldehyde. The separators, when present in the hydroformylation facility, may be used to separate the C4 aldehyde isomers from one another so that, for example, the product stream withdrawn from the hydroformylation unit/facility can be at least 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 97, or 99 weight percent of normal butyraldehyde, based on the total weight of the C4 aldehydes in the stream. Of that, at least a portion, or all, can comprise recycle content normal butyraldehyde (r-normal butyraldehyde).
Various hydroformylation processes and systems are described in U.S. Pat. Nos. 2,464,916; 4,148,830; 5,264,600; 4,593,127; 7,935,850; 7,420,092; 6,492,564; 4,625,068; 4,169,861; 3,448,157; European Patent No. 0804398; and U.S. Pat. No. 7,049,473, the entire disclosures are incorporated herein by reference to the extent not inconsistent with the present disclosure.
The resulting r-aldehyde may comprise at least one pyoil-derived impurity derived from the r-propylene or other recycle content intermediates used to form the r-oxo plasticizer. In certain embodiments, the r-aldehyde may comprise at least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 ppm and/or not more than 1,000, 900, 800, 700, 600, 500, 400, 300, 200, or 100 ppm of at least one pyoil-derived impurity derived from the r-propylene.
As shown in
In an embodiment or in combination with any of the embodiments mentioned herein, at least 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 percent of the total weight of the feed to the aldol condensation unit/facility can include an aldehyde, including r-aldehyde such as r-butyraldehyde or, in particular, r-n-butyraldehyde. In some cases, the r-butyraldehyde can comprise, consist essentially of, or consist of r-n-butyraldehyde, or the total amount of r-butyraldehyde (or r-aldehyde) may include at least about 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 weight percent of r-n-butyraldehyde (or r-butyraldehyde), based on the total weight or r-aldehyde in the feed stream to the aldol condensation unit/facility. The total amount of r-aldehyde in the feed stream to the aldol condensation unit can be at least 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 weight percent, based on the total weight of the aldol condensation feed stream. Additionally or alternatively, in certain embodiments, the feed stream going into the aldol condensation reactor may comprise not more than 99, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, or 1 weight percent of the r-butyraldehyde or r-n-butyraldehyde.
In certain embodiments, at least 5, 10, 15, 02, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 99 percent of the total amount of aldehyde (or butyraldehyde) fed into the aldol condensation zone comprises r-butyraldehyde (or r-n-butyraldehyde), with the balance (if any) being non-recycle content butyraldehyde (or n-butyraldehyde). In certain embodiments, the feed stream going into the aldol condensation reactor may comprise a butyraldehyde to r-butyraldehyde (or n-butyraldehyde to r-n-butyraldehyde) weight ratio of at least 0.1:1, 0.5:1, 1:1, 2:1, 3:1, or 4:1. Additionally or alternatively, in certain embodiments, the feed going into the aldol condensation reactor may comprise an a butyraldehyde to r-butyraldehyde (or n-butyraldehyde to r-n-butyraldehyde) weight ratio of not more than 100:1, 50:1, 25:1, 10:1, 5:1, 4:1, 3:1, 2:1, 1:1, 0.5:1, or 0.1:1.
In an embodiment or in combination with any of the embodiments mentioned herein, the effluent from the hydroformylation reaction may include a mixture of n-butyraldehyde and i-butyraldehyde, which it may be desirable to separate. For example, the effluent stream may include at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, or 55 weight percent and/or not more than 90, 85, 80, 75, 70, 65, 60, 55, 50, or 45 weight percent of n-butyraldehyde or of i-butyraldehyde. Thus, the effluent from the hydroformylation reactor may be passed through one or more separation columns (such as, for example, multi-stage distillation columns) to separate the i-butyraldehyde from the n-butyraldehyde. In some cases, the purified streams of n-butyraldehyde and i-butyraldehyde can include at least 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 97, or 99 percent by weight of i-butyraldehyde or n-butyraldehyde, respectively.
The aldehyde fed into the aldol condensation reactor may be condensed in the presence of a catalyst. The catalyst may be any type of catalyst suitable for such reactions and can comprise, for example, titanium dioxide, aluminum oxide, basic catalysts such as sodium hydroxide, potassium hydroxide, magnesium hydroxide, or calcium hydroxide, and other metallic catalysts such as tin, and combinations thereof. The catalyst can be homogenous or heterogeneous and the reaction can take place in the liquid or gas phase.
The product of the aldol condensation reaction can be a saturated or unsaturated aldehyde such as, for example, 2-ethylhexanal or 2-ethylhexenal when n-butyraldehyde is condensed. In some cases, the effluent stream removed form the condensation reaction may include an unsaturated aldehyde (such as 2-ethylhexenal) or a saturated aldehyde (such as 2-ethylhexanal) or in an amount of, for example, at least 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 percent by weight based on the total weight of the stream. The saturated aldehyde may be formed within the aldol condensation reactor or in a separate reactor or vessel by reacting the unsaturated aldehyde with hydrogen.
In an embodiment or in combination with any of the embodiments mentioned herein, the aldol condensation reaction can be carried out at a temperature of 100 to 300° C., 125 to 200° C., or 130 to 180° C. The pressure of the aldol condensation process can be in the range of from 0.01 to 35 MPa, 0.1 to 12 MPa, or 1 to 7 MPa.
Various aldol condensation processes and systems are described in U.S. Pat. Nos. 4,316,990 and 5,114,089, the entire disclosures are incorporated herein by reference to the extent not inconsistent with the present disclosure.
The resulting r-α,β-aldehyde may comprise at least one pyoil-derived impurity derived from the r-propylene or other recycle content intermediates used to form the r-oxo plasticizer. In certain embodiments, the r-α,β-aldehyde may comprise at least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 ppm and/or not more than 1,000, 900, 800, 700, 600, 500, 400, 300, 200, or 100 ppm of at least one pyoil-derived impurity derived from the r-propylene or other recycle content intermediate (r-aldehyde).
As shown in
In an embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the effluent from the aldol condensation unit/facility can be fed to a separate hydrogenation unit. The feed to the hydrogenation unit can comprise at least 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 percent of an α,β-aldehyde, including an r-α,β-aldehyde such as r-2-ethylhexenal or r-2-ethylhexanal. In some cases, the total amount of α,β-aldehyde may include at least about 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 weight percent of r-α,β-aldehyde, based on the total weight of α,β-aldehyde in the feed stream to the hydrogenation unit/facility.
The total amount of r-α,β-aldehyde in the feed stream to the hydrogenation unit can be at least 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 weight percent and/or not more than 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, or 35 weight percent, based on the total weight of the feed stream. In certain embodiments, the feed stream going into the hydrogenation reactor may comprise an α,β-aldehyde to r-α,β-aldehyde weight ratio of at least 0.1:1, 0.5:1, 1:1, 2:1, 3:1, or 4:1. Additionally or alternatively, in certain embodiments, the feed going into the hydrogenation reactor may comprise an α,β-aldehyde to r-α,β-aldehyde weight ratio of not more than 100:1, 50:1, 25:1, 10:1, 5:1, 4:1, 3:1, 2:1, 1:1, 0.5:1, or 0.1:1.
The α,β-aldehyde, such as 2-ethylhexenal and 2-ethylhexanal, may be reacted with hydrogen in the hydrogenation reactor. The stream of hydrogen introduced into the reactor can have a purity of at least 70, 75, 80, 85, 90, 95, 97, or 99 weight percent hydrogen, based on the total weight of the stream. In an embodiment or in combination with any of the embodiments mentioned herein, the molar ratio of hydrogen to α,β-aldehyde can be at least 0.5:1, 0.75:1, 0.9:1, 1:1, 1.1:1, 1.25:1, 1.5:1, 1.75:1, or 2:1.
The hydrogenation may also be performed in the presence of a catalyst. Examples of suitable catalysts include, but are not limited to, single metal, bimetallic, and trimetallic catalysts including supported Group VIII and/or Group IVB metals. In particular, the Group VIB metal may comprise chromium, molybdenum, tungsten, or mixtures thereof. Suitable Group VIII non-noble metals may include iron, cobalt, nickel, copper, or mixtures thereof. The catalyst may be heterogeneous and can be present in the form of a supported catalyst.
