WO2025219166A1

WO2025219166A1 - Producing renewable olefins

Info

Publication number: WO2025219166A1
Application number: PCT/EP2025/059667
Authority: WO
Inventors: Olga OCHKIN-KOENIG; Alexander PIETSCHAK; Stephan A Schunk
Original assignee: BASF SE
Current assignee: BASF SE
Priority date: 2024-04-18
Filing date: 2025-04-09
Publication date: 2025-10-23
Anticipated expiration: 2026-10-18

Abstract

A process and a system to produce renewable olefins from biomass-derived oils are provided.

Description

Producing Renewable Olefins

Field of the Invention

This invention relates to a process and a system to produce renewable olefins from biomass-derived oils.

Background of the Invention

For decades, fossil carbon resources like coal, oil, and gas have been extensively used as the predominant raw material for energy production and petrochemical processes. This has led to an enormous increase of the carbon dioxide concentration in the atmosphere causing global warming and climate change. In view of the finite availability of fossil resources and the urgency to reduce carbon dioxide emissions, there is a high need to replace fossil carbon resources by renewable and recycled carbon resources.

Thus, the production of hydrocarbons, i.e., alkanes, olefins, and aromatics, from renewable and recycled resources like biomass and waste, in particular for the use as fuels and base materials for chemical processes, has been attracting increasing interest. Such bio-based and recycling-based hydrocarbons exhibit a reduced product carbon footprint and reduce the demand for fossil carbon resources.

Animal fats, vegetable oils (e.g., rapeseed, soybean, palm, and camelina oil), waste oils and fats (e.g., used cooking oil, waste animal fats), microbial and algal oils, and fatty acids represent the most important biomass-derived raw materials for bio-based hydrocarbon production. Among the major pathways towards bio-based hydrocarbons is the catalytic hydrotreatment of these mono-, di-, and triglycerides and fatty acids, which includes hydrogenation, decarboxylation, decarbonylation, hydroisomerization, and cracking processes under high temperature and pressure conditions, frequently also including a catalytic isomerization step, resulting in a hydrocarbon mixture comprising n- and isoparaffins, among others. These reaction products may be further separated into gaseous and liquid fractions, which constitute valuable transportation fuels and chemical feedstocks, e.g., as renewable diesel (hydrotreated vegetable oils: HVOs), renewable jet fuel (sustainable aviation fuel: SAF), bio-naphtha (a mixture of hydrocarbons mainly comprising paraffins, e.g. of up to 10 carbon atoms, that can be used - similar to naphtha of fossil origin - as a gasoline blending component or as a chemical feedstock, e.g., for crackers), and other low-boiling hydrocarbons (i.e. mainly C1-4 hydrocarbons, in particular C1-4 alkanes) like bio-based liquefied petroleum gas (LPG; e.g. bio-based butane, propane, and ethane). Further unsaturated bio-based hydrocarbons like olefins and aromatics (in particular ethylene, propylene, C4-olefins, benzene, toluene, and xylenes), which constitute valuable chemical building blocks for further downstream syntheses, are accessible via cracking processes, e.g., steam cracking.

While said product streams are in principle fully bio-based regarding their carbon content, it must be borne in mind that there are at least two process steps which negatively impact the carbon footprint of olefins and aromatics obtained by the above-mentioned route:

Firstly, hydrocarbon cracking requires high temperatures which is often achieved by burning natural gas, above all. Thus, large amounts of carbon dioxide of fossil origin are emitted. To alleviate this problematic side-effect, cracking products of minor relevance for chemical downstream processes, in particular hydrogen and low-boiling hydrocarbons (also termed light hydrocarbons) like Ci-6-alkanes, are co-fed to the cracker furnaces. Secondly, large amounts of hydrogen are needed for the hydrotreatment of the biomass-derived raw materials, e.g., bio-oils, which typically comprise high amounts of oxygenates. To date, however, the predominant production routes of hydrogen are based on fossil resources, mainly on natural gas (above all methane) and other low-boiling hydrocarbons, from which hydrogen may be generated via steam reforming. Thus, the provision of sufficient amounts of hydrogen for bio-oil hydrotreatment may represent a challenge where the use of fossil resources should be avoided for sustainability reasons. In addition, using fossil feedstocks to produce hydrogen increases greenhouse gas emissions of the plant and thus increases the product carbon footprint (carbon intensity) of the products obtained on the basis of said hydrogen. While hydrogen and low-boiling hydrocarbons like Ci-6-alkanes, both obtained as product fractions from the cracking process, might in principle be employed as hydrogen sources, e.g., via reforming, for hydrotreatment purposes, they are often consumed as fuels for the cracker furnaces to reduce the amount of fossil furnace fuels. Thus, there is still a need to improve the carbon footprint of olefins and other cracking products like aromatics.

Summary of the Invention

In a first aspect, the present invention relates to a process for producing olefins, the process comprising the steps

A) providing at least one raw material stream comprising bio-oil;

B) providing hydrogen, wherein at least a part of said hydrogen originates from step D);

C) subjecting said at least one raw material stream comprising bio-oil to catalytic hydrotreatment, wherein said hydrogen is used, to obtain hydrotreated intermediates and separating said hydrotreated intermediates to obtain at least one first intermediate stream comprising bio-naphtha; and

D) subjecting said at least one first intermediate stream comprising bio-naphtha to hydrocarbon cracking, wherein said hydrocarbon cracking is carried out by thermal cracking in a moving bed reactor, to obtain cracking products and separating said cracking products to obtain at least one first product stream comprising olefins, optionally at least one second product stream comprising aromatics, and to obtain at least one first by-product stream comprising hydrogen, optionally at least one second by-product stream comprising low-boiling alkanes.

In a second aspect, the invention relates to a system for producing olefins, the system comprising the units

I) a raw material feeding unit for providing at least one raw material stream comprising bio-oil to unit III);

II) a hydrogen supply unit for receiving at least one first by-product stream comprising hydrogen from unit IV) and for providing hydrogen to unit III);

III) a bio-oil refinery unit for receiving said at least one raw material stream comprising bio-oil from unit I) and for receiving said hydrogen from unit II), for catalytically hydrotreating said at least one raw material stream comprising bio-oil to hydrotreated intermediates, and for separating said hydrotreated intermediates into at least one first intermediate stream comprising bio-naphtha; and IV) a hydrocarbon cracking unit, comprising a moving bed reactor subunit, for receiving said at least one first intermediate stream comprising bio-naphtha from unit III), for cracking said at least one first intermediate stream comprising bio-naphtha to cracking products, and for separating said cracking products into at least one first product stream comprising olefins and at least one first by-product stream comprising hydrogen.

Further aspects of the present invention will become apparent to the person skilled in the art directly from the foregoing and following description.

General Terms and Definitions

The terms "comprise(s)”, "comprising” etc. are inclusive of and may, in a preferred embodiment, be replaced by the terms "consist(s) of', "consisting of' etc.

The term "at least a part of refers to a fraction that is nonzero. It includes any fractions larger than 0 %, in particular it means a fraction of > 10 %, preferably > 20 %, more preferably > 30 %, more preferably > 40 %, more preferably > 50 %, more preferably > 60 %, more preferably > 70 %, more preferably > 80 %, more preferably > 90 %, most preferably 100 %.

Brief Description of the Drawings

FIG 1 : Flow diagram showing a process for co-producing C2-4-olefins, aromatics, and Ci-6-alkanes along with renewable fuels and bio-Cu-HCs from bio-oil and hydrogen.

FIG 2: Flow diagram showing a process for co-producing C2-4-olefins, aromatics, and Ci-6-alkanes along with renewable fuels and bio-Cu-HCs from bio-oil (optionally from biomass) and hydrogen.

FIG 3: Flow diagram showing a process for co-producing C2-4-olefins and aromatics along with renewable fuels and bio-Ci-4-HCs from bio-oil (optionally from biomass) and hydrogen.

FIG 4: Flow diagram showing a process for co-producing C2-4-olefins and aromatics along with renewable fuels and Ci-6-alkanes from bio-oil (optionally from biomass) and hydrogen.

FIG 5: Flow diagram showing a process for co-producing C2-4-olefins and aromatics along with bio-Cu-HCs and C1-6- alkanes from bio-oil (optionally from biomass) and hydrogen.

FIG 6: System for performing the processes according to FIGs 1-2

FIG 7: System for performing the processes according to FIGs 1-5

Legend for FIG 1-7:

0: biomass; 1 : bio-oil; 2: hydrogen; 3: renewable fuels (HVO and/or SAF); 4: bio-naphtha; 5: bio-Ci-4-HCs; 6: diluent and/or recycled feedstock; 7: C2-4-olefi ns; 8: aromatics; 9: Ci^-alkanes; 10: external hydrogen and/or external hydrogen carriers;

20: conversion; 21 : hydrotreatment and separation; 22: hydrocarbon cracking and separation; 23: hydrogen production 101 : raw material feeding unit; 102: hydrogen supply unit; 103: bio-oil refinery; 104: hydrocarbon cracking unit; 105: hydrogen production unit Detailed Description of the Invention

The present invention provides a process and a system for producing olefins, and optionally further cracking products like aromatics, from a raw material stream comprising bio-oil.

The production of renewable olefins and other renewable cracker products may start with the conversion of biomass to bio-oil, e.g., via mechanical operations and chemical processes. Due to its chemical composition, especially due to its high oxygen content, said bio-oil is typically not directly suitable to be used in cracking processes to obtain olefins, aromatics, and other cracking products, but needs to be further refined and/or upgraded, especially catalytically hydrotreated. This hydrotreatment yields hydrocarbons that may be separated into different fractions like renewable fuels (HVO, SAF), bio-naphtha, and bio-based Cu-hydrocarbons (bio-Ci -HCs). Above all bio-naphtha can be utilized as a feedstock for further petrochemical processes, in particular for cracking processes to produce olefins, aromatics, and other cracking products.

It is described herein that bio-naphtha may be subjected to hydrocarbon cracking such that olefins, aromatics, and low- boiling alkanes, in particular methane as well as alkanes of chain lengths of up to six carbon atoms, are formed. As one additional by-product of said cracking process, hydrogen is obtained. Said hydrogen may be used in full or in part for the hydrotreatment of bio-oils to produce the bio-naphtha feedstock for the cracking process along with other hydrocarbons like renewable fuels. Further, if performed as thermal cracking in a moving bed, the hydrocarbon cracking delivers solid carbon as an additional value product.

The products obtained by the process according to the invention may possess favorable sustainability properties, e.g., they may be characterized by a particularly low carbon footprint, in the case of long-lived products even by net-negative carbon dioxide emissions. This is because at least a part of the carbon atoms contained in said products are bio-based. Also, the hydrogen used for the catalytic hydrotreatment of the bio-oil originates at least in part from the bio-based feedstock itself, i.e. , is not of fossil origin, and is obtained from the cracking process itself, i.e., unlike by steam reforming of natural gas, without carbon dioxide process emissions. Further, different from the traditional steam cracking process which is driven by firing fossil fuels like natural gas, the hydrocarbon cracking process according to the invention, in particular thermal cracking in a moving bed, is preferably carried out by electric heating; preferably, renewable energies are used for said heating such that the use of fossil resources and the greenhouse gas emissions may be further reduced or avoided completely. As an additional advantage, the cracking process in a moving bed delivers solid carbon, e.g., in the form of granular carbon, as an additional by-product, which has positive effects in terms of economic efficiency and ecologic impact of the overall process. Solid carbon may be attractive for various further industrial applications, in particular for adsorption processes, like treatment of liquids such as wastewater, purifications of gases such as air or exhaust gases, and filtration processes, as an electrode material, in asphalt production, in gasification processes, for soil improvement, or as a fertilizer.

Moreover, the process of the invention provides also low-boiling hydrocarbons and low-boiling alkanes from the catalytic hydrotreatment and the hydrocarbon cracking, respectively. In the absence of combustion furnaces, typical parts of steam cracking facilities, in which they are often used as fuels, however, said by-products may be used materially rather than energetically. In particular, they may be subjected to hydrogen-producing processes like hydrocarbon reforming or hydrocarbon pyrolysis to provide further amounts of hydrogen and solid carbon that may add to the hydrogen and carbon streams and applications described herein and thus increase the extent of the above-mentioned benefits.

Thus, the process according to the invention allows for a more complete conversion of biomass into value products. In addition, the disclosed process, being in part self-supplying regarding its hydrogen demand, may be particularly advantageous where there is no well-established natural gas or low-boiling hydrocarbon infrastructure which could secure reliable supply of hydrogen or of raw materials for hydrogen production. Similarly, for a moving bed process, the solid carbon deposited on the carrier material may be recovered by appropriate processing (e.g., particle size reduction and re-agglomeration) and recycled to the process as a carrier material.

