Methods and design for production of cracked- naphtha range hydrocarbon from waste carbon materials

Abstract

It is provided a system and process for producing a recycled cracked naphtha product slate comprising gasifying in a gasifier waste material to obtain a crude syngas, the waste material comprising carbon and hydrogen in a molar ratio H:C; cleaning the crude syngas in a cleaning unit to obtain a clean syngas comprising H 2 and CO in a molar ratio H 2 :CO of between 0.5:1 and 5:1; and reacting the clean syngas in a reactor in the presence of a catalyst comprising a mixture of transition metal oxides to obtain the recycled cracked naphtha product slate, wherein the molar ratio H:C is less than 2.5.

1 - 14 . (canceled) 
     
     
         15 . A method of producing a recycled cracked naphtha product slate, the method comprising:
 gasifying a waste material to obtain a crude syngas, the waste material comprising carbon and hydrogen in a molar ratio H:C;   cleaning the crude syngas to obtain a clean syngas comprising H 2  and CO in a molar ratio H 2 :CO of between 0:5:1 and 5:1; and   reacting the clean syngas in the presence of a catalyst comprising a mixture of transition metal oxides to obtain the recycled cracked naphtha product slate,   
       wherein the molar ratio H:C is less than 2.5 
     
     
         16 . The method according to  claim 15 , wherein the waste material is selected from at least one of consisting of municipal solid waste (MSW), commercial solid waste, institutional solid waste, plastic waste, homogenous solid biomass, non-homogeneous solid biomass, and combinations thereof. 
     
     
         17 . The method according to  claim 16 , wherein said waste material is diapers. 
     
     
         18 . The method according to  claim 16 , wherein said waste material is single use waste plastics. 
     
     
         19 . The method according to  claim 15 , further comprising, reforming the crude synthesis gas and/or the clean synthesis gas to adjust the H 2 :CO ratio. 
     
     
         20 . The method according to  claim 15 , wherein cleaning comprises quenching, scrubbing, and adsorbing the crude syngas. 
     
     
         21 . The method according to  claim 15 , wherein the step of cleaning comprises removing at least one of ammonia (NH 3 ), sulfur, chlorine, volatile metals, aromatic tars, tars, fine ashes, and char. 
     
     
         22 . The method according to  claim 15 , further comprising recycling at least a portion of the waste material generated by the reactor to the gasifier. 
     
     
         23 . The method according to  claim 15 , wherein the recycled cracked naphtha product slate comprises less than 10% of methane. 
     
     
         24 . The method according to  claim 15 , wherein the step of reacting the clean syngas is performed at a temperature of between 160° C. and 400° C. and/or at a pressure of between 1 and 100 barg. 
     
     
         25 . (canceled) 
     
     
         26 . The method according to  claim 15 , further comprising separating the recycled cracked naphtha product slate into different hydrocarbon compositions. 
     
     
         27 . The method according to  claim 26 , further comprising separating higher carbon molecules from the recycled cracked naphtha product slate and feeding said higher carbon molecules into a naphtha cracker producing lower olefins, and/or further comprising separating the lighter carbon molecules from the recycled cracked naphtha product slate and mixing said lighter carbon molecules with lower olefins recovered from the naphtha cracker. 
     
     
         28 . (canceled) 
     
     
         29 . A system for producing a recycled cracked naphtha product slate in accordance to the method of claim  1 , the system comprising:
 a gasifier to gasify a waste material comprising carbon and hydrogen in a molar ratio H:C, to produce a crude syngas;   a cleaning unit to clean the crude syngas and produce a clean syngas comprising H 2  and CO in a molar ratio H 2 :CO of between 0.5:1 to 5:1; and   a reactor comprising a catalyst to produce the recycled cracked naphtha product slate from the clean syngas, the catalyst comprising a mixture of transition metal oxides,   wherein the molar ratio H:C in the gasifier is less than 2.5.   
     
     
         30 . The system according to  claim 29 , wherein the waste material is selected from municipal solid waste (MSW), commercial solid waste, institutional solid waste, plastic waste, homogenous solid biomass, non-homogeneous solid biomass, and a combination thereof. 
     
     
         31 . The system according  claim 29 , wherein the gasifier comprises a fluidized bed, a fixed bed, a slurry phase and/or a reforming section. 
     
     
         32 . The system according to  claim 29 , further comprising a storage unit for storing the waste material. 
     
     
         33 . The system according to  claim 29 , further comprising a recycling stream from the reactor to the gasifier. 
     
     
         34 . The system according to  claim 29 , further comprising a separation unit to separate different hydrocarbon components of the recycled cracked naphtha product slate. 
     
     
         35 . The system according to  claim 29 , wherein the catalyst comprises in weight percent 53.16 O, 6.01 Al, 33.22 Si, 2.98 Fe, 0.75 Na and 6.42 K. 
     
     
         36 . The system according to  claim 29 , wherein the catalyst comprises in weight percent 55.5 0, 7.2 Al, 33.2 Si, 3 Fe, 1 Zn, and 0.1 K.