In certain embodiments, the hydrogenation process may occur in the presence of hydrogen gas and at a temperature in the range of 75 to 350° C., 100 to 300° C., or 150 to 250° C. In certain embodiments, the hydrogenation process may occur at a pressure in the range of 1 to 35 MPa, 3 to 25 MPa, or 5 to 20 MPa. In certain embodiments, the hydrogenation process may occur over a time period in the range of 1 minute to 18 hours, 5 minutes to 10 hours, or 10 minutes to 5 hours.
Various processes and systems suitable for hydrogenating the effluent from an aldol condensation reaction are described in the references listed herein, as well as U.S. Pat. No. 6,278,030, the entire disclosure of which is incorporated herein by reference to the extent not inconsistent with the present disclosure.
The resulting r-alcohols (or r-oxo alcohols) may comprise at least one pyoil-derived impurity derived from the r-propylene or other recycle content intermediates used to form the r-oxo plasticizer. In certain embodiments, the r-alcohols or r-oxo alcohols may comprise at least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 ppm and/or not more than 1,000, 900, 800, 700, 600, 500, 400, 300, 200, or 100 ppm of at least one pyoil-derived impurity derived from the r-propylene or other recycle content intermediate (r-aldehyde or r-α,β-aldehyde).
The effluent from the hydrogenation unit/facility can comprise a recycle content oxo alcohol (r-alcohol). When the feed to the hydrogenation unit comprises 2-ethylhexenal and/or 2-ethylhexanal, the resulting hydrogenated alcohol may comprise 2-ethylhexanol. Thus, when recycle content 2-ethylhexenal and/or 2-ethylhexanal (r-2-ethylhexenal and/or r-2-ethylhexanal) is hydrogenated, the resulting stream comprises recycle content 2-ethylhexanol (r-2-ethylhexanol). In an embodiment or in combination with any of the embodiments mentioned herein, the effluent from the hydrogenation unit may comprise 2-ethylhexanol in an amount of at least 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 percent of the total weight of the stream, with at least 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 weight percent of the total amount of 2-ethylhexanol being recycle content 2-ethylhexanol (r-2-ethylhexanol).
The r-aldehyde, the r-α,β-aldehyde, and/or the r-oxo alcohol as discussed above may comprise at least one pyoil-derived impurity derived from the r-propylene in the feed to the hydroformylation reaction. In certain embodiments, the r-aldehyde, the r-α,β-aldehyde, and/or the r-oxo alcohol may comprise at least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 ppm and/or not more than 1,000, 900, 800, 700, 600, 500, 400, 300, 200, or 100 ppm of at least one pyoil-derived impurity derived from the r-propylene in the hydroformylation feed.
Process of Making and Use of r-Oxo Plasticizers
In the present disclosure, it is envisioned that at least a portion of the r-propylene may be subjected to hydroformylation, aldol condensation and hydrogenation in order to produce r-oxo alcohols as discussed previously. These r-oxo alcohols may then be used to form one or more ester-based plasticizers, which also include recycle content (r-oxo plasticizer). As used herein, “r-oxo plasticizers” refers to one or more plasticizers including recycle content.
In general, oxo plasticizers may be formed by reacting an oxo alcohol with an esterifying agent to provide a plasticizer. Examples of suitable esterifying agents may include, but are not limited to, adipic acid, trimellitic acid, phthalic anhydride, and dialkyl terephthalate, including dimethyl terephthalate (DMT). The resulting plasticizers can include, but are not limited to, bis(2-ethylhexyl)terephthalate (DOTP), bis(2-ethylhexyl)phthalate (DOP), tris(2-ethylhexyl)trimellitate (TOTM), bis(2-ethylhexyl)adipate (DOA). All or a portion of the olefin, aldehyde, α,β-aldehyde, oxo alcohol, and/or oxo plasticizer may or may include recycle content, as described in further detail herein.
Further, as shown in
In certain embodiments, the feed stream being introduced into one or more of the esterification reactors (or units/facilities) may include at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 weight percent of 2-ethylhexanol. In some cases, at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 weight percent of the 2-ethylhexanol can be recycle content 2-ethylhexanol. When non-recycle content 2-ethylhexanol is present, it may be present in the feed stream in an amount of at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 weight percent, based on the total weight of the feed stream. At least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 percent of the total amount of 2-ethylhexanol present in the feed stream to the esterification reactor or facility/unit can be r-2-ethylhexanol.
In an embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the r-2-ethylhexanol can be reacted with an esterifying agent including terephthalic acid or a dialkyl terephthalate (such as, for example, dimethylterephthalate) to form a bis(alkyl)terephthalate, which may also comprise a recycle content bis(alkyl)terephthalate (r-bis(alkyl)terephthalate). The alkyl group of the dialkyl terephthalate reactant can be linear or branched and may include at least 1, 2, 3, 4, or 5 and/or not more than 10, 8, or 6 carbon atoms per molecule. When reacted with r-2-ethylhexanol, the alkyl group of the resulting r-bis(alkyl)terephthalate can be a 2-ethylhexyl (C8) group, and may be referred to as r-bis(2-ethylhexyl)terephthalate or r-bis(dioctyl)terephthalate (r-DOTP). The molar ratio of 2-ethylhexanol to terephthalic acid or terephthalate is at least 2:1, 2.1:1, 2.2:1, 2.25:1, 2.5:1, 2.75:1, or 3:1 and/or not more than 5:1, 4.5:1, 4:1, 3.5:1, 3:1, or 2.5:1.
In an embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the terephthalic acid or terephthalate may also itself comprise a recycle content terephthalic acid (r-terephthalic acid) or recycle content terephthalate, such as, for example, a recycle content dimethyl terephthalate (r-DMT). In certain embodiments, the terephthalic acid or terephthalate may comprise at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 and/or not more than 100, 99, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, or 30 weight percent of recycle content terephthalic acid or terephthalate. Such recycle content r-TPA or r-DMT may come from the cracking of r-pyoil or the pyrolysis of waste plastic to form an r-pyoil and subsequent separation and/or purification techniques to provide the recycle content material.
The esterification reaction of 2-ethylhexanol may be performed in the presence of at least one esterification catalyst. Examples include, for example, titanium compounds such as alkyl titanites and, in particular, tetralkyl titanates, as well as mineral and strong organic acids such as methanesulfonic acid and p-toluenesulfonic acid. Other examples include, but are not limited to, tin oxide, zinc oxide, antimony oxide, titanium peroxide, an alumina-sodium hydroxide mixed system, magnesium-silicon double oxide, sodium-aluminum double oxide, and magnesium-aluminum double oxide. The catalyst may be present in the reaction medium in an amount of at least 0.1, 0.25, 0.5, 0.75, 1, 1.5, 2, 3, 5, 8, or 10 weight percent and/or not more than 20, 15, 10, 8, 6, 5, 3, 2, or 1 weight percent based on the total weight of the reaction medium.
In certain embodiments, the reaction temperature at which the esterification reaction can occur may be at least 70, 80, 90, 100, 105, or 110° C. and/or not more than 230, 220, 210, 200, 195, 190° C. The pressure of the reaction can be around atmospheric or within about 25, 10, 5, or 2 psi of atmospheric (not including the hydrostatic head of any liquid).
The resulting product stream withdrawn or recovered from the esterification unit or reactor can comprise at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 weight percent of DOPT and/or not more than 99, 95, 90, 85, 80, 75, 70, 65, or 60 weight percent of DOPT. Of the DOPT in the product stream, at least 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 or 99 percent and/or not more than 99, 95, 90, 85, 80, 75, 70, or 65 weight percent may comprise recycle content DOPT (r-DOPT).
In an embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the r-2-ethylhexanol can be reacted with an esterifying agent comprising trimellitic acid or anhydride to form tris(2-ethylhexyl)trimellitate (TOTM), which may also comprise a recycle content tris(2-ethylhexyl)trimellitate (r-TOTM). Also suitable for reacting with the 2-ethylhexanol is the half or monoester of trimellitate.