The present invention furthermore allows for a flexibilization of the overall production pathways, both in terms of feedstock and in terms of product spectrum. In principle, the process is run with biomass and hydrogen to produce olefins and aromatics as main value products, but also renewable fuels, low-boiling hydrocarbons, low-boiling alkanes, and solid carbon as interesting by-products. In case external hydrogen supply is short or no external hydrogen supply is available at all, hydrogen may be produced internally, especially from low-boiling hydrocarbons and alkanes. If, on the other hand, sufficient hydrogen supplies, preferably of sustainable origin, are available from external sources, i.e., from outside the process or system of the invention, the low-boiling hydrocarbons and alkanes may be used differently, e.g., as energy sources or fuels (LPG) for other purposes. Also, by way of handling and employing hydrogen streams from different sources, a hydrogen mixture may be provided that fulfills certain, possibly pre-defined criteria, e.g., sustainability criteria; in particular, a hydrogen mixture may be generated and used that minimizes the product carbon footprint and optimizes energy efficiency. Furthermore, HVO and SAF fractions of the hydrocarbon stream obtained by catalytic hydrotreatment may be either used as renewable fuels or may be fed back to the hydrotreatment process to obtain, by way of hydrocracking as part of the hydrotreatment process, larger amounts of bio-naphtha useful as a cracker feedstock.

Thus, in a first aspect, the present invention provides a process for producing olefins, the process comprising the steps

A) providing at least one raw material stream comprising bio-oil;

Preferred Embodiments

1.1) The process according to the first aspect of the invention.

The sets of preferred embodiments described in the following for the different process steps are intended to further illustrate, but in no way to restrict the present invention as described herein. They represent a suitably structured part of the description and thus support, but do not represent the claims of the present invention.

Bio-oil, as comprised in the at least one raw material stream provided in step A), designates a liquid compound mixture mainly comprising highly oxygenated compounds (e.g., glycerides, esters, carboxylic acids, phenols, alcohols, ketones, aldehydes, furans, and sugars) and water, while its exact composition depends on the biomass feedstocks and the processing steps, from which it is obtained. The term bio-oil includes in particular vegetable oils like rapeseed oil, sunflower oil, soybean oil, corn oil, castor oil, palm oil, jatropha oil, macauba palm (kernel or pulp) oil, and processing residues thereof (like palm fatty acid distillate), waste cooking oils, tall oils, and animal fats; further, the term bio-oil includes in particular oils obtained by thermochemical conversion of biomass, e.g., biomass-derived pyrolysis or hydrothermal liquefaction oils, as well as mixtures thereof.

Bio-oils may be obtained from biomass via different processing steps and routes. The term biomass, as used herein, designates any material of vegetable or animal origin that is in principle suitable to be converted at least into bio-oils. In particular, the term biomass comprises plants or parts thereof like crops, wood, or residues thereof, marine organisms like algae, and bio waste such as organic food waste, e.g., animal fat from meat industry waste, fish fat from fish processing waste, or used cooking oil. For instance, biomass may comprise or be derived from algae, oil crops, oil palms, soybeans, rapeseed, mustard, flax, cottonseed, sunflower, corn, castor beans, hemp, field pennycress, pongamia, jatropha, macauba palm, mahua, camelina, salicornia, carinata, lignocellulose, wood, forestry residues, agricultural residues, crop residues, straw, residues from vegetable oil production, green waste, food waste, and used vegetable cooking oil. Of note, the biomass may be composed of biomass streams from various of the above-mentioned sources.

The processing of biomass into bio-oil may comprise both mechanical and physical operations, like harvesting and collecting as well as crushing, cracking, cutting, shredding, grinding, chipping, milling, extrusion, irradiation, squeezing, pressing, filtering, sieving, adsorption, and thermal treatments such as drying and torrefaction, and chemical processes, like extraction, distillation, thermochemical conversions like pyrolysis or hydrothermal liquefaction, gasification followed by Fischer-Tropsch processes, hydrolysis, saponification, neutralization, ketonization, or hydrogenation. Also, the mechanical, physical, and/or chemical separation of the products and by-products of said operations and processes, in particular the separation of gaseous, liquid, and solid fractions like solid biomass residues and biomass waste, forms part of the processing of biomass into bio-oils. In essence, processing of biomass into bio-oil comprises purification steps, inter alia the removal of all by-products from the bio-oil that are not suitable or are detrimental for further use as a feedstock for subsequent hydrotreatment. The right choice of suitable process steps and operating conditions is mainly dependent on the biomass to be processed; but the one skilled in the art will be familiar with such considerations. In particular, processing biomass into bio-oil suitable for subsequent hydrotreatment may include the removal of solids, ash particles, and/or metal residues, e.g., via filtration and adsorption steps. Further, said processing may include extraction, distillation, neutralization, esterification, and ketonization steps, e.g., to remove water, oxygen-rich species, and/or high-boiling components. Said process steps may also be used to increase the stability and/or the heating value of the bio-oil or to reduce its viscosity and/or its corrosivity.

It is to be understood that processing the biomass into bio-oil may also comprise purification steps, e.g., to remove contaminants or impurities that may be detrimental for the further process steps or for further use of the end products of the process.

Preferred Embodiments

1.2) The process according to any of the preceding embodiments, wherein in step A), said bio-oil is selected from the group consisting of vegetable oils, waste cooking oils, tall oils, animal fats, oils obtained by thermochemical conversion of biomass, and mixtures thereof.

1.3) The process according to the preceding embodiment, wherein in step A), said vegetable oil is selected from the group consisting of rapeseed oil, sunflower oil, soybean oil, corn oil, castor oil, palm oil, jatropha oil, and macauba palm oil and/or said oil obtained by thermochemical conversion of biomass is selected from biomass-derived pyrolysis or hydrothermal liquefaction oils.

1.4) The process according to any of the preceding embodiments, wherein step A) comprises the substeps of

A1) providing biomass; and

A2) processing said biomass into at least one raw material stream comprising bio-oil.

1.5) The process according to embodiment 1.4, wherein in substep A1), the biomass is of vegetable or animal origin or a mixture thereof.

1.6) The process according to any of embodiments 1.4 to 1.5, wherein in substep A1), the biomass is of vegetable origin and preferably comprises or is derived from algae, oil crops, oil palms, soybeans, rapeseed, mustard, flax, cottonseed, sunflower, corn, castor beans, hemp, field pennycress, pongamia, jatropha, macauba palm, mahua, camelina, salicornia, carinata, lignocellulose, wood, forestry residues, agricultural residues, crop residues, residues from vegetable oil production, green waste, food waste, and used vegetable cooking oil; more preferably it comprises or is derived from algae, oil crops, oil palms, soybeans, rapeseed, pongamia, jatropha, macauba palm, camelina, and carinata; most preferably it comprises or is derived from oil palms, soybeans, rapeseed, jatropha, and macauba palm.

1.7) The process according to any of embodiments 1.4 to 1.5, wherein in substep A1), the biomass is of animal origin and preferably comprises or is derived from animal fat, livestock-related products like tallow, fish fat, or food waste.

1.8) The process according to any of embodiments 1.4 to 1.7, wherein in substep A2), said processing comprises mechanical operations and chemical processes, optionally also the separation of the obtained at least one raw material stream comprising bio-oil from any by-products. 1.9) The process according to any of embodiments 1.4 to 1.8, wherein in substep A2), said processing comprises extraction, pyrolysis, and/or hydrothermal liquefaction of the biomass provided in substep A1).

1.10) The process according to any of embodiments 1.4 to 1.9, wherein in substep A2), said processing comprises purification steps applied to the at least one raw material stream comprising bio-oil.

The raw material stream of step A) is typically not directly suitable, e.g., due to its high oxygen content, for many subsequent unit operations like cracking processes to obtain olefins, aromatics, and other cracking products. Thus, there is a need to refine and/or upgrade said raw material stream. In many instances, this is carried out by catalytical hydrotreatment, as described in more detail for step C) hereinafter. Large amounts of hydrogen are typically needed for such catalytic hydrotreatment, i.e., to accomplish the goal of converting bio-oils into hydrotreated intermediates. Most of the available hydrogen currently being derived from fossil sources, the carbon footprint of such hydrotreated intermediates is often negatively impacted by the hydrogen demand. Therefore, preferably, at least a part of the hydrogen needed for hydrotreatment of the raw material stream, especially of bio-oils, is provided from renewable sources such that carbon dioxide emissions are reduced or completely avoided and the carbon footprint of hydrotreated intermediates and products derived therefrom is further reduced; renewable sources of hydrogen include hydrogen-gener- ating processes based on biomass-derived feedstocks (including the hydrogen-generating processes and process steps described herein, see steps D) and E)), reforming and pyrolysis of biogas, cracking of "green” ammonia (i.e., ammonia produced from hydrogen of non-fossil origin), and cracking of "green” methanol (i.e., methanol produced from hydrogen of non-fossil origin) as well as water electrolysis powered by non-fossil, preferably renewable, electricity, e.g., by solar, wind, nuclear, geothermal, or hydropower, or by power generated from waste or biomass. The term "at least a part of the hydrogen” means that a part of the hydrogen needed can still be produced from fossil resources, preferably from natural gas. However, the fraction of hydrogen of fossil origin should be as low as possible; ideally, the hydrogen is obtained exclusively from non-fossil sources. Hydrogen fractions may be determined, calculated, or evaluated on the basis of a certain observation period, production cycle, or batch manufacturing in subsequent process steps.

The hydrogen amounts required for the hydrotreatment of step C) are provided in step B). According to the invention, at least a part of the hydrogen provided in step B) is obtained from subsequent hydrocarbon cracking of hydrotreated intermediates (see step D) as described below), in particular of bio-naphtha as obtained in step C). Further amounts of the required hydrogen may be obtained from subsequent hydrocarbon reforming and/or hydrocarbon pyrolysis (see step E)), in particular of bio-Cu-HCs as obtained in step C). Likewise, Ci-6-alkanes, especially methane, as obtained in step D) described below, may be used as an additional source of hydrogen via hydrocarbon reforming and/or hydrocarbon pyrolysis (see step E)). The hydrogen amounts obtained in steps D) and E) may not be sufficient to meet the demand of step C). Thus, these hydrogen amounts may be complemented with hydrogen from other external, preferably renewable, sources as described above.

Said amounts of hydrogen obtainable from bio-based hydrocarbons in steps D) and E) may be replaced in part and may be complemented, respectively, with hydrogen obtained from other renewable sources as described above. However, at least a part, preferably all, of the hydrogen produced in step D) is provided according to step B). Likewise, at least a part, preferably all, of the hydrogen produced in step E) is provided according to step B).

Preferred Embodiments

1.11) The process according to any of the preceding embodiments, wherein in step B), the mass fraction of said hydrogen that is of fossil origin is < 90 %, preferably < 80 %, more preferably < 70 % more preferably < 60 % more preferably < 50 % more preferably < 40 % more preferably < 30 %, more preferably < 20 %, more preferably < 10 %, most preferably said hydrogen is exclusively of non-fossil origin.

1.12) The process according to any of the preceding embodiments, wherein in step B), at least a part of said hydrogen is of renewable origin, the renewable origin being preferably selected from hydrogen-generating processes based on biomass-derived feedstocks, reforming of biogas, pyrolysis of biogas, cracking of green ammonia, cracking of green methanol, and water electrolysis preferably powered by solar, wind, nuclear, geothermal, or hydropower, or by power generated from waste or biomass.

1.13) The process according to any of the preceding embodiments, wherein in step B), at least a part of said hydrogen originates from the at least one first by-product stream comprising hydrogen obtained in step D).

1.14) The process according to any of the preceding embodiments, wherein in step B), at least a part of said hydrogen originates from step E).

1.15) The process according to any of the preceding embodiments, wherein in step B), at least a part, but not all of said hydrogen originates from external, preferably renewable sources.

1.16) The process according to any of the preceding embodiments, wherein at least a part of the hydrogen obtained in step D) is provided according to step B).

1.17) The process according to any of the preceding embodiments, wherein at least a part of the hydrogen obtained in step E) is provided according to step B).

The raw material stream of step A) is subjected to catalytic hydrotreatment wherein the hydrogen provided in step B) is used; it is encompassed within this disclosure that the raw material stream is hydrotreated either alone or in admixture with other suitable feedstocks, preferably of renewable or recycled origin. The terms renewable and recycled, respectively, refer to the origin of the carbon content of the respective feedstocks; for instance, feedstocks based on resources like biomass are considered to be of renewable origin while feedstocks based on resources like plastic waste are considered to be of recycled origin. When a feedstock mixture is used for hydrotreatment in step C), the mass fraction of the raw material stream of step A) therein should be chosen as high as possible to profit the most from the benefits and advantages of the invention as described herein. The content of carbon atoms originating from biomass can be determined via measurement of the ¹⁴C mole fraction, see e.g., DIN EN 16640:2017-08.

