Fluid catalytic cracking method employing a waste plastic feedstock

Abstract

A method includes introducing one or more waste plastic feedstocks in neat form to a fluid catalyst cracking unit, and processing the one or more waste plastic feedstocks in neat form in the presence of a catalyst under fluidized catalytic cracking conditions.

What is claimed is: 
     
         1 . A method, comprising:
 introducing one or more waste plastic feedstocks in neat form to a fluid catalyst cracking unit; and   processing the one or more waste plastic feedstocks in neat form in the presence of a catalyst under fluidized catalytic cracking conditions.   
     
     
         2 . The method according to  claim 1 , wherein the one or more waste plastic feedstocks comprise one or more polyesters, one or more polyolefins and combinations thereof. 
     
     
         3 . The method according to  claim 1 , wherein the one or more waste plastic feedstocks comprise a low melting point polyethylene. 
     
     
         4 . The method according to  claim 1 , wherein the one or more waste plastic feedstocks comprise a low melting point polyethylene having a melting point of from about 35° C. to about 100° C. 
     
     
         5 . The method according to  claim 1 , wherein the one or more waste plastic feedstocks comprise one or more of a high density polyethylene, a low density polyethylene, a high molecular weight polyethylene, a low molecular weight polyethylene, polypropylene, polystyrene and combinations thereof. 
     
     
         6 . The method according to  claim 1 , wherein introducing the one or more waste plastic feedstocks in neat form to a fluid catalyst cracking unit comprises introducing the one or more waste plastic feedstocks in neat form in a solid state to the fluid catalyst cracking unit. 
     
     
         7 . The method according to  claim 1 , wherein introducing the one or more waste plastic feedstocks in neat form to a fluid catalyst cracking unit comprises introducing the one or more waste plastic feedstocks in neat form in a semi-melted state to the fluid catalyst cracking unit. 
     
     
         8 . The method according to  claim 1 , wherein introducing the one or more waste plastic feedstocks in neat form to a fluid catalyst cracking unit comprises introducing the one or more waste plastic feedstocks in neat form in a melted state to the fluid catalyst cracking unit. 
     
     
         9 . The method according to  claim 1 , wherein the catalyst is a fluid catalytic cracking catalyst. 
     
     
         10 . The method according to  claim 1 , wherein the catalyst is a deactivated fluid catalytic cracking catalyst. 
     
     
         11 . The method according to  claim 1 , wherein the catalyst is a deactivated fluid catalytic cracking catalyst discharged from a fluid catalytic cracking process, the catalyst having deactivating deposits accumulated thereon. 
     
     
         12 . The method according to  claim 11 , wherein the deactivating deposits comprise at least one metal contaminant selected from the group consisting of sodium, potassium, magnesium, calcium, vanadium, nickel, iron, zinc and a mixture thereof. 
     
     
         13 . The method according to  claim 1 , wherein the catalyst has been subjected to a steam treatment. 
     
     
         14 . The method according to  claim 13 , wherein the steam treatment comprises steaming the catalyst under a steam and inert gas atmosphere at a temperature of at least about 500° C. 
     
     
         15 . The method according to  claim 1 , wherein the catalyst is a fresh fluid catalytic cracking catalyst. 
     
     
         16 . The method according to  claim 1 , wherein the catalyst comprises a ZSM-5 catalyst. 
     
     
         17 . The method according to  claim 1 , wherein the fluidized catalytic cracking conditions comprise a temperature of 425° C. to about 650° C., a catalyst regeneration temperature of about 600° C. to about 800° C., a hydrocarbon partial pressure of about 100 to about 1100 kPa, a catalyst-to-oil ratio from about 2:1 to about 20:1, and a catalyst contact time of about 0.1 to about 15 seconds. 
     
     
         18 . The method according to  claim 1 , which is carried out in a fluid catalytic cracking unit. 
     
     
         19 . The method according to  claim 1 , wherein processing the one or more waste plastic feedstocks in neat form in the presence of a catalyst under fluidized catalytic cracking conditions obtains a product stream comprising hydrocarbons. 
     
     
         20 . The method according to  claim 19 , further comprising separating at least one hydrocarbon fraction from the product stream.