As discussed above, the esterification reaction of 2-ethylhexanol may be performed in the presence of at least one esterification catalyst. Examples include, for example, titanium compounds such as alkyl titanites and, in particular, tetralkyl titanates, as well as mineral and strong organic acids such as methanesulfonic acid and p-toluenesulfonic acid. Other examples include, but are not limited to, tin oxide, zinc oxide, antimony oxide, titanium peroxide, an alumina-sodium hydroxide mixed system, magnesium-silicon double oxide, sodium-aluminum double oxide, and magnesium-aluminum double oxide. The catalyst may be present in the reaction medium in an amount of at least 0.1, 0.25, 0.5, 0.75, 1, 1.5, 2, 3, 5, 8, or 10 weight percent and/or not more than 20, 15, 10, 8, 6, 5, 3, 2, or 1 weight percent based on the total weight of the reaction medium.
In certain embodiments, the reaction temperature at which the esterification reaction can occur may be at least 70, 80, 90, 100, 105, or 110° C. and/or not more than 230, 220, 210, 200, 195, 190° C. The pressure of the reaction can be around atmospheric or within about 25, 10, 5, or 2 psi of atmospheric (not including the hydrostatic head of any liquid).
The resulting product stream withdrawn or recovered from the esterification unit or reactor can comprise at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 weight percent of TOTM and/or not more than 99, 95, 90, 85, 80, 75, 70, 65, or 60 weight percent of TO™. Of the TOTM in the product stream, at least 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 or 99 percent and/or not more than 99, 95, 90, 85, 80, 75, 70, or 65 weight percent may comprise recycle content TOTM (r-TOTM).
In an embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the r-2-ethylhexanol can be reacted with an esterifying agent including adipic acid or anhydride to form bis(2-ethylhexyl)adipiate (DOA), which may also comprise a recycle content bis(2-ethylhexyl)adipiate (DOA). Other suitable carboxylic acids suitable for reaction with the 2-ethylhexanol can include acetic acid, butyric acid, valeric acid, succinic acid, sebacic acid, lactic acid, tartaric acid, combinations thereof, and anhydrides thereof.
As discussed above, the esterification reaction of 2-ethylhexanol may be performed in the presence of at least one esterification catalyst. Examples include, for example, titanium compounds such as alkyl titanites and, in particular, tetralkyl titanates, as well as mineral and strong organic acids such as methanesulfonic acid and p-toluenesulfonic acid. Other examples include, but are not limited to, tin oxide, zinc oxide, antimony oxide, titanium peroxide, an alumina-sodium hydroxide mixed system, magnesium-silicon double oxide, sodium-aluminum double oxide, and magnesium-aluminum double oxide. The catalyst may be present in the reaction medium in an amount of at least 0.1, 0.25, 0.5, 0.75, 1, 1.5, 2, 3, 5, 8, or 10 weight percent and/or not more than 20, 15, 10, 8, 6, 5, 3, 2, or 1 weight percent based on the total weight of the reaction medium.
In certain embodiments, the reaction temperature at which the esterification reaction can occur may be at least 70, 80, 90, 100, 105, or 110° C. and/or not more than 230, 220, 210, 200, 195, 190° C. The pressure of the reaction can be around atmospheric or within about 25, 10, 5, or 2 psi of atmospheric (not including the hydrostatic head of any liquid). Alternatively, the reaction may be conducted at a slight vacuum.
The resulting product stream withdrawn or recovered from the esterification unit or reactor can comprise at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 weight percent of DOA and/or not more than 99, 95, 90, 85, 80, 75, 70, 65, or 60 weight percent of DOA. Of the DOA in the product stream, at least 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 or 99 percent and/or not more than 99, 95, 90, 85, 80, 75, 70, or 65 weight percent may comprise recycle content DOA (r-DOA).
In an embodiment or in combination with any of the embodiments mentioned herein, at least a portion of the r-2-ethylhexanol can be reacted with an esterifying agent comprising phthalic acid or anhydride to form bis(2-ethylhexyl)phthalate (DOP), which may also comprise a recycle content bis(2-ethylhexyl)adipiate (DOP). Other suitable carboxylic acids suitable for reaction with the 2-ethylhexanol can include acetic acid, butyric acid, valeric acid, succinic acid, sebacic acid, lactic acid, tartaric acid, combinations thereof, and anhydrides thereof.
As discussed above, the esterification reaction of 2-ethylhexanol may be performed in the presence of at least one esterification catalyst. Examples include, for example, titanium compounds such as alkyl titanites and, in particular, tetralkyl titanates, as well as mineral and strong organic acids such as methanesulfonic acid and p-toluenesulfonic acid. Other examples include, but are not limited to, tin oxide, zinc oxide, antimony oxide, titanium peroxide, an alumina-sodium hydroxide mixed system, magnesium-silicon double oxide, sodium-aluminum double oxide, and magnesium-aluminum double oxide. The catalyst may be present in the reaction medium in an amount of at least 0.1, 0.25, 0.5, 0.75, 1, 1.5, 2, 3, 5, 8, or 10 weight percent and/or not more than 20, 15, 10, 8, 6, 5, 3, 2, or 1 weight percent based on the total weight of the reaction medium.
In certain embodiments, the reaction temperature at which the esterification reaction can occur may be at least 70, 80, 90, 100, 105, or 110° C. and/or not more than 230, 220, 210, 200, 195, 190° C. The pressure of the reaction can be around atmospheric or within about 25, 10, 5, or 2 psi of atmospheric (not including the hydrostatic head of any liquid). Alternatively, the reaction may be conducted at a slight vacuum.
The resulting product stream withdrawn or recovered from the esterification unit or reactor can comprise at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 weight percent of DOP and/or not more than 99, 95, 90, 85, 80, 75, 70, 65, or 60 weight percent of DOP. Of the DOP in the product stream, at least 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 or 99 percent and/or not more than 99, 95, 90, 85, 80, 75, 70, or 65 weight percent may comprise recycle content DOP (r-DOP).
Various processes and systems suitable for esterifying 2-ethylhexanol to form one or more plasticizers as described herein are described in more detail in European Patent No. 3063122; U.S. Pat. No. 4,216,337, Chinese Patent Application No. 106008218A, U.S. Pat. No. 9,309,183, Chinese Patent No. 102249909, and U.S. Patent Application Publication No. 2018/0163018, the entire disclosures of which are incorporated herein by reference to the extent not inconsistent with the present disclosure.
The resulting r-oxo plasticizers may comprise at least one pyoil-derived impurity derived from the r-propylene or other recycle content intermediates used to form the r-oxo plasticizer. In certain embodiments, the r-oxo plasticizers may comprise at least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 ppm and/or not more than 1,000, 900, 800, 700, 600, 500, 400, 300, 200, or 100 ppm of at least one pyoil-derived impurity derived from the r-propylene or other recycle content intermediate (r-aldehyde, r-α,β-aldehyde, r-alcohol).
In an embodiment or in combination with any of the embodiments mentioned herein, a plasticizer composition is provided that includes one or more of the r-oxo plasticizers described previously. In certain embodiments, the plasticizer composition can include at least about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95 or 99 and/or not more than 99, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, or 35 weight percent of r-oxo plasticizer, based on the total weight of plasticizer in the composition. The plasticizer composition can comprise, consist essentially of, or consist of the plasticizer or r-oxo plasticizer described herein, or it can include one or more other plasticizers, which may or may not comprise recycle content oxo plasticizers. In certain embodiments, the amount of r-oxo plasticizer in the plasticizer composition can be at least 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 weight percent and/or not more than 99, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, or 40 weight percent, based on the total weight of the composition, with the balance being other plasticizers and various other ingredients, if present.
In an embodiment or in combination with any of the embodiments mentioned herein, a plasticized polymer composition is provided that includes one or more of the r-oxo plasticizers described previously. The plasticizer polymer composition may include, for example, at least 1, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80 and/or not more than 200, 150, 100, 95, 90, 85, 80, 75, or 70 parts by weight of plasticizer based on 100 parts by weight of the polymer. Suitable types of polymers can include, for example, rubber and polyvinylchloride (PVC).