Catalytic hydrotreatment, i.e., chemical operations using hydrogen in the presence of at least one (preferably heterogeneous) catalyst at high temperatures and pressures, is a well-established upgrading technology, e.g., for processing bio-oils, that may include more specifically the processes of hydrogenation, hydrodeoxygenation (as well as the removal of other heteroatoms, e.g., hydrodenitrogenation, hydrodesulfurization, hydrodehalogenation), hydrodemetallation, hydrocracking, and hydroisomerization.

Thus, the resulting hydrotreated intermediates are depleted, in comparison to the raw material stream provided in step A), in at least one respect selected from the group consisting of amount of C-C double bonds, amount of C-C triple bonds, amount of dienes, amount of aromatics, amount of heteroatoms like oxygen, nitrogen, halogens, sulfur, and metals, amount of organic compounds comprising at least one heteroatom, the heteroatoms preferably selected from the group consisting of nitrogen, oxygen, halogens, and sulfur, and/or mass fraction of hydrocarbons comprising more than 9 carbon atoms. The exact composition of the obtained hydrotreated intermediate mixture will depend, for example, on the feedstock composition, the processing conditions, and the catalyst properties. Catalytic hydrotreatment is hence intended to improve the properties and the suitability of the raw material stream comprising bio-oil for further uses, thus, to obtain a more valuable feedstock for successive processing, e.g., in cracking processes. Other reasons for a catalytic hydrotreatment of bio-oils comprise the prevention of fouling in further process steps, the improvement of the physical and chemical (storage) stability, the increase of the heating value, and the provision of feedstocks which are within required specifications for successive unit operations, in particular for successive steam cracking. Such specifications may comprise final boiling point, chemical composition, concentration limits for heteroatoms such as nitrogen, oxygen, or sulfur, viscosity, miscibility, and the like.

Hydrotreatment of bio-oils is typically carried out to obtain valuable renewable hydrotreated intermediates that are suitable for further use, be it as fuels (in particular renewable diesel, renewable jet fuel, and bio-LPG), fuel blendstocks, or as chemical feedstocks (in particular bio-naphtha), e.g., for subsequent steam cracking to obtain olefins and aromatics, among others. Also, hydrotreatment or partial hydrotreatment of bio-oils may be performed to increase their (chemical and/or physical) storage stability or to prevent fouling in further process steps. In any case, the exact composition of the obtained renewable hydrocarbon mixture will depend, for example, on the feedstock composition, the processing conditions, and the catalyst properties.

Catalytic hydrotreatment reactions can be single-phase reactions or multi-phase reactions. Accordingly, different types of reactors can be used for such hydrotreatment reactions, depending for example on the number of phases which must be brought to a reaction, including trickle-bed reactors and fixed bed reactors. Said hydrotreatment can be conducted in a single stage (reactor) or in successive stages (successive reactors) in which case different process conditions, reactor types and catalysts may be employed to achieve an improved result compared to a single stage hydrotreatment. Heterogeneous catalysts employed in hydrotreatment reactions comprise solid catalysts, in particular at least one active metal and a support. The at least one active metal is preferably selected from nickel, cobalt, molybdenum, tungsten, palladium, rhodium, and the like. Combinations of said active metals such as for example nickelmolybdenum, cobalt-molybdenum and the like can also be used. The support in such heterogeneous catalysts may preferably be selected from alumina and silica. Hydrotreatment conditions like temperature, pressure, residence time, reactor type, catalyst type and other parameters depend for example on the type and composition of the feedstock used for the hydrotreatment reaction and the type of the desired hydrotreatment reaction, i.e., which components should be depleted. The one of skill in the art will be familiar with such considerations and will find sufficient guidance in the prior art to select suitable process parameters. In particular, said parameters may be chosen to increase the yield of bio-naphtha over the other hydrocarbons produced. Furthermore, isomerization and cracking steps, in particular hydroisomerization and hydrocracking, of the obtained hydrotreated intermediates may be encompassed in step C) to shift the relative yields of the different fractions in a desired way and/or to improve their properties and performances (e.g., at low temperatures) during further use, e.g., as fuels, fuel blendstocks, or as chemical feedstocks. Said isomerization and cracking processes may run simultaneously or sequentially to the other above-mentioned processes encompassed by catalytic hydrotreatment, e.g., to hydrogenation and/or hydrodeoxygenation. Isomerization may, for example, be carried out as hydroisomerization and/or catalytic isomerization of the bio-naphtha fraction, with or without prior separation, to convert n-paraffins to iso-paraf- fins. Cracking may, for example, be carried out as hydrocracking and/or catalytic cracking of renewable diesel and/or renewable jet fuel fractions, with or without prior separation, e.g., to increase the yield of bio-naphtha and/or bio-Ci-4- HC (like propane) fractions and to decrease the yields of HVO and SAF fractions. To this end, preferably, hydrocarbon fractions with longer alkyl chains such as the HVO and SAF fractions or parts thereof, as obtained by the hydrotreatment of step C), are combined with the raw material stream comprising bio-oil and thus fed back to the hydrotreatment process. This may be particularly attractive when the hydrotreatment process comprises hydrocracking reactions and the yields of short-chain hydrocarbons like bio-naphtha and bio-Ci-4-HCs are to be increased. In hydrocracking reactions, long-chain hydrocarbons (i.e., for instance the HVO and SAF fractions) are broken into shorter hydrocarbons in the presence of hydrogen. Catalytic hydrocracking is typically carried out over bifunctional catalysts in a hydrogen atmosphere at pressures between 40 bar and 200 bar and temperatures between 300 °C and 600 °C. If the process takes place at medium pressure between 40 bar to 80 bar, it is referred to as mild hydrocracking (MHO). The bifunctional catalysts contain a de-/hydrogenation and an acid functionality, e.g., nickel, molybdenum or noble metals on alumina, zeolites, or other aluminosilicates. Hydrocracking methods are for example disclosed in WO 2019/229072 A1, EP 2770040 A2, and US 2013/0116491 A1. Typically, alkanes and alkyl residues having more than 9 carbon atoms are at least partially converted into alkanes and alkyl residues of less carbon atoms and shorter chain lengths.

The hydrotreated intermediates obtained in step C) may be separated into different value products according to established fractionation techniques, especially to obtain separated renewable diesel, renewable jet fuel, bio-naphtha, and/or bio-Ci-4-HC (like propane) fractions. Also, excess hydrogen may be separated from the hydrotreated intermediates and may be recycled as an input to the catalytic hydrotreatment. Depending on the desired output of the overall process and the nature of the subsequent cracking process (see step D) below), said separation of hydrotreated intermediates and hydrogen may be skipped or performed according to a reduced separation scheme. The terms "separation” or "separating” as used herein means the use of chemical and/or physical techniques to generate from one mixture at least two fractions (either specific substances or further sub-mixtures) with differing chemical and/or physical properties; thus, fractionation is included by the term separation. For instance, separation may be performed by distillation using at least one distillation column, at least one thin film evaporator or a combination thereof, preferably using one distillation column. The distillation may be carried out at a temperature in the range of about 0 °C to about 600 °C, more preferably from about 20 °C to about 400 °C, most preferably from about 80 °C to about 250 °C (the temperature ranges refer to atmospheric pressure of 1 .013 bar). The corresponding operating pressure of the at least one distillation column preferably ranges from about 0.001 bar to about 4 bar (abs), more preferably from about 0.001 bar to about 2.0 bar (abs), most preferably from about 0.9 bar to about 1.8 bar (abs). The temperature is adjusted accordingly in case the pressure is A 1.013 bar. Optionally, the distillation unit comprises at least one thin-film evaporator. In thin-film evaporators, the medium to be evaporated or the solution to be concentrated by evaporation, respectively, is applied to the evaporator area as a thin film. Thereby, a short contact time with the heating surface is feasible and thermally unstable liquids and substances, respectively, can be evaporated in such thin-film evaporators. Furthermore, thin-film evaporators can be used for separation tasks if the product accumulating as a residue has poor flow properties and/or is prone to agglutinations. Thin-film evaporation processes are based on the principle of simple distillation according to which the separating capacity of said type of evaporator is limited. Suitable thin-film evaporators are available in various designs, for example as falling-film evaporators or as rotary evaporators.

In addition, as the different hydrotreated intermediate fractions obtained in step C) as described herein may be further utilized in refinery or petrochemical processes, for instance as blendstocks for fuels or as feedstocks for cracking, blending may be a further substep of step C). E.g., for cracking purposes, bio-naphtha may be blended with diluents, i.e., with other hydrocarbons suitable for cracking like fossil naphtha or other intermediate fractions obtained in step C), and/or with recycled feedstocks, i.e., with feedstocks suitable for cracking obtained from waste streams, thus containing recycling content, such as pyrolysis oils and the like. The term "suitable for cracking” designates in particular feedstocks that meet conventional steam cracker specifications or comply with conventional fossil naphtha specifications. Blending of chemical feedstocks is not unusual to improve their characteristics, e.g., to optimize their physical or chemical properties for the intended use, e.g., for further process steps. Also, blending may be necessary to meet the chemical and/or physical specifications of plants, equipment, and catalysts that are utilized to process the feedstock and/or blend further. For blending according to the present invention, the amounts of non-renewable, in particular fossil, feedstocks should be limited to the necessary minimum; in turn, the amounts of bio-based and/or recycled feedstocks should be maximized such that the sustainability properties like bio-based content or recycling content of the products obtained by the process according to the invention are optimized.

Preferred Embodiments

1.18) The process according to any of the preceding embodiments, wherein step C) comprises separating, preferably by distillation, the hydrotreated intermediates into at least two fractions, preferably into at least one first intermediate stream comprising bio-naphtha and at least one second intermediate stream comprising hydrotreated intermediates other than bio-naphtha, preferably renewable diesel and/or renewable jet fuel, or bio-Cu-HCs.

1.19) The process according to any of the preceding embodiments, wherein in step C), at least one second intermediate stream comprising one or more of renewable diesel and/or renewable jet fuel is obtained.

1.20) The process according to any of the preceding embodiments, wherein in step C), at least one second intermediate stream comprising bio-Cu-HCs is obtained.

1.21) The process according to any of the preceding embodiments, wherein step C) further comprises the substeps C1), C2), and/or C3)

C1) optionally combining at least a part of said at least one second intermediate stream comprising one or more of renewable diesel and/or renewable jet fuel with said at least one raw material stream comprising bio-oil to obtain a combined raw material stream,

C2) subjecting said at least one raw material stream comprising bio-oil, said combined raw material stream, and/or at least a part of said at least one second intermediate stream comprising one or more of renewable diesel and/or renewable jet fuel to cracking, especially to hydrocracking, preferably to increase the yield of bio-naphtha;

C3) subjecting said at least one raw material stream comprising bio-oil, said combined raw material stream, and/or at least a part of said at least one first intermediate stream comprising bio-naphtha to isomerization, especially to hydroisomerization, preferably to form iso-paraffins.

1.22) The process according to any of the preceding embodiments, wherein step C) further comprises the substeps C4a) or C4b)

C4a) blending said at least one first intermediate stream comprising bio-naphtha with at least one fuel, e.g., with gasoline, to obtain a fuel blend with improved characteristics;

C4b) blending said at least one first intermediate stream comprising bio-naphtha with at least one diluent like fossil naphtha and/or with at least one recycled feedstock like waste-derived pyrolysis oil to obtain a cracker feedstock blend.

1.23) The process according to embodiment 1.22, wherein in substep C4b), the mass fraction of said at least one first intermediate stream comprising bio-naphtha in the cracker feedstock blend is > 2 %, preferably > 5 %, more preferably > 10 %, more preferably > 20 %, more preferably > 30 %, more preferably > 40 %, more preferably > 50 %, more preferably > 60 %, more preferably > 70 %, more preferably > 80 %, most preferably > 90 %.

1.24) The process according to any of embodiments 1.22 to 1.23, wherein in substep C4b), the mass fraction of fossil naphtha in the cracker feedstock blend is < 98 %, preferably < 95 %, more preferably < 90 %, more preferably < 80 %, more preferably < 70 %, more preferably < 60 %, more preferably < 50 %, more preferably < 40 %, more preferably < 30 %, more preferably < 20 %, most preferably < 10 %.