In one embodiment or in combination with any of the mentioned embodiments, there is now provided a method for processing pr-oxo alcohol by feeding the pr-oxo alcohol to a reactor in which is made oxo plasticizers or an oxo plasticizer composition. In another embodiment, there is provided a method for making an r-oxo plasticizer or pr-oxo plasticizer by reacting an r-oxo alcohol or pr-oxo alcohol with an esterifying agent to form an oxo plasticizer. Examples of suitable oxo plasticizers include, but are not limited to, dioctyl adipate (DOA), bis(2-ethylhexyl)phthalate (DOP), various di(C1 to C8)alkylterephthalates (including dioctyl terephthalate (DOTP)), and tris(2-ethylhexyl)trimellitate (TOTM).
In one embodiment or in combination with any of the mentioned embodiments, the concentration of r-oxo alcohol or pr-oxo alcohol, introduced into a reactor vessel is at least 90 wt. %, or at least 95 wt. %, or at least 97 wt. %, or at least 99 wt. %, based on the weight of the oxo alcohol composition fed to the reactor.
In one embodiment or in combination with any of the mentioned embodiments, the oxo plasticizer manufacturer, or one among its Family of Entities, can make oxo plasticizer, or process an oxo alcohol, or process oxo alcohol and make an r-oxo plasticizer, or make r-oxo plasticizer, by obtaining any source of an oxo alcohol composition from a supplier, whether or not such oxo alcohol composition has any direct or indirect recycle content, and either:
The allotment in (i) is obtained from an oxo alcohol supplier, and the oxo alcohol supplier also supplies oxo alcohol to the oxo plasticizer manufacturer or within its Family of Entities. The circumstance described in (i) allows an oxo plasticizer manufacturer to obtain a supply of an oxo alcohol composition that is a non-recycle content oxo alcohol, yet obtain a recycle content allotment from the oxo alcohol supplier. In one embodiment or in combination with any of the mentioned embodiments, the oxo alcohol supplier transfers a recycle content allotment to the oxo plasticizer manufacturer and a supply of oxo alcohol to the oxo plasticizer manufacturer, where the recycle content allotment is not associated with the oxo alcohol supplied, or even not associated with any oxo alcohol made by the oxo alcohol supplier. The recycle content allotment does not have to be tied to an amount of recycle content in an oxo alcohol composition or to any compound used to make oxo plasticizer, but rather the recycle content allotment transferred by the oxo alcohol supplier can be associated with other products derived directly or indirectly from recycled waste, the pyrolysis of recycled waste, pyrolysis gas produced from the pyrolysis of recycled waste, and/or the cracking of r-pyoil produced from the pyrolysis of recycled waste or the recycle content of any downstream compounds obtained from the pyrolysis of recycled waste, such as r-ethylene, r-propylene, r-butadiene, r-aldehydes, r-alcohols, r-benzene, etc. For example, the oxo alcohol supplier can transfer to the oxo plasticizer manufacturer a recycle content associated with r-propylene and also supply a quantity of oxo alcohol even though r-propylene was not used in the synthesis of the oxo alcohol. This allows flexibility among the oxo alcohol supplier and oxo plasticizer manufacturer to apportion a recycle content among the variety of products they each make.
There is now also provided a method of introducing or establishing a recycle content in an oxo plasticizer without necessarily using an r-oxo alcohol feedstock. In this method,
In this method, the oxo plasticizer manufacturer need not purchase r-oxo alcohol from any entity or from the supplier of oxo alcohol, and does not require the oxo plasticizer manufacturer to purchase ethylene, r-ethylene, or oxo alcohol from a particular source or supplier, and does not require the oxo plasticizer manufacturer to use or purchase an oxo alcohol composition having r-oxo alcohol in order to successfully establish a recycle content in the oxo plasticizer composition. The oxo alcohol manufacturer may use any source of oxo alcohol and apply at least a portion of the allocation or credit to at least a portion of the oxo alcohol feedstock or to at least a portion of the oxo plasticizer product. When the allocation or credit is applied to the feedstock oxo alcohol, this would be an example of an r-oxo alcohol feedstock indirectly derived from the cracking of r-pyoil or obtained from r-pygas. The association by the oxo plasticizer manufacturer may come in any form, whether by on in its recycle inventory, internal accounting methods, or declarations or claims made to a third party or the public.
In another method, the direct method, a recycle content can be introduced or established in oxo plasticizer by:
obtaining recycle oxo alcohol composition at least a portion of which is indirectly derived from cracking r-pyoil or indirectly obtained from r-pygas (“r-oxo alcohol”),
making an oxo plasticizer composition from a feedstock comprising r-oxo alcohol,
applying a recycle content value to at least a portion of any oxo plasticizer composition made by the same entity that made the oxo plasticizer composition in step b), and the recycle content value is based at least partly on the amount of recycle content contained in the r-oxo alcohol.
In another more detailed direct method, a recycle content can be introduced or established in oxo plasticizer by:
In these direct methods, the r-oxo alcohol content used to make the oxo plasticizer would be traceable to the olefin made by a supplier by cracking r-pyoil or obtained from r-pygas. Not all of the amount of r-olefin used to make the oxo alcohol need be designated or associated with the oxo alcohol. For example, if 1000 kg of r-olefin is used to make r-oxo alcohol, the oxo alcohol manufacturer can designate less than 1000 kg of recycle content toward a particular batch of feedstock used to make the oxo alcohol and may instead spread out the 1000 kg recycle content amount over various productions runs to make oxo alcohol. The oxo alcohol manufacturer may elect to offer for sale its dr-oxo plasticizer and in doing so may also elect to represent the r-oxo plasticizer that is sold as containing, or obtained with sources that contain, a recycle content.
There is also provided a use for an oxo alcohol derived directly or indirectly from cracking r-pyoil or obtained from r-pygas, the use including converting r-oxo alcohol in any synthetic process to make oxo plasticizers.
There is also provided a use for an r-oxo alcohol allotment or an r-olefin allotment that includes converting an oxo alcohol in a synthetic process to make oxo plasticizers and applying at least a portion of an r-oxo alcohol allotment or the r-olefin allotment to the oxo plasticizer. An r-oxo alcohol allotment or an r-olefin allotment is an allotment that is created by pyrolyzing recycled waste. Desirably, the allotments originate from the cracking of r-pyoil, or cracking of r-pyoil in a gas furnace, or from r-pygas.
There is also provided a use for an oxo plasticizer formed by hydroformylating an r-olefin and condensing the resulting aldehyde to provide an α,β-aldehyde, then hydrogenating the α,β-aldehyde to form an oxo alcohol, where the r-oxo alcohol is derived directly or indirectly from pyrolyzing recycled waste. The r-oxo alcohol can be reacted with one or more esterifying agents as described herein to form an esterified r-oxo plasticizer. At least a portion of the recycle inventory from which the recycle content allotment is applied to the oxo plasticizer are allotments originating from pyrolyzing recycled waste. Desirably, the allotments originate from the cracking of r-pyoil, or cracking of r-pyoil in a gas furnace, or from r-pygas. Also, the allotment applied to the oxo plasticizer can be a recycle content allotment originating from pyrolyzing recycled waste.
In one embodiment or in combination with any of the mentioned embodiments, there is also provided a use of a recycle inventory by converting any oxo alcohol composition in a synthetic process to make an oxo plasticizer composition (“oxo plasticizer”); deducting a recycle content value from the recycle inventory and applying at least a portion of the deducted recycle content value to the oxo plasticizer, and at least a portion of the inventory contains a recycle content allotment. The recycle content allotment can be present in the inventory at the time of deducting a recycle content value from the recycle inventory, or a recycle content allotment deposit is made into the recycle inventory before deducting a recycle content value (but need not be present or accounted for when a deduction is made), or it can be present within a year from the deduction, or within the same calendar year as the deduction, or within the same month as the deduction, or within the same week as the deduction. In one embodiment or in combination with any of the mentioned embodiments, the recycle content deduction is withdrawn against a recycle content allotment.
In one embodiment or in combination with any of the mentioned embodiments, there is provided an oxo plasticizer composition that is obtained by any of the methods described above.
In one embodiment or in combination with any of the mentioned embodiments, one may integrate two or more facilities and make r-oxo plasticizer. The facilities to make r-oxo plasticizer, the oxo alcohol, the olefins, and the r-pyoil and/or r-pygas, can be stand-alone facilities or facilities integrated to each other. For example, one may establish a system of producing and consuming a recycle oxo alcohol composition at least a portion of which is obtained from directly or indirectly from cracking r-pyoil or obtaining r-pygas; or a method of making r-oxo plasticizer, as follows:
The feeding in step c) can be a supply system providing fluid communication between these two facilities and capable of supplying an oxo alcohol composition from the oxo alcohol manufacturing facility to the oxo plasticizer manufacturing facility, such as a piping system that has a continuous or discontinuous flow.
The oxo plasticizer manufacturing facility can make r-oxo plasticizer, and can make the r-oxo plasticizer directly or indirectly from the pyrolysis of recycled waste or the cracking of r-pyoil or from r-pygas. For example, in a direct method, the oxo plasticizer manufacturing facility can make r-oxo plasticizer by accepting r-oxo alcohol from the oxo alcohol manufacturing facility and feeding the r-oxo alcohol as a feed stream to a reactor to make oxo plasticizer. Alternatively, the oxo plasticizer manufacturing facility can make r-oxo plasticizer by accepting any oxo alcohol composition from the oxo alcohol manufacturing facility and applying a recycle content to oxo plasticizer made with the oxo alcohol composition by deducting recycle content value from its recycle inventory and applying them to the oxo plasticizer, optionally in amounts using the methods described above. The allotments obtained and stored in recycle inventory can be obtained by any of the methods described above, and need not necessarily be allotments associated with r-oxo alcohol.
In one embodiment or in combination with any of the mentioned embodiments, there is also provided a system for producing r-oxo plasticizer as follows:
The oxo plasticizer manufacturing facility can make r-oxo plasticizer, and can make the r-oxo plasticizer directly or indirectly from the pyrolysis of recycled waste. In this system, the olefin (or propylene) manufacturing facility can have its output in fluid communication with the oxo alcohol manufacturing facility which in turn can have its output in fluid communication with the oxo plasticizer manufacturing facility. Alternatively, the manufacturing facilities of a) and b) alone can be in fluid communication, or only b) and c), or only c) and d). In the latter case, the oxo plasticizer manufacturing facility can make r-oxo plasticizer directly by having the r-olefin or r-propylene produced in the olefin manufacturing facility converted all the way to oxo plasticizer, or indirectly by accepting any oxo alcohol composition from the oxo alcohol manufacturing facility and applying a recycle content to oxo plasticizer by deducting allotments from its recycle inventory and applying them to the oxo plasticizer, optionally in amounts using the methods described above. The allotments obtained and stored in recycle inventory can be obtained by any of the methods described above, and need not necessarily be allotments associated with r-oxo alcohol or the r-olefin or r-aldehyde. For example, the allotments can be obtained from any facility or source, so long as they originate from the pyrolysis of recycled waste, or the cracking r-pyoil or obtained from r-pygas.
In one embodiment or in combination with any of the mentioned embodiments, there is also provided an integrated r-olefin and r-oxo plasticizer generating and consumption system. This system includes:
The system does not necessarily require a fluid communication between the two facilities, although fluid communication is desirable. In this system, propylene made at the olefin manufacturing facility can be delivered to the oxo alcohol facility through the interconnecting piping network that can be interrupted by other processing equipment, such as treatment, purification, pumps, compression, or equipment adapted to combine streams, or storage facilities, all containing optional metering, valving, or interlock equipment. The equipment can be a fixed to the ground or fixed to structures that are fixed to the ground. The interconnecting piping does not need to connect to the oxo alcohol reactor or the cracker, but rather to a delivery and receiving point at the respective facilities. The same concept applies between the oxo alcohol facility and the oxo plasticizer facility. The interconnecting pipework need not connect all three facilities to each other, but rather the interconnecting pipework can be between facilities a)-b), or b)-c), or c)-d), or between a)-b)-c) or b)-c)-d), or between a)-b)-c)-d), or any combination thereof.
Table 1 shows the composition of r-pyoil samples by gas chromatography. The r-pyoil samples produced the material from waste high- and low-density polyethylene, polypropylene, and polystyrene. Sample 4 was a lab-distilled sample in which hydrocarbons greater than C21 were removed. The boiling point curves of these materials are shown in
Six r-pyoil compositions were prepared by distillation of r-pyoil samples. They were prepared by processing the material according the procedures described below.
A 250 g sample of r-pyoil from Example 3 was distilled through a 30-tray glass Oldershaw column fitted with glycol chilled condensers, thermowells containing thermometers, and a magnet operated reflux controller regulated by electronic timer. Batch distillation was conducted at atmospheric pressure with a reflux rate of 1:1. Liquid fractions were collected every 20 mL, and the overhead temperature and mass recorded to construct the boiling curve presented in
A 150 g sample of r-pyoil from Example 3 was distilled through a 30-tray glass Oldershaw column fitted with glycol chilled condensers, thermowells containing thermometers, and a magnet operated reflux controller regulated by electronic timer. Batch distillation was conducted at atmospheric pressure with a reflux rate of 1:1. Liquid fractions were collected every 20 mL, and the overhead temperature and mass recorded to construct the boiling curve presented in
A procedure similar to Example 8 was followed with fractions collected from 120° C. to 210° C. at atmospheric pressure and the remaining fractions (up to 300° C., corrected to atmospheric pressure) under 75 torr vacuum to give a composition of 200 g with a boiling point curve described by
Approximately 200 g of residuals from Example 6 were distilled through a 20-tray glass Oldershaw column fitted with glycol chilled condensers, thermowells containing thermometers, and a magnet operated reflux controller regulated by electronic timer. One neck of the base pot was fitted with a rubber septum, and a low flow N2 purge was bubbled into the base mixture by means of an 18″ long, 20-gauge steel thermometer. Batch distillation was conducted at 70 torr vacuum with a reflux rate of 1:2. Temperature measurement, pressure measurement, and timer control were provided by a Camille Laboratory Data Collection System. Liquid fractions were collected every 20 mL, and the overhead temperature and mass recorded. Overhead temperatures were corrected to atmospheric boiling point by means of the Clausius-Clapeyron Equation to construct the boiling curve presented in
A procedure similar to Example 5 was followed with fractions collected boiling between 60° C. and 230° C. to give a composition of 200 g with a boiling point curve described by
A 250 g sample of r-pyoil with high aromatic content was distilled through a 30-tray glass Oldershaw column fitted with glycol chilled condensers, thermowells containing thermometers, and a magnet operated reflux controller regulated by electronic timer. Batch distillation was conducted at atmospheric pressure with a reflux rate of 1:1. Liquid fractions were collected every 10-20 mL, and the overhead temperature and mass recorded to construct the boiling curve presented in
Table 2 shows the composition of Examples 5-10 by gas chromatography analysis.