The intermediate stream comprising bio-naphtha obtained in step C) is subjected to a hydrocarbon cracking process wherein cracking products are formed and separated into different fractions and/or components. Hydrocarbon cracking processes will typically deliver product and by-product streams comprising various hydrocarbons. Typically, hydrocarbon cracking products comprise olefins (in particular C2-4-olefins: ethylene, propylene, butylene isomers, butadiene) and aromatics (in particular Ce-s-aromatics: benzene, toluene, xylene isomers, ethyl benzene, and styrene) as well as low-boiling alkanes (in particular methane as well as alkanes of chain lengths of up to six carbon atoms, in particular of up to four carbon atoms) and hydrogen as by-products; the exact product spectrum and product distribution will depend on the feedstock as well as on the process technologies and parameters applied.

Hydrocarbon cracking technologies comprise thermal cracking in a moving bed reactor, steam cracking, and catalytic cracking, in particular fluid catalytic cracking (FCC), among others. In particular, those processes are preferred in which there is no need or tendency to use the produced low-boiling alkanes or hydrogen as fuels to provide the heat needed for the cracking reactions, e.g., by combustion in cracker furnaces. Therefore, preferably, the hydrocarbon cracking is conducted by thermal cracking in an electric (i.e., electrically heated), preferably heat-integrated, moving bed reactor or by steam cracking with at least one cracker furnaces being heated by electrical power; preferably, the used electricity is of non-fossil, preferably renewable origin, as described hereinbefore. Thus, at least a part of the hydrogen produced can be provided according to step B) and can be used for the catalytic hydrotreatment of step C). Said hydrocarbon cracking processes are known in the art and for example described in G. Alfke, Ullmann's Encyclopedia of Industrial Chemistry, 2012, Chapter "Oil Refining”, pp. 216-245, in H. Zimmermann et al., Ullmann's Encyclopedia of Industrial Chemistry, 2012, Chapter "Ethylene”, pp. 469-515, and the references cited therein.

The utilization of common fractionation, separation, and purification techniques, especially of extraction and distillation steps, allows to obtain hydrocarbon product and by-product streams as described herein.

Preferably, the hydrocarbon cracking reaction is carried out in a moving bed reactor, more preferably in an electrically heated (especially by resistive heating, i.e., Joule heating, of the carrier material), heat-integrated moving bed reactor. Such reactors and processes, are, for instance, described in WO 2018/083002, WO 2019/145279, WO 2020/200522, and WO 2023/057242. The application of moving bed reactors with a direct electrical heating concept via electrodes located along the axis of the reactor enables an efficient heat integration within the reactor as well as an efficient energy supply for the reactions taking place. Therefore, such concepts are well suited for endothermic reactions, such as the cracking of hydrocarbons. Being conducted at comparable temperatures and with comparable reaction times as in steam cracking processes, thermal cracking of hydrocarbons in a moving bed reactor delivers similar products, product spectra and distributions as steam cracking.

By operating the moving bed reactor in counter current mode, i.e., a flow of solid material directed against a flow of a fluid or a fluid mixture, the gaseous educt mixture is preheated after entering the reactor by the hot solid flow directed against it. The required energy of the system is supplied via the electrodes within the reaction zone. The distance of the reaction zone is defined by the distance between the electrodes. The gaseous product mixture leaving the reaction zone is then cooled by the solid material entering the reactor. Therefore, no additional quench to stop the reaction as it is in the case of conventional steam cracking plants is necessary.

The resident time of the gaseous flow within the reaction zone is a crucial parameter affecting the reactor performance. Besides the distance between the electrodes, the residence time depends on a multitude of parameters, such as the mass flow of the gaseous feed, the degree of feed dilution, the temperature in the reactor, the pressure in the reactor, and the voidage within the moving bed. In addition, in case the number of moles changes during the course of the reaction, the residence time is also affected by the progress of the reaction, as the resulting volumetric gas flow changes.

To achieve the desired composition of the product gasflow, defined reaction conditions, including temperature, pressure and residence time, have to be set. This is realized by the selection of optimal design and operating parameters of the moving bed reactor.

The desired value of the residence time is therefore a part of a set of desired reaction conditions, depending on the boundary conditions of the process, such as the feedstock, the desired composition of the product gasflow, the required production capacity and the design specifications of the reactor.

In addition to the cracking products mentioned above, hydrocarbon cracking in a moving bed reactor may deliver solid, high-purity carbon (e.g., as granular carbon) as a by-product, which is favorable both from an economic and an ecologic point of view. The processing and separation of solid carbon is known to the person skilled in the art. The solid carbon may be deposited on the surface of the catalyst and/or carrier material and may be taken off the reactor via the catalyst and/or carrier material. The solid carbon may be separated by a cyclone or a filter and may be post-treated, e.g., subjected to particle size reduction and re-agglomerated, to make it suitable for further utilization, in particular for recycling as a carrier material to the moving bed reactor. Further, the carbon may be purified by washing and/or evaporation techniques.

To increase the yields of olefins and aromatics, said at least one second by-product stream comprising low-boiling alkanes obtained by hydrocarbon cracking may be fed back at least in part to the hydrocarbon cracking process, in particular when said hydrocarbon cracking is carried out as thermal cracking in a moving bed reactor.

Along similar lines, a second intermediate stream comprising bio-Ci-4-HCs obtained in step C) may be used along with said first intermediate stream comprising bio-naphtha for hydrocarbon cracking according to step D), in particular for thermal cracking in a moving bed reactor. Said second intermediate stream may further comprise residual amounts of the hydrogen which was used in excess for the catalytic hydrotreatment of step C). When intermediate streams of step C) comprising bio-naphtha and bio-Cu-HCs (optionally further comprising hydrogen) are to be used for step D) in admixture, their prior separation as part of step C) may be limited to the necessary minimum or skipped completely.

Preferred Embodiments

1.25) The process according to any of the preceding embodiments, wherein in step D) said hydrocarbon cracking is carried out by thermal cracking in a moving bed reactor, and optionally by steam cracking or by fluid catalytic cracking.

1.26) The process according to embodiment 1.25, wherein in step D) said hydrocarbon cracking is carried out by thermal cracking in a moving bed reactor, preferably in an electric heat-integrated moving bed reactor.

1.27) The process according to embodiment 1.25, wherein in step D), said hydrocarbon cracking is carried out by steam cracking, preferably wherein at least one of the steam cracking furnaces is heated electrically.

1.28) The process according to embodiment 1.25, wherein in step D), said hydrocarbon cracking is carried out by fluid catalytic cracking, preferably by electrically heated fluid catalytic cracking.

1.29) The process according to any of the preceding embodiments, wherein in step D), said olefins are selected from the group consisting of C2-4-olefins, preferably from ethylene and propylene.

1.30) The process according to any of the preceding embodiments, wherein in step D), said aromatics are selected from the group consisting of Ce-s-aromatics, preferably from benzene, toluene, and xylenes.

1.31) The process according to any of the preceding embodiments, wherein in step D), said low-boiling alkanes are selected from the group consisting of Ci-6-alkanes, preferably from Cu-alkanes, more preferably from methane and ethane.

1.32) The process according to any of embodiments 1 .25 to 1 .26, wherein in step D), at least one third product stream comprising solid carbon is obtained.

1.33) The process according to any of the preceding embodiments, wherein step D) further comprises

D1) subjecting at least a part of said at least one second intermediate stream comprising bio-Cu-HCs to hydrocarbon cracking, in particular to thermal cracking in a moving bed reactor. 1.34) The process according to any of the preceding embodiments, wherein step D) further comprises

D2) subjecting at least a part of said at least second by-product stream comprising low-boiling alkanes to hydrocarbon cracking, in particular to thermal cracking in a moving bed reactor.

Further process steps

The sequence of process steps described herein does not require adherence to the specified order unless technical requirements dictate otherwise. Generally, the outlined process steps can be performed independently from one another, in any technically feasible sequence, or concurrently. Furthermore, intermediate steps may be integrated before, between, or after the indicated process steps, provided they do not disrupt the overall technical procedure or impede subsequent steps.

Thus, the process according to the invention may in particular comprise further optional steps where needed or advisable to improve the overall performance of the process. In particular, purification and separation steps may be applied to the intermediate streams obtained in step C) as well as to the product and by-product streams obtained in step D) to improve their properties or to meet certain specifications for further process steps.

Also, steps E) and/or F), described hereinafter, may be comprised by the process of the invention.

The hydrogen obtained in step D) may not be available in amounts sufficient to meet the demand of step C). Thus, according to and as described for step B), the hydrogen of step D) may be complemented with hydrogen from other external, preferably renewable, sources. In the alternative, intermediates and by-products of the process according to the invention, preferably methane, but also other low-boiling hydrocarbons, may be used as hydrogen sources: Firstly, catalytic hydrotreatment according to step C) typically delivers an intermediate stream comprising bio-Cu-HCs and, secondly, hydrocarbon cracking according to step D) provides Ci^-alkanes, in particular methane. These low boiling- hydrocarbons may be employed, separately or in admixture, simultaneously or sequentially, as feedstocks to produce hydrogen, e.g., via reforming of hydrocarbons or pyrolysis of hydrocarbons.

Reforming of hydrocarbons is a mature process to produce hydrogen (see, e.g., R. Reimert et al., Gas Production, 2. Processes, in Ullmann's Encyclopedia of Industrial Chemistry, Wiley-VCH, Weinheim 2012. DOI: 10.1002/14356007. o12_o01). The most important hydrocarbon reforming technologies are steam (methane) reforming, partial oxidation, and autothermal reforming (the latter being basically a combination of the former two processes), all of which are well-known to the one of skill in the art. For instance, in steam reforming, methane or other low-boiling hydrocarbons are reacted with steam in the presence of a catalyst under high temperature and high-pressure conditions, whereas in partial oxidation, methane or other low-boiling hydrocarbons are reacted with sub-stoichiometric amounts of oxygen. In both cases, a mixture consisting primarily of hydrogen, carbon monoxide, and relatively small amounts of carbon dioxide is obtained. A subsequent water-gas shift reaction allows for increasing the hydrogen yield further by converting carbon monoxide and water to hydrogen and carbon dioxide. The resulting gas stream may be finally purified by a pressure swing adsorption process to remove remaining impurities like carbon dioxide and to yield essentially pure hydrogen. In hydrocarbon pyrolysis (also referred to as "hydrocarbon decomposition”), low-boiling hydrocarbons, in particular methane ("methane pyrolysis”), e.g., in the form of natural gas or biogas, is decomposed without the involvement of oxygen into hydrogen and solid, high-purity carbon (e.g., as carbon black, carbon powder, or granular carbon). In contrast to reforming, however, no gaseous carbon dioxide is produced, but solid carbon is formed as a by-product, which has a positive effect on economic efficiency and ecologic impact. Further, compared to water electrolysis, methane pyrolysis requires significantly less energy.

Hydrocarbon pyrolysis may be carried out in different ways known to the one skilled in the art (Muradov et al., International Journal Hydrogen Energy 2008, 33, 6804-6839; Abbas et al., International Journal Hydrogen Energy 2010, 35, 1160-1190); Dagle et al.: An Overview of Natural Gas Conversion Technologies for Co-Production of Hydrogen and Value-Added Solid Carbon Products, Report by Argonne National Laboratory and Pacific Northwest National Laboratory (ANL-17/11, PNNL-26726, November 2017): catalytically or thermally, and with heat input via plasma, microwave, heated carrier gas, resistance heating, induction, liquid metal processes, or autothermally, in particular via plasma pyrolysis (WO 2015/116797, WO 2015/116800), metal melting/metal salt melting (WO 2020/161192, WO 2021/183959), moving bed process (US 2982622, WO 2019/145279, WO 2020/200522, WO 2023/057242), (fluidized bed) catalytic process (WO 2011/029144, WO 2016/154666), or partial/pulsed combustion (WO 2020/118417 and US 2022/0185664), the moving bed process being particularly advantageous due to its high efficiency, heat integration, flexibility, and favorable product carbon footprint. These processes differ i.a. in the form of the energy used (thermal, electrical, etc.), the process conditions (temperature, pressure, etc.), the catalysts, and/or auxiliary materials used. The pyrolysis process is preferably heated electrically, even more preferably by resistive heating (Joule heating) of the substrate material (US 2982622, WO 2019/145279, and WO 2020/200522).

The solid carbon type generated in the methane decomposition depends on the reaction conditions, reactor, and heating technology. Examples are carbon black from plasma processes carbon powder from liquid metal processes granular carbon from thermal decomposition in fixed, moving, or fluidized bed reactors.

The processing and separation of solid carbon depends on the chosen pyrolysis technology and is known by the person skilled in the art. For example, in a plasma pyrolysis process, the solid carbon in the form of carbon black is discharged from the reactor with the gas and then separated, e.g., by a cyclone. The solid carbon might be post-treated, e.g., agglomerated. Depending on the process and the metals used, in molten metal pyrolysis, the carbon floats on the melt and is skimmed off or leaves the reactor together with the gas stream and is then separated, e.g., by a filter or cyclone. In addition, a purification step to remove residual metal from the carbon could be required e.g., washing or evaporation. In the catalytic pyrolysis technology and in the fixed and moving bed technology, the solid carbon is deposited on the surface of the catalyst and/or support and taken off the reactor via the catalyst and/or support.

Thus, solid carbon may be separated by a cyclone or a filter and may be post-treated, e.g., to achieve agglomeration; further, the carbon may be purified by washing and/or evaporation techniques to remove, for instance, residual metal contamination. The resulting gas stream comprising hydrogen may be finally purified by a pressure swing adsorption process to remove remaining impurities like hydrogen sulfide, carbon oxides, hydrocarbons, and inert gases like nitrogen, to yield purified hydrogen. Preferred Embodiments

1.35) The process according to any of the preceding embodiments, wherein in step C), at least one second intermediate stream comprising bio-Cu-HCs is obtained; and/or in step D), at least one second by-product stream comprising Ci^-alkanes, in particular methane, is obtained; and wherein the process further comprises step E)

E) subjecting at least a part of said at least one second intermediate stream comprising bio-Cu-HCs and/or at least a part of said at least one second by-product stream comprising Ci-6-alkanes, in particular methane, to hydrogen production to obtain a stream comprising hydrogen.

1.36) The process according to embodiment 1.35, wherein in step E), said hydrogen production is carried out by hydrocarbon reforming, in particular by steam reforming, partial oxidation, or autothermal reforming, preferably by steam reforming, and preferably comprises the substeps E1), E2), and E3)

E1) steam reforming or partial oxidation or autothermal reforming of hydrocarbons, preferably methane, to obtain a first gas stream comprising hydrogen, carbon monoxide, and carbon dioxide;

E2) water-gas shift reaction of the first gas stream of substep E1) to obtain a second gas stream comprising, preferably consisting essentially of, hydrogen and carbon dioxide; and

E3) purification of the second gas stream of substep E2), preferably by pressure swing adsorption, to obtain a third gas stream consisting essentially of hydrogen.

1.37) The process according to embodiment 1.35, wherein in step E), said hydrogen production is carried out by hydrocarbon pyrolysis and preferably comprises the substeps E4), E5), and E6)

E4) hydrocarbon decomposition to obtain a first gas stream comprising hydrogen;

E5) processing of solid carbon, optionally carbon separation, carbon post-treatment, and/or carbon purification, to obtain a carbon stream comprising solid carbon; and

E6) purification of the first gas stream of E4), preferably by pressure swing adsorption, to obtain a second gas stream consisting essentially of hydrogen.

The process according to the invention may also comprise a step of controlling the hydrogen supply, in terms of both sufficient amounts and desired attributes:

The controlling of the hydrogen supply includes the determination of the hydrogen amount needed, i.e., the hydrogen demand, for the catalytic hydrotreatment of step C), which of course depends on the amount, type, composition, and properties (e.g., the oxygen content) of the raw material stream used as well as on the type and goals of the hydrotreatment reaction, i.e., which components should be depleted. Determining the hydrogen demand includes establishing a reasonable amount of excess hydrogen for the catalytic hydrotreatment and taking into account hydrogen amounts that may be recovered after the hydrotreatment step. The term "determination” and the like as used herein refers to the process of reaching a conclusion or result and may encompass means and steps suitable for that purpose, in particular to gather information, including by way of measurements, analysis, research, or investigation, and to use technical considerations and logical reasoning, including process knowledge, mathematical calculations, and computer-aided approaches like simulations and predictions. The one of skill in the art will be aware of such methods and considerations to successfully perform the determination steps described herein.

The controlling of the hydrogen supply further includes the determination of the amount of hydrogen produced in step D), which depends on the amount, type, composition, and properties of the intermediate stream used as well as on the process conditions applied in step D).

Likewise, the controlling of the hydrogen supply includes the determination of the amounts and compositions of the feedstocks available for the hydrogen production of step E), especially the amounts of bio-Cu-HCs from step C) and of Ci-6-alkanes, in particular methane, from step D). Again, these amounts and compositions will depend on the amounts, types, compositions, and properties of the used raw material and intermediate streams, respectively, as well as on the process conditions applied in steps C) and D). Also, these amounts and compositions will depend on the desired output of the different carbon and hydrocarbon species to be delivered from process steps C) and D). On the basis of this information and the process knowledge of the hydrogen production techniques, the one of skill in the art will be able to predict and thus to determine with reasonable accuracy the amounts of hydrogen that are obtainable and are to be expected from the hydrogen production according to step E).

Further, the controlling of the hydrogen supply includes the determination of the amounts of hydrogen available from external sources. This also refers to the determination of the amounts of hydrogen that may be obtained by releasing hydrogen from hydrogen carriers available from external sources and possibly stored within the system according to the invention.

Controlling the hydrogen supply is intended to meet the hydrogen demand of step C) and to ensure a continuous and sufficient hydrogen supply to step C). Thus, said controlling includes the controlling of the supply means to provide hydrogen according to step B), but also the controlling of the supply means to provide bio-Ci-4-HCs from step C) and of Ci-6-alkanes, in particular methane, from step D) to hydrogen production of step E). Controlling supply means may include controlling volumes, flow rates, and the like. Also said controlling includes controlling the processes of the hydrocarbon cracking of step D) and of the hydrogen production of step E) in terms of controlling their hydrogen outputs, e.g., by controlling their process parameters and conditions, as well as controlling the process of hydrogen release from hydrogen carriers that may have been obtained from external sources.

Controlling the hydrogen supply may also be intended to adjust or modify attributes of the cracking products of step D), e.g., of olefins and aromatics, and any downstream products obtained therefrom. In particular, these attributes may be sustainability attributes like product carbon footprint, carbon intensity, greenhouse gas emissions, sustainability certifications, renewable content, bio-based or biogenic content, recycling content, fossil-based content, energy sources used, energy efficiency, and the like. Controlling the hydrogen supply allows for such attribute adjustment or modification due to the different origins of the hydrogen employed, e.g., the feedstock from which it is obtained, the pathway according to which it is produced, or the energy which is used for its production. For instance, said controlling may accordingly be used to minimize the product-carbon footprint or the fossil-based content of cracking products or downstream products obtained therefrom or to optimize their renewable content or energy efficiency. Thus, said controlling may include the assignment of qualitative and/or quantitative attributes, in particular sustainability attributes, to the hydrogen streams of different sources. On this basis, the volumes of the different hydrogen streams may be varied and adjusted to obtain a combined hydrogen stream with desired qualitative and/or quantitative attributes that is then provided to step C). Thus, cracking products and downstream products with pre-defined desired attributes may be produced.

Of note, computer-aided methods and applications may be used to achieve the above-mentioned objectives by allowing for a straightforward, precise, and rapid controlling of the hydrogen supply as described hereinbefore.

Preferred Embodiments

1.38) The process according to any of the preceding embodiments, the process further comprising step F)

F) controlling the hydrogen supply.

1.39) The process according to any of the preceding embodiments, wherein in step C), at least one second intermediate stream comprising bio-Cu-HCs is obtained; and/or in step D), at least one second by-product stream comprising Ci^-alkanes, in particular methane, is obtained; and wherein the process further comprises steps E) and F)

E) subjecting at least a part of said at least one second intermediate stream comprising bio-Cu-HCs and/or at least a part of said at least one second by-product stream comprising Ci-6-alkanes, in particular methane, to hydrogen production to obtain a stream comprising hydrogen;

F) controlling the hydrogen supply.

1.40) The process according to any of embodiments 1 .38 to 1 .39, wherein step F) comprises the substeps

F1) determining the hydrogen demand of step C);

F2) determining the amounts of hydrogen obtainable from step D), from step E) carried out with said at least one second intermediate stream comprising bio-Ci-4-HCs, from step E) carried out with said at least one second byproduct stream comprising Ci-6-alkanes, and from each external source, optionally obtainable by releasing hydrogen from one or more hydrogen carriers; and

F3) controlling supply means for providing said at least one second intermediate stream comprising bio-Cu-HCs and/or said at least one second by-product stream comprising Ci-6-alkanes to step E), controlling steps D) and E), controlling hydrogen release from hydrogen carriers, and controlling supply means for providing hydrogen from steps D), E), and from said hydrogen release to step B), so that a total amount of hydrogen is provided that is sufficient to meet the hydrogen demand as determined in substep F1).

1.41) The process according to any of embodiments 1.38 to 1.40, wherein step F) comprises the substeps

F1 a) determining the hydrogen demand of step C) and defining at least one qualitative and/or quantitative attribute that said hydrogen should fulfill;

F2a) determining the amounts of hydrogen obtainable from step D), from step E) carried out with said at least one second intermediate stream comprising bio-Ci-4-HCs, from step E) carried out with said at least one second by-product stream comprising Ci-6-alkanes, and from each external source, optionally obtainable by releasing hydrogen from one or more hydrogen carriers and assigning at least one qualitative and/or quantitative attribute to said amounts of hydrogen from each of said sources; and

F3a) controlling supply means for providing said at least one second intermediate stream comprising bio-Ci-4- HCs and/or said at least one second by-product stream comprising Ci-6-alkanes to step E), controlling steps D) and E), controlling hydrogen release from hydrogen carriers, and controlling supply means for providing hydrogen from steps D), E), and from said hydrogen release to step B), so that a total amount of hydrogen is provided that is sufficient to meet the hydrogen demand as determined in substep F1 a) and that fulfills the at least one qualitative and/or quantitative attribute as defined in substep F1 a).

Additional process steps may follow to yield further downstream products which means chemicals, chemical materials, related products, monomers, polymers, and polymer products manufactured in successive processing from the cracking products of step D), e.g., from olefins and aromatic hydrocarbons.

In particular, a process step may be comprised for converting the olefins and/or aromatic hydrocarbons, obtained in the above-mentioned cracking and/or subsequent separation steps, and/or any other downstream products obtainable by or obtained by the process as described herein to obtain a chemical material, monomer, polymer, or polymer product.

The publication Prior Art Disclosure; Issue 684; paragraphs [1000] to [8005]; ISSN: 2198-4786; published: February 12, 2024 will be regarded as Reference RF1 , which is incorporated herein by reference in its entirety. Preferably, the downstream product is a product as described in Reference RF1; paragraphs [1000] to [8005], Preferably, the process described herein is further a process for the production of a downstream product.

The converting step to obtain the downstream product preferably comprises one or more step(s) as described below and can be performed by conventional methods well known to a person skilled in the art. The converting step preferably comprises one or more step(s) selected from: recycling, preferably depolymerizing, gasifying, pyrolyzing, and/or steam cracking; and/or purifying, preferably crystallizing, (solvent) extracting, distilling, evaporating, hydrotreating, absorbing, adsorbing and/or subjecting to ion exchanger; and/or assembling, preferably foaming, synthesizing, chemical conversion, chemically transforming, polymerizing and/or compounding; and/or forming, preferably foaming, extruding and/or molding; and/or finishing, preferably coating and/or smoothing.

In addition, the one or more step(s) are described in detail in Reference RF1 ; paragraphs [1000] to [8005],

The term "building block”, as used herein, comprises compounds, which are in a gaseous or liquid state under standard conditions of 0°C and 0.1 MPa. Building blocks are typically used in chemical industry to form secondary products, which provide a higher structural complexity and/or higher molecular weight than the building block on which the secondary product is based. The building block is preferably selected from the group consisting of hydrogen, carbon monoxide, carbon dioxide, ethylene oxide, ethylene glycols, syngas comprising a mixture of hydrogen and carbon monoxide, alkanes, alkenes, alkynes, and aromatic compounds. The alkanes, alkenes, alkynes, and aromatic compounds comprise in particular 1 to 12 carbon atoms, respectively.

The term "monomer”, as used herein, comprises molecules, which can react with each other to form polymer chains by polymerization. The monomer is preferably selected from the group consisting of (meth)acrylic acid, salts of (meth)acrylic acid; in particular sodium, potassium and zinc salts; (meth)acrolein and (meth)acrylates. (Meth)acrylates comprising 1 to 22 carbon atoms are preferred, in particular comprising 1 to 8 carbon atoms. The terms (meth)acrylic acid, (meth)acrolein or (meth)acrylate relate to acrylic acid, acrolein or acrylate and also to methacrylic acid, methacrolein or methacrylate, where applicable. Further, the monomer can be selected from hexamethylenediamine (HMD) and adipic acid.

The building block can further be an intermediate compound. The term "intermediate compound”, as used herein, comprises organic reagents, which are applied for formation of compounds with higher molecular complexity. The intermediate compound can be selected for example from the group consisting of phosgene, polyisocyanates and propylene oxide. The polyisocyanates are in particular aromatic di- and polyisocyanates, preferably toluene diisocyanate (TDI) and/or diphenylmethane diisocyanate (MDI).