The invention is further illustrated by the following steam cracking examples. Examples were performed in a laboratory unit to simulate the results obtained in a commercial steam cracker. A drawing of the lab steam cracker is shown in
Analysis of reaction feed components and products was done by gas chromatography. All percentages are by weight unless specified otherwise. Liquid samples were analyzed on an Agilent 7890A using a Restek RTX-1 column (30 meters×320-micron ID, 0.5 micron film thickness) over a temperature range of 35° C. to 300° C. and a flame ionization detector. Gas samples were analyzed on an Agilent 8890 gas chromatograph. This GC was configured to analyze refinery gas up to C6 with H2S content. The system used four valves, three detectors, 2 packed columns, 3 micro-packed columns, and 2 capillary columns. The columns used were the following: 2 ft× 1/16 in, 1 mm i.d. HayeSep A 80/100 mesh UltiMetal Plus 41 mm; 1.7 m× 1/16 in, 1 mm i.d. HayeSep A 80/100 mesh UltiMetal Plus 41 mm; 2 m× 1/16 in, 1 mm i.d. MolSieve 13×80/100 mesh UltiMetal Plus 41 mm; 3 ft×⅛ in, 2.1 mm i.d. HayeSep Q 80/100 mesh in UltiMetal Plus; 8 ft×⅛ in, 2.1 mm i.d. Molecular Sieve 5A 60/80 mesh in UltiMetal Plus; 2 m×0.32 mm, Sum thickness DB-1 (123-1015, cut); 25 m×0.32 mm, 5 um thickness HP-AL/S (19091P-S12). The FID channel was configured to analyze the hydrocarbons with the capillary columns from C1 to C5, while C6/C6+ components are backflushed and measured as one peak at the beginning of the analysis. The first channel (reference gas He) was configured to analyze fixed gases (such as CO2, CO, O2, N2, and H2S). This channel was run isothermally, with all micro-packed columns installed inside a valve oven. The second TCD channel (third detector, reference gas N2) analyzed hydrogen through regular packed columns. The analyses from both chromatographs were combined based on the mass of each stream (gas and liquid where present) to provide an overall assay for the reactor.
A typical run was made as follows:
Nitrogen (130 sccm) was purged through the reactor system, and the reactor was heated (zone1, zone 2, zone 3 setpoints 300° C., 450° C., 300° C., respectively). Preheaters and cooler for post-reactor liquid collection were powered on. After 15 minutes and the preheater was above 100° C., 0.1 mL/min water was added to the preheater to generate steam. The reactor temperature setpoints were raised to 450° C., 600° C., and 350° C. for zones 1, 2, and 3, respectively. After another 10 minutes, the reactor temperature setpoints were raised to 600° C., 700° C., and 375° C. for zones 1, 2, and 3, respectively. The N2 was decreased to zero as the propane flow was increased to 130 sccm. After 100 min at these conditions either r-pyoil or r-pyoil in naphtha was introduced, and the propane flow was reduced. The propane flow was 104 sccm, and the r-pyoil feed rate was 0.051 g/hr for a run with 80% propane and 20% r-pyoil. This material was steam cracked for 4.5 hr (with gas and liquid sampling). Then, 130 sccm propane flow was reestablished. After 1 hr, the reactor was cooled and purged with nitrogen.
Steam Cracking with r-Pyoil Example 1.
Table 3 contains examples of runs made in the lab steam cracker with propane, r-pyoil from Example 1, and various weight ratios of the two. Steam was fed to the reactor in a 0.4 steam to hydrocarbon ratio in all runs. Nitrogen (5% by weight relative to the hydrocarbon) was fed with steam in the run with only r-pyoil to aid in even steam generation. Comparative Example 1 is an example involving cracking only propane.
As the amount of r-pyoil used is increased relative to propane, there was an increase in the formation of dienes. For example, both r-butadiene and cyclopentadiene increased as more r-pyoil is added to the feed. Additionally, aromatics (C6+) increased considerably with increased r-pyoil in the feed.
Accountability decreased with increasing amounts of r-pyoil in these examples. It was determined that some r-pyoil in the feed was being held up in the preheater section. Due to the short run times, accountability was negatively affected. A slight increase in the slope of the reactor inlet line corrected the issue (see Example 24). Nonetheless, even with an accountability of 86% in Example 15, the trend was clear. The overall yield of r-ethylene and r-propylene decreased from about 50% to less than about 35% as the amount of r-pyoil in the feed increased. Indeed, feeding r-pyoil alone produced about 40% of aromatics (C6+) and unidentified higher boilers (see Example 15 and Example 24).
r-Ethylene Yield—r-Ethylene yield showed an increase from 30.7% to >32% as 15% r-pyoil was co-cracked with propane. The yield of r-ethylene then remained about 32% until >50% r-pyoil was used. With 100% r-pyoil, the yield of r-ethylene decreased to 21.5% due to the large amount of aromatics and unidentified high boilers (>40%). Since r-pyoil cracks faster than propane, a feed with an increased amount of r-pyoil will crack faster to more r-propylene. The r-propylene can then react to form r-ethylene, diene and aromatics. When the concentration of r-pyoil was increased the amount of r-propylene cracked products was also increased. Thus, the increased amount of dienes can react with other dienes and olefins (like r-ethylene) leading to even more aromatics formation. So, at 100% r-pyoil in the feed, the amount of r-ethylene and r-propylene recovered was lower due to the high concentration of aromatics that formed. In fact, the olefin/aromatic dropped from 45.4 to 1.4 as r-pyoil was increased to 100% in the feed. Thus, the yield of r-ethylene increased as more r-pyoil was added to the feed mixture, at least to about 50% r-pyoil. Feeding pyoil in propane provides a way to increase the ethylene/propylene ratio on a steam cracker.
r-Propylene Yield—r-Propylene yield decreased with more r-pyoil in the feed. It dropped from 17.8% with propane only to 17.4% with 15% r-pyoil and then to 6.8% as 100% r-pyoil was cracked. r-Propylene formation did not decrease in these cases. r-Pyoil cracks at lower temperature than propane. As r-propylene is formed earlier in the reactor it has more time to converted to other materials—like dienes and aromatics and r-ethylene. Thus, feeding r-pyoil with propane to a cracker provides a way to increase the yield of ethylene, dienes and aromatics.
The r-ethylene/r-propylene ratio increased as more r-pyoil was added to the feed because an increase concentration of r-pyoil made r-propylene faster, and the r-propylene reacted to other cracked products—like dienes, aromatics and r-ethylene.
The ethylene to propylene ratio increased from 1.72 to 3.14 going from 100% propane to 100% r-pyoil cracking. The ratio was lower for 15% r-pyoil (0.54) than 20% r-pyoil (0.55) due to experimental error with the small change in r-pyoil feed and the error from having just one run at each condition.
The olefin/aromatic ratio decreased from 45 with no r-pyoil in the feed to 1.4 with no propane in the feed. The decrease occurred mainly because r-pyoil cracked more readily than propane and thus more r-propylene was produced faster. This gave the r-propylene more time to react further—to make more r-ethylene, dienes, and aromatics. Thus, aromatics increased, and r-propylene decreased with the olefin/aromatic ratio decreasing as a result.
r-Butadiene increased as the concentration of r-pyoil in the feed increased, thus providing a way to increase r-butadiene yield. r-Butadiene increased from 1.73% with propane cracking, to about 2.3% with 15-20% r-pyoil in the feed, to 2.63% with 33% r-pyoil, and to 3.02% with 50% r-pyoil. The amount was 2.88% at 100% r-pyoil. Example 24 showed 3.37% r-butadiene observed in another run with 100% r-pyoil. This amount may be a more accurate value based on the accountability problems that occurred in Example 15. The increase in r-butadiene was the result of more severity in cracking as products like r-propylene continued to crack to other materials.
Cyclopentadiene increased with increasing r-pyoil except for the decrease in going from 15%-20% r-pyoil (from 0.85 to 0.81). Again, some experimental error was likely. Thus, cyclopentadiene increased from 0.48% cracking propane only, to about 0.85% at 15-20% r-pyoil in the reactor feed, to 1.01% with 33% r-pyoil, to 1.25 with 50% r-pyoil, and 1.58% with 100% r-pyoil. The increase in cyclopentadiene was also the result of more severity in cracking as products like r-propylene continued to crack to other materials. Thus, cracking r-pyoil with propane provided a way to increase cyclopentadiene production.
Operating with r-pyoil in the feed to the steam cracker resulted in less propane in the reactor effluent. In commercial operation, this would result in a decreased mass flow in the recycle loop. The lower flow would decrease cryogenic energy costs and potentially increase capacity on the plant if it is capacity constrained. Additionally, lower propane in the recycle loop would debottleneck the r-propylene fractionator if it is already capacity limited.
Table 4 contains examples of runs made with the r-pyoil samples found in Table 1 with a propane/r-pyoil weight ratio of 80/20 and 0.4 steam to hydrocarbon ratio.
Steam cracking of the different r-pyoil Examples 1˜4 at the same conditions gave similar results. Even the lab distilled sample of r-pyoil (Example 19) cracked like the other samples. The highest r-ethylene and r-propylene yield was for Example 16, but the range was 48.01-49.43. The r-ethylene/r-propylene ratio varied from 1.76 to 1.84. The amount of aromatics (C6+) only varied from 2.62 to 3.11. Example 16 also produced the smallest yield of aromatics. The r-pyoil used for this example (r-Pyoil Example 1, Table 1) contained the largest amount of paraffins and the lowest amount of aromatics. Both are desirable for cracking to r-ethylene and r-propylene.
Table 5 contains runs made in the lab steam cracker with propane (Comparative Example 2), r-pyoil Example 2, and four runs with a propane/pyrolysis oil weight ratio of 80/20. Comparative Example 2 and Example 20 were run with a 0.2 steam to hydrocarbon ratio. Steam was fed to the reactor in a 0.4 steam to hydrocarbon ratio in all other examples. Nitrogen (5% by weight relative to the r-pyoil) was fed with steam in the run with only r-pyoil (Example 24).
Comparing Example 20 to Examples 21-23 shows that the increased feed flow rate (from 192 sccm in Example 20 to 255 sccm with more steam in Examples 21-23) resulted in less conversion of propane and r-pyoil due to the 25% shorter residence time in the reactor (r-ethylene and r-propylene: 49.3% for Example 20 vs 47.1, 48.1, 48.9% for Examples 21-23). r-Ethylene was higher in Example 21 with the increased residence time since propane and r-pyoil cracked to higher conversion of r-ethylene and r-propylene and some of the r-propylene can then be converted to additional r-ethylene. And conversely, r-propylene was higher in the higher flow examples with a higher steam to hydrocarbon ratio (Example 21-23) since it has less time to continue reacting. Thus, Examples 21-23 produced a smaller amount of other components: r-ethylene, C6+(aromatics), r-butadiene, cyclopentadiene, etc., than found in Example 20.
Examples 21-23 were run at the same conditions and showed that there was some variability in operation of the lab unit, but it was sufficiently small that trends can be seen when different conditions are used.
Example 24, like example 15, showed that the r-propylene and r-ethylene yield decreased when 100% r-pyoil was cracked compared to feed with 20% r-pyoil. The amount decreased from about 48% (in Examples 21-23) to 36%. Total aromatics was greater than 20% of the product as in Example 15.
Table 6 contains runs made in the lab steam cracker with propane and r-pyoil Example 3 at different steam to hydrocarbon ratios.
The same trends observed from cracking with r-pyoil Examples 1-2 were demonstrated for cracking with propane and r-pyoil Example 3. Example 25 compared to Example 26 showed that a decrease in the feed flow rate (to 192 sccm in Example 26 with less steam from 255 sccm in Example 25) resulted in greater conversion of the propane and r-pyoil due to the 25% greater residence time in the reactor (r-ethylene and r-propylene: 48.77% for Example 22 vs 49.14% for the lower flow in Example 26). r-Ethylene was higher in Example 26 with the increased residence time since propane and r-pyoil cracked to higher conversion of r-ethylene and r-propylene and some of the r-propylene was then converted to additional r-ethylene. Thus, Example 25, with the shorter residence time produced a smaller amount of other components: r-ethylene, C6+(aromatics), r-butadiene, cyclopentadiene, etc., than found in Example 26.
Table 7 contains runs made in the lab steam cracker with propane and pyrolysis oil sample 4 at two different steam to hydrocarbon ratios.
The results in Table 7 showed the same trends as discussed with Example 20 vs Examples 21-23 in Table 5 and Example 25 vs Example 26 in Table 6. At a smaller steam to hydrocarbon ratio, higher amounts of r-ethylene and r-propylene and higher amounts of aromatics were obtained at the increased residence time. The r-ethylene/r-propylene ratio was also greater.
Thus, comparing Example 20 with Examples 21-23 in Table 5, Example 25 with Example 26, and Example 27 with Example 28 showed the same effect. Decreasing the steam to hydrocarbon ratio decreased the total flow in the reactor. This increased the residence time. As a result, there was an increase in the amount of r-ethylene and r-propylene produced. The r-ethylene to r-propylene ratio was larger which indicated that some r-propylene reacted to other products like r-ethylene. There was also an increase in aromatics (C6+) and dienes.
Table 8 contains the results of runs made in the lab steam cracker with propane (Comparative example 3) and the six r-pyoil samples listed in Table 2. Steam was fed to the reactor in a 0.4 steam to hydrocarbon ratio in all runs.
Examples 30, 33, and 34 were the results of runs with r-pyoil having greater than 35% C4-C7. The r-pyoil used in Example 40 contained 34.7% aromatics. Comparative Example 3 was a run with propane only. Examples 29, 31, and 32 were the results of runs with r-pyoil containing less than 35% C4-C7.
The examples in Table 8 involved using an 80/20 mix of propane with the various distilled r-pyoils. The results were like those in previous examples involving cracking r-pyoil with propane. All the examples produced an increase in aromatics and dienes relative to cracking propane only. As a result, the olefins to aromatic ratio was lower for cracking the combined feeds. The amount of r-propylene and r-ethylene produced was 47.01-48.82% for all examples except for the 46.31% obtained with the r-pyoil with 34.7% aromatic content (using r-pyoil Example 10 in Example 34). Except for that difference, the r-pyoils performed similarly, and any of them can be fed with C-2 to C-4 in a steam cracker. r-Pyoils having high aromatic content like r-pyoil Example 10 may not be the preferred feed for a steam cracker, and a r-pyoil having less than about 20% aromatic content should be considered a more preferred feed for co-cracking with ethane or propane.
Steam Cracking r-Pyoil with Ethane
Table 9 shows the results of cracking ethane and propane alone, and cracking with r-pyoil Example 2. The examples from cracking either ethane or ethane and r-pyoil were operated at three Zone 2 control temperatures: 700° C., 705° C., and 710° C.
A limited number of runs with ethane were made. As can be seen in the Comparative Examples 5-7 and Comparative Example 3, conversion of ethane to products occurred more slowly than with propane. Comparative Example 5 with ethane and Comparative Example 3 with propane were run at the same molar flow rates and temperatures. However, conversion of ethane was only 52% (100%-46% ethane in product) vs 75% for propane. However, the r-ethylene/r-propylene ratio was much higher (67.53 vs 1.65) as ethane cracking produced mainly r-ethylene. The olefin to aromatics ratio for ethane cracking was also much higher for ethane cracking. The Comparative Examples 5-7 and Examples 41-43 compare cracking ethane to an 80/20 mixture of ethane and r-pyoil at 700° C., 705° C. and 710° C. Production of total r-ethylene plus r-propylene increased with both ethane feed and the combined feed when the temperature was increased (an increase from about 46% to about 55% for both). Although the r-ethylene to r-propylene ratio decreased for ethane cracking with increasing temperature (from 67.53 at 700° C. to 60.95 at 705° C. to 54.13 at 710° C.), the ratio increased for the mixed feed (from 20.59 to 24.44 to 28.66). r-Propylene was produced from the r-pyoil and some continued to crack generating more cracked products such as r-ethylene, dienes and aromatics. The amount of aromatics in propane cracking with r-pyoil at 700° C. (2.86% in Comparative Example 8) was about the same as cracking ethane and r-pyoil at 710° C. (2.79% in Example 43).
Co-cracking ethane and r-pyoil required higher temperature to obtain more conversion to products compared to co-cracking with propane and r-pyoil. Ethane cracking produced mainly r-ethylene. Since a high temperature was required to crack ethane, cracking a mixture of ethane and r-pyoil produced more aromatics and dienes as some r-propylene reacted further. Operation in this mode would be appropriate if aromatics and dienes were desired with minimal production of r-propylene.