The building block and the monomer and typical converting step(s) to obtain the building block or monomer are described in more detail in paragraphs [1000] to [1012] of Reference RF1.

The term "polymer A”, as used herein, comprises thermoplastic, e.g., polyamide or thermoplastic polyurethane, thermoset, e.g., polyurethane, elastomer, e.g., polybutadiene, or a copolymer or a mixture thereof and is defined in more detail in paragraphs [2001] to [2007] of Reference RF1.

The term "polymer composition A”, as used herein, comprises all compositions comprising a polymer as described above and one or more additive(s), e.g. reinforcement, colorant, modifier and/or flame retardant, and is defined in more detail in paragraph [2008] of Reference RF1.

The term "polymer product A”, as used herein, comprises any product comprising the polymer A and/or polymer composition A as described above and is defined in more detail in paragraphs [2009] and [2010] of Reference RF1.

The step(s) to obtain the polymer, preferably polymer A, polymer composition, preferably polymer composition A or polymer product, preferably polymer product A is/are described in more detail in paragraph [2011] of Reference RF1 . The term "industrial use polymer”, as used herein, comprises rheology, polycarboxylate, alkoxylated polyalkylenamine, alkoxylated polyalkylenimine, polyether-based, dye inhibition and soil release cleaning polymers defined in more detail in paragraphs [3035] to [3044] of Reference RF1 . The term "industrial use surfactant”, as used herein, comprises nonionic, anionic and amphoteric industrial use surfactants defined in more detail in paragraphs [3008] to [3034] of Reference RF1. The term "industrial use descaling compound”, as used herein, comprises non-phosphate-based builders (NPB) and phosphonates (CoP) described in more detail in paragraphs [3001] to [3005] of Reference RF1. The term "industrial use biocide”, as used herein, refers to a chemical compound that kills microorganisms or inhibits their growth or reproduction defined in more detail in paragraphs [3006] to [3007] of Reference RF1. The term "industrial use solvent”, as used herein, comprises alkyl amides, alkyl lactamides, alkyl esters, lactate esters, alkyl diester, cyclic alkyl diester, cyclic carbonates, aromatic aldehydes and aromatic esters defined in more detail in paragraphs [3045] to [3055] of Reference RF1 . The term "industrial use dispersant”, as used herein, comprises anionic and non-ionic industrial use dispersants defined in more detail in paragraphs [3056] to [3058] of Reference RF1. The term "composition and/or formulation thereof' with reference to the industrial use polymers, industrial use surfactants, descaling compounds and/or industrial use biocides refers to industrial use compositions and/or institutional use products and/or fabric and home care products and/or personal care products defined in more detail in paragraph [3059] of Reference RF1. The converting step(s) to obtain the industrial use polymer, industrial use surfactant, descaling compound and/or industrial use biocide are defined in more detail in paragraph [3060] of Reference RF1. The converting steps to obtain the industrial use composition or formulation of the industrial use polymer, industrial use surfactant, descaling compound and/or industrial use biocide are defined in more detail in paragraph [3061] of Reference RF1.

The term "agrochemical composition”, as used herein, typically relates to a composition comprising an agrochemically active ingredient and at least one agrochemical formulation auxiliary. Examples of agrochemical compositions, active ingredients and auxiliaries are described in more detail in Reference RF1 , paragraph [4001],

The agrochemical composition may take the form of any customary formulation. The agrochemical compositions are prepared in a known manner, e.g. described by Mollet and Grubemann, Formulation technology, Wiley VCH, Weinheim, 2001 ; or Knowles, New developments in crop protection product formulation, Agrow Reports DS243, T&F Informa, London, 2005. The converting step(s) to obtain the agrochemically active ingredients and auxiliaries may be conducted in analogy to the production step(s) of their analogues that are based on petrochemicals or other precursors that are not gained by recycling processes. In addition, conversion to compounds mentioned in sections "Polymer” and "Cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter, further cosmetic ingredient or compositions or formulations thereof' may be performed as described in these sections as well as the respective paragraphs in Reference RF1.

The term active pharmaceutical ingredients and/or intermediates thereof, as used herein, comprises substances that provide pharmacological activity or other direct effect in the diagnosis, cure, mitigation, treatment, or prevention of disease, or to affect the structure or any function of the body. Intermediates thereof are isolated products that are generated during a multi-step route of synthesis of an active pharmaceutical ingredient. The term pharmaceutical excipients, as used herein, comprises compounds or compound mixtures used in compositions for various pharmaceutical applications, which are not substantially pharmaceutically active on itself. Active pharmaceutical ingredients and/or intermediates thereof and pharmaceutical excipients are defined in more detail in paragraph [5001] of Reference RF1 . The converting step(s) to obtain the active pharmaceutical ingredients and/or intermediates thereof and pharmaceutical excipients may comprise one or more synthesis steps and can be performed by conventional synthesis and techniques well known to a person skilled in the art.

The terms animal feed additives, human food additives, dietary supplements, as used herein, comprises Vitamins, Pro- Vitamins and active metabolites thereof including intermediates and precursors, especially Vitamin A, B, E, D, K and esters thereof, like acetate, propionate, palmitate esters or alcohols thereof like retinol or salts thereof and any combinations thereof; Tetraterpenes, especially isoprenoids like carotenoids and xanthophylls including their intermediates and precursors as well as mixtures and derivates thereof, especially beta carotene, Canthaxanthin, Citranaxanthin, Astaxanthin, Zeaxanthin, Lutein, Lycopene, Apo-carotenoids, and any combinations thereof; organic acids, especially formic acid, propionic acid and salts thereof, such as sodium, calcium or ammonium salts, and any combinations thereof, such as but not limited to mixtures of formic acid and sodium formiate, propionic acid and ammonium propionate, formic acid and propionic acid, formic acid and sodium formiate and propionic acid, propionic acid and sodium propionate and formic acid and sodium formiate; glycerides of carboxylic acids and short and medium chain fatty acids, conjugated linoleic acids, such as omega-6 fatty acid (C18:2) methyl ester and 1 ,2-propandiol and beverage stabilizers, such as polyvinylpyrrolidone-polymer or polyvinylimidazole/polyvinylpyrrolidone-copolymer. Animal feed additives, human food additives and dietary supplements are defined in more detail in paragraph [5002] of Reference RF1.

The converting step(s) to obtain the animal feed additives, human food additives, dietary supplements may comprise one or more synthesis steps and can be performed by conventional synthesis and techniques well known to a person skilled in the art.

The terms aroma chemical and aroma composition as used herein, comprise a volatile organic substance with a molecular weight between 70-250 g/mol comprising a functional group with a carbon skeleton of C5-C16 carbon atoms comprising linear, branched, cyclic, for example with a ring size of C5-C18, bicyclic or tricyclic aliphatic chains and but not necessarily one or more unsaturated structural elements like double bonds, triple bonds, aromatics or heteroaromatics and preferably the one or more additional functional groups are selected from alcohol, ether, ester, ketone, aldehyde, acetal, carboxylic acid, nitrile, thiol, amine. In one aspect, the aroma chemical is a terpene-based aroma chemical, for example selected from monoterpenes and monoterpenoids, sesquiterpenes and sesquiterpenoids, diterpenes, triterpenes or tetraterpenes. Aroma chemicals can be combined with further aroma chemicals to give an aroma composition. Aroma chemicals and aroma compositions are defined in more detail in paragraph [5003] of Reference RF1.

The converting step(s) to obtain the aroma chemical and aroma composition may comprise one or more synthesis steps and can be performed by conventional synthesis and techniques well known to a person skilled in the art.

The term "aqueous polymer dispersion”, as used herein, comprises aqueous composition(s) comprising dispersed polymer(s) and is defined in more detail in the section [6001] entitled "aqueous polymer dispersion” of Reference RF1 . The dispersed polymer(s) may be selected from acrylic emulsion polymer(s), styrene acrylic emulsion polymer(s), styrene butadiene dispersion(s), aqueous dispersion(s) comprising composite particles, acrylate alkyd hybrid disper- sion(s), polyurethane(s) (including UV-curable polyurethanes) and polyurethane - poly(meth)acrylate hybrid poly- mer(s). The term "emulsion polymer”, as used herein, comprises polymer(s) made by free-radical emulsion polymerization. Aqueous polyurethane dispersion(s) are defined in more detail in the section [6002] entitled "Polyurethane dispersions” of Reference RF1. UV-curable polyurethane(s) is/are defined in more detail in the section [6017] of Reference RF1. Polyurethane - poly(meth)acrylate hybrid polymer(s) is/are defined in more detail in the section [6016] of Reference RF1.

The term "polymeric dispersant”, as used herein, comprises preferably polymer(s) comprising polyether side chain, in particular polycarboxylate ether polymer(s) and polycondensation product(s) defined in more detail in paragraph [6020] entitled "Polymeric dispersant” of Reference RF1.

The converting (polymerization) step(s) to obtain the aqueous polymer dispersion(s) comprising emulsion polymer(s) is/are defined in more detail in the section [6003] entitled "Emulsion polymerization” of Reference RF1.

The converting (polymerization) step(s) to obtain the aqueous polyurethane dispersion(s) is/are defined in more detail in the section [6014] entitled "Process for the preparation of aqueous polyurethane dispersions” and section [6017)] entitled "Aqueous UV-curable polyurethane dispersions, their preparation and use and compositions containing them” of Reference RF1.

Composition(s) and uses of aqueous polymer dispersion(s) and of polymeric dispersant(s) are defined in more detail in the following sections of Reference RF1 : section [6004] entitled "Uses of aqueous polymer dispersions”, section [6005] entitled "Binders for architectural and construction coatings” section [6006] entitled "Binders for paper coating” section [6007] entitled "Binders for fiber bonding” section [6008] entitled "Adhesive polymers and adhesive compositions” section [6015] entitled "Aqueous polyurethane dispersions suitable for use in coating compositions” section [6016] entitled "Aqueous polyurethane - poly(meth)acrylate hybrid polymer dispersions suitable for use in coating compositions” section [6017] entitled "Aqueous UV-curable polyurethane dispersions, their preparation and use and compositions containing them” section [6018] entitled "Inorganic binder compositions comprising polymeric dispersants and their use” [6019] 100% curable coating compositions

UV-crosslinkable poly(meth)acrylate(s) and its/their uses are defined in more detail in section [6009] entitled "UV- crossli nkable poly(meth)acrylates for use in UV-curable solvent-free hotmelt adhesives and their use for making pressure-sensitive self-adhesive articles” of Reference RF1.

Polyisocyanate(s), composition(s) comprising them and their uses are defined in more detail in section [6010] entitled "Polyisocyanates” of Reference RF1.

Hyperbranched polyester polyol(s) and its/their uses are defined in more detail in section [6011] entitled "Organic solvent based hyperbranched polyester polyols suitable for use in coating compositions” of Reference RF1. The converting step(s) to obtain the hyperbranched polyester polyols is/are defined in more detail in the section [6012] entitled "Preparation of organic solvent based hyperbranched polyester polyols” of Reference RF1. Coating composition(s) comprising hyperbranched polyester polyol (s), polyisocyanate(s) and additive(s) and substrate(s) coated therewith are defined in more detail in section [6013] entitled "Organic solvent based two component coating compositions comprising hyperbranched polyester polyols and polyisocyanates” of Reference RF1.

Unsaturated polyester polyol(s), solvent-based coating composition(s) comprising said unsaturated polyester polyol(s) and substrate(s) for coating with said coating composition(s) are defined in more detail in section [6018] entitled "Organic solvent-based coating composition comprising unsaturated polyester polyols” of Reference RF1.

100% curable coating composition(s) is/are defined in more detail in section [6019] of Reference RF1.

Polymeric dispersant(s) for inorganic binder compositions is/are defined in more detail in section [6020] of Reference RF1 . The inorganic binder composition(s) comprising the polymeric dispersants and their use are defined in more detail in section [6021] of Reference RF1. The converting step(s) to obtain the polymeric dispersant(s) are defined in more detail in section [6020] of Reference RF1. The term "inorganic binder composition” comprising the polymeric disper- sant(s), as used herein, comprises preferably in particular hydraulically setting compositions and compositions comprising calcium sulfate and is defined in more detail in section [6021] of Reference RF1 entitled "Inorganic binder compositions comprising the polymeric dispersant and their use”. Specific building material formulation(s) comprising polymeric dispersant(s) or building product(s) produced by a building material formulation comprising a polymeric dispersant are disclosed in more detail in section [6021] of Reference RF1.