About 13,000 gallons from tank 1012 of r-pyoil were used in the plant test as show in
For the testing coils, propane flow 1054a and 1054b were controlled and measured independently. Steam flow 1058a and 1058b were either controlled by Steam/HC ratio controller or in an AUTO mode at a constant flow, depending on the objective of the test. In the non-testing coils, the propane flow was controlled in AUTO mode and steam flow was controlled in a ratio controller at Steam/Propane=0.3.
r-pyoil was obtained from tank 1012 through r-pyoil flow meters and flow control valves into propane vapor lines, from where r-pyoil flowed along with propane into the convection section of the furnace and further down into the radiant section also called the firebox.
The r-pyoil properties are shown in and Table 10 and
Before the plant test started, eight (8) furnace conditions (more specifically speaking, eight conditions on the testing coils) were chosen. These included r-pyoil content, coil outlet temperature, total hydrocarbon feeding rate, and the ratio of steam to total hydrocarbon. The test plan, objective and furnace control strategy are shown in Table 12. “Float Mode” means the testing coil outlet temperature is not controlling the furnace fuel supply. The furnace fuel supply is controlled by the non-testing coil outlet temperature, or the coils that do not contain r-pyoil.
Effect of Addition of r-Pyoil
The results of r-Pyoil addition can be observed differently depending on how propane flow, steam/HC ratio and furnace are controlled. Temperatures at crossover and coil outlet changed differently depending on how propane flow and steam flow are maintained and how the furnace (the fuel supply to the firebox) was controlled. There were six coils in the testing furnace. There were several ways to control the furnace temperature via the fuel supply to the firebox. One of them was to control the furnace temperature by an individual coil outlet temperature, which was used in the test. Both a testing coil and a non-testing coil were used to control the furnace temperature for different test conditions.
In order to check the r-pyoil 1052a addition effect, propane flow and steam/HC ratio were held constant, and furnace temperature was set to control by a non-testing coil (Coil-C) outlet temperature. Then r-pyoil 1052a, in liquid form, without preheating, was added into the propane line at about 5% by weight.
Temperature changes: After the r-pyoil 1052a addition, the crossover temperature dropped about 10° F. for A and B coil, COT dropped by about 7° F. as shown in Table 13. There are two reasons that the crossover and COT temperature dropped. One, there was more total flow in the testing coils due to r-pyoil 1052a addition, and two, r-pyoil 1052a evaporation from liquid to vapor in the coils at the convection section needed more heat thus dropping the temperature down. With a lower coil inlet temperature at the radiant section, the COT also dropped. The TLE exit temperature went up due to a higher total mass flow through the TLE on the process side.
Cracked gas composition change: As can be seen from the results in Table 13, methane and r-ethylene decreased by about 1.7 and 2.1 percentage points, respectively, while r-propylene and propane increased by 0.5 and 3.0 percentage points, respectively. The propylene concentration increased as did the propylene:ethylene ratio relative to the baseline of no pyoil addition. This was the case even though the propane concentration also increased. Others did not change much. The change in r-ethylene and methane was due to the lower propane conversion at the higher flow rate, which was shown by a much higher propane content in the cracked gas.
In order to check how the temperatures and crack gas composition changed when the total mass of hydrocarbons to the coil was held constant while the percent of r-pyoil 1052a in the coil varied, steam flow to the testing coil was held constant in AUTO mode, and the furnace was set to control by a non-testing coil (Coil-C) outlet temp to allow the testing coils to be in Float Mode. The r-pyoil 1052a, in liquid form, without preheating, was added into propane line at about 5, 10 and 15% by weight, respectively. When r-pyoil 1052a flow was increased, propane flow was decreased accordingly to maintain the same total mass flow of hydrocarbon to the coil. Steam/HC ratio was maintained at 0.30 by a constant steam flow.
Temperature Change: As the r-pyoil 1052a content increased to 15%, crossover temperature dropped modestly by about 5° F., COT increased greatly by about 15° F., and TLE exit temperature just slightly increased by about 3° F., as shown in Table 14A.
Cracked gas composition change: As r-pyoil 1052a content in the feed increased to 15%, methane, ethane, r-ethylene, r-butadiene and benzene in cracked gas all went up by about 0.5, 0.2, 2.0, 0.5, and 0.6 percentage points, respectively. r-Ethylene/r-propylene ratio went up. Propane dropped significantly by about 3.0 percentage points, but r-propylene did not change much, as shown in Table 14A. These results showed the propane conversion increased. The increased propane conversion was due to the higher COT. When the total hydrocarbon feed to coil, steam/HC ratio and furnace fuel supply are held constant, the COT should go down when crossover temperature drops. However, what was seen in this test was opposite. The crossover temperature declined but COT went up, as shown in Table 14A. This indicates that r-pyoil 1052a cracking does not need as much heat as propane cracking on the same mass basis.
In the previous test and comparison, effect of r-pyoil 1052a addition on cracked gas composition was influenced not only by r-pyoil 1052a content but also by the change of COT because when r-pyoil 1052a was added, COT changed accordingly (it was set to Float Mode). In this comparison test, COT was held constant. The test conditions and cracked gas composition are listed in Table 14B. By comparing the data in Table 14B, the same trend in cracked gas composition was found as in the case Example 59.2. When r-pyoil 1052a content in the hydrocarbon feed was increased, methane, ethane, r-ethylene, r-butadiene in cracked gas went up, but propane dropped significantly while r-propylene did not change much.
r-Pyoil 1052a in the hydrocarbon feed was held constant at 15% for 2B, and 2C. r-pyoil for 5A and 5B were reduced to 4.8%. The total hydrocarbon mass flow and steam to HC ratio were both held constant.
On cracked gas composition. When COT increased from 1479° F. to 1514° F. (by 35° F.), r-ethylene and r-butadiene in the cracked gas went up by about 4.0 and 0.4 percentage points, respectively, and r-propylene went down by about 0.8 percentage points, as shown in Table 15.
When r-pyoil 1052a content in the hydrocarbon feed was reduced to 4.8%, the COT effect on the cracked gas composition followed the same trend as that with 15% r-Pyoil 1052a.
Steam/HC ratio effect is listed in Table 16A. In this test, r-pyoil 1052a content in the feed was held constant at 15%. COT in the testing coils was held constant in SET mode, while the COTs at non-testing coils were allowed to float. Total hydrocarbon mass flow to each coil was held constant.
On temperature. When steam/HC ratio was increased from 0.3 to 0.5, the crossover temperature dropped by about 17° F. since the total flow in the coils in the convection section increased due to more dilution steam, even though the COT of the testing coil was held constant. Due to the same reason, TLE exit temperature went up by about 13F.
On cracked gas composition. In the cracked gas, methane and r-ethylene were reduced by 1.6 and 1.4 percentage points, respectively, and propane was increased by 3.7 percentage points. The increased propane in the cracked gas indicated propane conversion dropped. This was due to, firstly, a shorter residence time, since in the 4B condition, the total moles (including steam) going into the coils was about 1.3 times of that in 2° C. condition (assuming the average molecular weight of r-pyoil 1052a was 160), and secondly, to the lower crossover temperature which was the inlet temperature for the radiant coil, making the average cracking temperature lower.
On cracked gas composition. In the cracked gas, methane and r-ethylene were reduced by 1.6 and 1.4 percentage points, respectively, and propane was increased
Renormalized cracked gas composition. In order to see what the lighter product composition could be if ethane and propane in the cracked gas would be recycled, the cracked gas composition in Table 16A was renormalized by taking off propane or ethane+propane. The resulting composition is listed in the lower part of Table 16B. It can be seen, olefin (r-ethylene+r-propylene) content went up with steam/HC ratio.
Effect of total hydrocarbon feed flow (Conditions 2C & 3B) An increase in total hydrocarbon flow to the coil means a higher throughput but a shorter residence time, which reduces conversion. With r-pyoil 1052a at 15% in the HC feed, a 10% increase of the total HC feed brought about a slight increase in the propylene:ethylene ratio along with an increase in the concentration of propane without a change in ethane, when COT was held constant. Other changes were seen on methane and r-ethylene. Each dropped about 0.5˜0.8 percentage points. The results are listed in Table 17.
r-pyoil 1052a is successfully co-cracked with propane in the same coil on a commercial scale furnace.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2020/059327 | 11/6/2020 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 62932023 | Nov 2019 | US |