The term "cosmetic surfactant”, as used herein, comprises non-ionic, anionic, cationic and amphoteric surfactants and is defined in more detail in paragraph [7002] of Reference RF1. The term "emollient”, as used herein, refers to a chemical compound used for protecting, moisturizing, and/or lubricating the skin and is defined in more detail in paragraph [7003] of Reference RF1. The term "wax”, as used herein, comprises pearlizers and opacifiers and is defined in more detail in paragraph [7004] of Reference RF1. The term "cosmetic polymer”, as used herein, comprises any polymer that can be used as an ingredient in a cosmetic formulation and is defined in more detail in paragraph [7005] of Reference RF1. The term "UV filter”, as used herein, refers to a chemical compound that blocks or absorbs ultraviolet light and is defined in more detail in paragraph [7006] of Reference RF1. The term "further cosmetic ingredient”, as used herein, comprises any ingredient suitable for making a cosmetic formulation. Several sources disclose cosmetically acceptable ingredients. E. g. the database Cosing on the internet pages of the European Commission discloses cosmetic ingredients and the International Cosmetic Ingredient Dictionary and Handbook, edited by the Personal Care Products Council (PCPC), discloses cosmetic ingredients. The term "composition and/or formulation thereof” with reference to the cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter and/or further cosmetic ingredient refers to personal care and/or cosmetic compositions or formulations defined in more detail in paragraph [7007] of Reference RF1. The converting step(s) to obtain the cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter or further cosmetic ingredient is/are defined in more detail in paragraph [7008] of Reference RF1.

The terms "polymer B”, "polymer composition B”, "coating composition”, "other functional composition”, "foil”, "molded body”, "coating” and "coated substrate” are well known to the person skilled in the art and are defined in more detail from paragraph [8000] to [8005] of Reference RF1.

Preferred embodiments

1.42) A process for producing at least one downstream product, the process comprising the process according to any of the preceding embodiments and further comprising step G)

G) converting at least one first product stream comprising olefins obtained in step D) and/or at least one second product stream comprising aromatics obtained in step D) to obtain at least one downstream product.

1.43) The process according to embodiment 1.42, wherein the downstream product is selected from

I) building block or monomer; or ii) polymer, preferably polymer A, polymer composition, preferably polymer composition A, or polymer product, preferably polymer product A; or ill) cleaning polymer, cleaning surfactant, descaling compound, cleaning biocide or composition or formulation thereof; or iv) agrochemical composition, agrochemical formulation auxiliary or agrochemically active ingredient; or v) active pharmaceutical ingredient or intermediate thereof, pharmaceutical excipient, animal feed additive, human food additive, dietary supplements, aroma chemical or aroma composition; or vi) aqueous polymer dispersion, preferably polyurethane or polyurethane - poly(meth)acrylate hybrid polymer dispersion, emulsion, binder for paper and fiber coatings, UV-curable acrylic polymer for hot melts and coatings polyisocyanates, hyperbranched polyester polyol, polymeric dispersant for inorganic binder compositions, unsaturated polyester polyol or 100% curable composition; or vii) cosmetic surfactant, emollient, wax, cosmetic polymer, UV filter, further cosmetic ingredient or composition or formulation thereof; or viii) polymer B, polymer composition B, coating composition, other functional composition, foil, molded body, coating or coated substrate.

1 .44) The process according to any of embodiments 1 .42 to 1.43, wherein the content of the bio-naphtha obtained from step C) and/or of the bio-Cu-HCs obtained from step C) in the downstream product is 1 weight-% or more, preferably 2 weight-% or more, more preferably 5 weight-% or more, more preferably 15 weight-% or more, more preferably 30 weight-% or more, more preferably 40 weight-% or more, more preferably 60 weight-% or more, more preferably 80 weight-% or more, more preferably 90 weight- % or more, more preferably 95 weight-% or more; and/or wherein the content of the bio-naphtha obtained from step C) and/or of the bio-Cu-HCs obtained from step C) in the downstream product is 100 weight-% or less, preferably 95 weight-% or less, more preferably 90 weight-% or less, more preferably 50 weight-% or less, more preferably 25 weight-% or less, more preferably 10 weight-% or less; and preferably wherein the content is determined based on identity preservation and/or segregation and/or mass balance and/or book and claim chain of custody models, preferably based on mass balance, preferably the International Sustainability and Carbon Certification (ISCC) standard.

Further embodiments of the first aspect of the disclosure are described by the combination of any and each of the above definitions and embodiments with one another, in particular by way of FIGs 1-5.

FIG 1 depicts a process for the co-production of C2-4-olefins (7), aromatics (8), and Ci-6-alkanes (9) along with renewable fuels (3: HVO and SAF) and bio-Cu-HCs (5) from bio-oil (1) and hydrogen (2). The bio-oil (1) is subjected to hydrotreatment (21) in the presence of hydrogen (2) and subsequent separation to yield fractions like renewable fuels (3: HVO and SAF preferably obtained as two separate fractions), bio-naphtha (4), and bio-Cu-HCs (5). Bio-naphtha (4) is used as a feedstock for hydrocarbon cracking (22), preferably thermal cracking in a moving bed, to obtain C2-4- olefins (7), aromatics (8), and Ci-6-alkanes (9). Also, hydrogen (2) is generated during hydrocarbon cracking (22) that is used for the hydrotreatment process (21). FIG 1 is meant to include the case that not all of the hydrogen (2) obtained by hydrocarbon cracking (22), but only a part thereof is used for hydrotreatment (21).

FIG 2 depicts a process for the co-production of C2-4-olefins (7), aromatics (8), and Ci-6-alkanes (9) along with renewable fuels (3: HVO and SAF) and bio-Cu-HCs (5) from bio-oil (1) (optionally from biomass (0)) and hydrogen (2). The process of FIG 2 differs from the one depicted in FIG 1 by the following optional process steps: The initial step of the process may be the conversion (20) of biomass (0) into bio-oil (1). The bio-naphtha (4) feedstock for hydrocarbon cracking (22), preferably thermal cracking in a moving bed, may be blended with at least one diluent and/or recycled feedstock (6). The hydrogen (2) amounts obtained by hydrocarbon cracking (22) may be complemented with external hydrogen (10), i.e., hydrogen or hydrogen carriers from external, preferably renewable, sources.

FIG 3 depicts a process for the co-production of C2-4-olefins (7) and aromatics (8) along with renewable fuels (3: HVO and SAF) and bio-Cu-HCs (5) from bio-oil (1) (optionally from biomass (0)) and hydrogen (2). The process of FIG 3 differs from the one depicted in FIG 2 by the fact that at least a part of the Ci^-alkanes (9), in particular of methane, is used as a feedstock for hydrogen production (23). Alternatively or additionally at least a part of the Ci-6-alkanes (9) is recycled to hydrocarbon cracking (22).

FIG 4 depicts a process for the co-production of C2-4-olefins (7) and aromatics (8) along with renewable fuels (3: HVO and SAF) from bio-oil (1) (optionally from biomass (0)) and hydrogen (2). The process of FIG 4 differs from the one depicted in FIG 2 by the fact that at least a part of the bio-Cu-HCs (5) is used as a feedstock for hydrogen production (23). Alternatively or additionally at least a part of the bio-Cu-HCs (5) is used as a feedstock for hydrocarbon cracking (22), in which case the prior separation of fractions (4) and (5) may be limited or skipped. Of note, the process of FIG 4 may optionally comprise the additional elements and features of the process of FIG 3.

FIG 5 depicts a process for the co-production of C2-4-olefins (7) and aromatics (8) from bio-oil (1) (optionally from biomass (0)) and hydrogen (2). The process of FIG 5 differs from the one depicted in FIG 2 by the fact that at least a part of the hydrocarbon fractions with longer alkyl chains (i.e., of the renewable fuels (3)), as obtained by hydrotreatment (21), is fed back to the hydrotreatment process (21), in particular if (21) comprises hydrocracking reactions. Of note, the process of FIG 5 may optionally comprise the additional elements and features of the processes of FIG 3 and/or FIG 4.

The different embodiments described herein for the first aspect of the invention apply equally to the further aspects of the invention.

Thus, in a second aspect, the present invention provides a system for producing olefins, the system comprising the units

III) a bio-oil refinery unit for receiving said at least one raw material stream comprising bio-oil from unit I) and for receiving said hydrogen from unit II), for catalytically hydrotreating said at least one raw material stream comprising bio-oil to hydrotreated intermediates, and for separating said hydrotreated intermediates into at least one first intermediate stream comprising bio-naphtha; and

IV) a hydrocarbon cracking unit, comprising a moving bed reactor subunit, for receiving said at least one first intermediate stream comprising bio-naphtha from unit III), for cracking said at least one first intermediate stream comprising bio-naphtha to cracking products, and for separating said cracking products into at least one first product stream comprising olefins and at least one first by-product stream comprising hydrogen. As used herein, the term system refers to an arrangement of units that allows for the exchange of material and/or energy streams between the different units. Said exchange may be accomplished by fluid connections, by pipelines, or by other means of transportation. In particular, said system may be embodied by a production plant, more specifically by an integrated production plant.

Preferred Embodiments

2.1) The system according to the second aspect of the invention.

2.2) The system according to any of the preceding embodiments, wherein the system is a production plant, preferably an integrated production plant.

The sets of preferred embodiments described in the following for the different system units are intended to further illustrate, but in no way to restrict the present invention as described herein. They represent a suitably structured part of the description and thus support, but do not represent the claims of the present invention.

Unit I)

The raw material feeding unit I) is equipped to receive, store, and provide a raw material stream comprising bio-oil to the bio-oil refinery unit III). Thus, it is fluidly connected and arranged upstream to unit III). The terms "arranged upstream” and "arranged downstream”, respectively, as used herein, refer to the direction in which a material stream under consideration is transferred from one unit to another.

The raw material feeding unit may further comprise a biomass conversion subunit that is fed with biomass and is equipped to process said biomass into a raw material stream comprising bio-oil as described for step A) above, including its different embodiments.

Preferred Embodiments

2.3) The system according to any of the preceding embodiments, wherein unit I) is fluidly connected and arranged upstream to unit III).

2.4) The system according to any of the preceding embodiments, wherein unit I) comprises a biomass conversion subunit.

2.5) The system according to embodiment 2.4, wherein said biomass conversion subunit is equipped to carry out mechanical operations and/or chemical processes.

2.6) The system according to any of embodiments 2.4 to 2.5, wherein said biomass conversion subunit is equipped to perform extraction, pyrolysis, and/or hydrothermal liquefaction of biomass.

2.7) The system according to any of embodiments 2.4 to 2.6, wherein said biomass conversion subunit is equipped to yield at least one raw material stream comprising bio-oil.

2.8) The system according to any of embodiments 2.4 to 2.7, wherein said biomass conversion subunit is equipped to carry out separation steps of said at least one raw material stream comprising bio-oil and by-products and/or purification steps of said at least one raw material stream comprising bio-oil.

2.9) The system according to any of the preceding embodiments, wherein unit I) comprises a raw material stream storage subunit. Unit

The hydrogen supply unit II) is equipped to receive hydrogen from different, preferably non-fossil and/or renewable, sources, to store them, and to provide hydrogen to the bio-oil refinery unit III). Hydrogen may be received from internal sources, i.e. from within the process or system according to the invention, or from external sources, i.e. from outside the process or system according to the invention, and may be stored in a hydrogen storage subunit. Said hydrogen may also be received and stored in the form of hydrogen carriers. Hydrogen carriers are substances or materials that can store and release hydrogen in a controlled manner; examples include ammonia, methanol, metal hydrides, organic hydrides, and liquid organic hydrogen carriers. In the case of hydrogen being received in the form of a hydrogen carrier, the hydrogen supply unit may comprise a hydrogen release subunit that is equipped to release hydrogen from a hydrogen carrier. Such processes are well-known to those of skill in the art and include, for instance, cracking of ammonia or cracking of methanol.

The hydrogen supply unit is in particular equipped to receive hydrogen-containing streams from hydrocarbon cracking unit IV) and optional hydrogen production unit V). Thus, it is fluidly connected and arranged downstream to unit IV) and optional unit V) and fluidly connected and arranged upstream to unit III). The hydrogen supply unit may also comprise a purification unit to obtain hydrogen of sufficient quality for use in unit III) from the hydrogen-containing streams of units IV) and V).

Preferred Embodiments

2.10) The system according to any of the preceding embodiments, wherein unit II) is fluidly connected and arranged downstream to unit IV) and to optional unit V).

2.11) The system according to any of the preceding embodiments, wherein unit II) is fluidly connected and arranged upstream to unit III).

2.12) The system according to any of the preceding embodiments, wherein unit II) is equipped to receive hydrogen, optionally in the form of one or more hydrogen carriers, from external sources.

2.13) The system according to any of the preceding embodiments, wherein unit II) comprises a hydrogen storage subunit for storing hydrogen and/or one or more hydrogen carriers.

2.14) The system according to any of the preceding embodiments, wherein unit II) comprises a hydrogen release subunit for releasing hydrogen from one or more hydrogen carriers.

2.15) The system according to any of the preceding embodiments, wherein unit II) comprises a hydrogen purification subunit for obtaining hydrogen from hydrogen-containing streams.

Unit ill)

The bio-oil refinery unit III) is fed with the raw material stream comprising bio-oil from unit I) and with hydrogen from unit II). It is equipped to perform catalytic hydrotreatment of the raw material stream, in particular of bio-oil, and further upgrading, refinery, and/or separation steps, as described for step C) above, including its different embodiments. In particular, unit III) may comprise a distillation subunit to separate the hydrotreated intermediates into at least two fractions. A suitable distillation subunit may comprise at least one distillation column, at least one thin film evaporator or a combination thereof. Preferably, the distillation subunit comprises or consists of one distillation column. Unit III) delivers at least one first intermediate stream comprising bio-naphtha to unit IV) for further cracking processes; likewise, low- boiling hydrocarbons may be delivered either as a part of the first intermediate stream comprising bio-naphtha or as a separate intermediate stream. Thus, unit III) is fluidly connected and arranged downstream to units I) and II) and fluidly connected and arranged upstream to unit IV). Unit III) may also deliver low-boiling hydrocarbons to optional unit V), described hereinafter, to produce additional amounts of hydrogen.

Further, unit III) may be equipped to receive and store other suitable cracking feedstocks like fossil naphtha and feedstocks obtained from waste processing. Said other suitable cracking feedstocks (also referred to as diluents) may be intended to be blended with said at least one first intermediate stream comprising bio-naphtha to generate a blend suitable for further cracking in unit IV) and as described in step D). In this case, unit III) delivers a blend comprising bio-naphtha to unit IV).

Preferred Embodiments

2.16) The system according to any of the preceding embodiments, wherein unit III) is fluidly connected and arranged downstream to units I) and II).

2.17) The system according to any of the preceding embodiments, wherein unit III) is fluidly connected and arranged upstream to unit IV) and to optional unit V).

2.18) The system according to any of the preceding embodiments, wherein unit III) comprises a distillation subunit for separating the hydrotreated intermediates.

2.19) The system according to any of the preceding embodiments, wherein unit III) is equipped to produce at least one second intermediate stream comprising one or more of renewable diesel and/or renewable jet fuel.

2.20) The system according to any of the preceding embodiments, wherein unit III) is equipped to produce at least one second intermediate stream comprising bio-Ci-4-HCs.

2.21) The system according to any of the preceding embodiments, wherein unit III) is equipped to perform cracking, especially hydrocracking, of said at least one raw material stream comprising bio-oil and/or of said at least one second intermediate stream comprising one or more of renewable diesel and/or renewable jet fuel, preferably to increase the yield of bio-naphtha.

2.22) The system according to any of the preceding embodiments, wherein unit III) is equipped to perform isomerization, especially hydro-isomerization, of said at least one raw material stream comprising bio-oil and/or of said at least one first intermediate stream comprising bio-naphtha, preferably to form iso-paraffins.

2.23) The system according to any of the preceding embodiments, wherein unit III) comprises a diluent storage subunit for storing at least one diluent like fossil naphtha and/or at least one recycled feedstock like waste-derived pyrolysis oil.

2.24) The system according to any of the preceding embodiments, wherein unit III) comprises a blending subunit for blending the at least one first intermediate stream comprising bio-naphtha with at least one diluent like fossil naphtha and/or with at least one recycled feedstock like waste-derived pyrolysis oil. Unit

The hydrocarbon cracking unit IV) is fed with the intermediate stream comprising bio-naphtha from unit III). It is equipped to perform hydrocarbon cracking of the intermediate stream, in particular of bio-naphtha, and further separation steps, as described for step D) above, including its different embodiments, to produce one or more product or byproduct streams comprising olefins, aromatics, hydrogen, or low-boiling alkanes, optionally also solid carbon. It may be further equipped to recycle the produced low-boiling alkanes to hydrocarbon cracking. Thus, unit IV) may comprise a moving bed reactor subunit, a steam cracker subunit, or a fluid catalytic cracker subunit. Preferablv, it comprises an electric heating subunit. Further, unit IV) may comprise a separation subunit to separate the cracking products and byproducts into different fractions.

Unit IV) provides hydrogen to unit II) and may deliver low-boiling alkanes to unit V), described hereinafter, to produce additional amounts of hydrogen. Thus, unit IV) is fluidly connected and arranged downstream to unit III) in respect of the intermediate stream and fluidly connected and arranged upstream to unit II) in respect of the hydrogen stream. Further, it may be fluidly connected and arranged upstream to unit V) in respect of the low-boiling alkane stream.

Preferred Embodiments

2.25) The system according to any of the preceding embodiments, wherein unit IV) is fluidly connected and arranged downstream to unit III).

2.26) The system according to any of the preceding embodiments, wherein unit IV) is fluidly connected and arranged upstream to unit II) and to optional unit V).

2.27) The system according to any of the preceding embodiments, wherein unit IV) comprises a moving bed reactor subunit, a steam cracker subunit, and/or a fluid catalytic cracker subunit.

2.28) The system according to any of the preceding embodiments, wherein unit IV) comprises an electric heating subunit.

2.29) The system according to any of the preceding embodiments, wherein unit IV) comprises a separation subunit for separating the cracking products and/or by-products into different fractions.

2.30) The system according to any of the preceding embodiments, wherein unit IV) is equipped to produce at least one first product stream comprising olefins and at least one first by-product stream comprising hydrogen.

2.31) The system according to any of the preceding embodiments, wherein unit IV) is equipped to produce at least one second product stream comprising aromatics and/or at least one second by-product stream comprising low- boiling alkanes.

2.32) The system according to any of the preceding embodiments, wherein unit IV) is equipped to produce at least one third product stream comprising solid carbon.

Further units

The system according to the invention may comprise further units and subunits, e.g., for performing the further process steps described above, like purification and separation of intermediate, product, and/or by-product streams. The hydrogen production unit V) comprises a reforming unit and/or a pyrolysis unit. It is equipped to perform hydrogen production, e.g., hydrocarbon reforming and/or hydrocarbon pyrolysis, as described for step E) above, including its different embodiments. It may be fed with methane and other low-boiling hydrocarbons, in particular with bio-Cu-HCs provided by unit III) and/or with Ci-6-alkanes provided by unit IV) and provides amounts of hydrogen obtained therefrom to unit II), e.g., to the hydrogen storage subunit of unit II). Thus, the hydrogen production unit V) may be fluidly connected and arranged downstream to units III) and/or IV) in respect of the hydrocarbon stream while it is fluidly connected upstream to unit II) in respect of the hydrogen stream.

Preferred Embodiments

2.33) The system according to any of the preceding embodiments, the system further comprising unit V)

V) a hydrogen production unit for receiving at least one second intermediate stream comprising bio-Cu-HCs from unit III) and/or at least one second by-product stream comprising Ci-6-alkanes, in particular methane, from unit IV) and for producing hydrogen from said at least one second intermediate stream and/or from said at least one second by-product stream.

2.34) The system according to embodiment 2.33, wherein unit V) is fluidly connected and arranged downstream to units III) and/or IV).

2.35) The system according to any of embodiments 2.33 to 2.34, wherein unit V) is fluidly connected upstream to unit II).

2.36) The system according to any of embodiments 2.33 to 2.35, wherein unitV) comprises a reforming unit, preferably equipped to perform hydrocarbon reforming by steam reforming, partial oxidation, or autothermal reforming, and/or a pyrolysis unit, preferably equipped to perform hydrocarbon pyrolysis.

2.37) The system according to embodiment 2.36, wherein said reforming unit comprises the subunits Va), Vb), and Vc)

Va) a steam reforming unit or partial oxidation unit or autothermal reforming unit, fluidly connected and arranged downstream to units III) and/or IV), for reforming hydrocarbons, preferably methane, to obtain a first gas stream comprising hydrogen, carbon monoxide, and carbon dioxide;

Vb) a water-gas shift unit, fluidly connected and arranged downstream to unit Vb), for performing the water-gas shift reaction for the first gas stream from unit Vb) to obtain a second gas stream comprising, preferably consisting essentially of, hydrogen and carbon dioxide; and

Vc) a purification unit, fluidly connected and arranged downstream to unit Vb), for purifying the second gas stream from unit Vb), preferably by pressure swing adsorption, to obtain a third gas stream consisting essentially of hydrogen.

2.38) The system according to any of embodiments 2.36 to 2.37, wherein said pyrolysis unit comprises the subunits Vd), Ve), and Vf)

Vd) hydrocarbon decomposition unit, fluidly connected and arranged downstream to units III) and/or IV), for decomposing hydrocarbons, preferably methane, to obtain a first gas stream comprising hydrogen; Ve) solid processing unit, fluidly connected and arranged downstream to unit Vd), for processing solid carbon, optionally comprising a carbon separation unit, a carbon post-treatment unit, and/or a carbon purification unit, to obtain a carbon stream comprising, preferably consisting essentially of, solid carbon; and

Vf) purification unit, fluidly connected and arranged downstream to unit Vd), for purifying the first gas stream from unit Vd), preferably by pressure swing adsorption, to obtain a second gas stream consisting essentially of hydrogen.

The system according to the invention may also comprise a hydrogen supply control unit VI) that is equipped to interact with other units of the system and to carry out the controlling of the hydrogen supply as described above for step F) and its different embodiments. In particular, the hydrogen supply control unit VI) may adjust flow volumes and flow rates between the units of the system such that a continuous and sufficient hydrogen supply for the bio-oil refinery unit III) is ensured and/or the hydrogen provided to unit III) furthermore fulfills certain desired attributes. To this end, it may comprise computer systems to aid in a straightforward, precise, and rapid controlling of the hydrogen supply as described for step F).

Preferred Embodiments

2.39) The system according to any of the preceding embodiments, the system further comprising the unit VI) VI) a hydrogen supply control unit for controlling the hydrogen supply.

2.40) The system according to embodiment 2.39, wherein unit VI) is equipped to interact with units II), III), IV), and V).

2.41) The system according to any of embodiments 2.39 to 2.40, wherein unit VI) is equipped to determine the hydrogen demand of unit III), to determine the amounts of hydrogen obtainable from unit IV), from unit V), and from each external source, optionally obtainable by releasing hydrogen from one or more hydrogen carriers, and to control supply means for providing bio-Cu-HCs from unit III) and/or Ci-6-alkanes from unit IV) to unit V), to control units IV) and V), to control hydrogen release from hydrogen carriers, and to control supply means for providing hydrogen from units IV), V), and from said hydrogen release to unit II), so that a total amount of hydrogen is provided that is sufficient to meet the hydrogen demand of unit III).

Further embodiments of the second aspect of the invention are described by the combination of any and each of the above definitions and embodiments with one another, in particular by way of FIGs 6 and 7.

FIG 6 depicts a system for performing the processes according to FIGs 1-2. A raw material feeding unit (101), optionally after receiving biomass (0), delivers bio-oil (1) to a bio-oil refinery (103). Said bio-oil refinery (103) further receives hydrogen (2) from a hydrogen supply unit (102) and optionally receives diluents and/or recycled feedstocks from external sources. The bio-oil refinery (103) provides renewable fuels (3: HVO and/or SAF) and bio-Cu-HCs (5). Further, the bio-oil refinery (103) delivers bio-naphtha (4) to a hydrocarbon cracking unit (104) which produces C2-4-olefins (7), aromatics (8), and Ci-6-alkanes (9). Hydrogen (2) that is generated in the hydrocarbon cracking unit (104) is provided to the hydrogen supply unit (102) which may be further complemented with hydrogen (2) from external sources, e.g., in the form of hydrogen carriers.

FIG 7 depicts a system for performing the processes according to FIGs 1-5. The system of FIG 7 differs from the one depicted in FIG 6 in that an additional hydrogen production unit (105) is present. The hydrogen plant (105) receives bio-Ci-4-HCs (5) from the bio-oil refinery (103) and/or Ci-6-alkanes (9) from the hydrocarbon cracking unit (104). It produces hydrogen (2) that is provided to the hydrogen supply unit (102). Also, bio-Cu-HCs (5) and Ci-6-alkanes (9) may be fed to the hydrocarbon cracking unit (104).

The systems of FIGs 6 and 7 may further comprise a hydrogen supply control unit as described hereinbefore.

In further aspects, the invention relates to the products obtained by carrying out the processes described herein, in particular to cracking products like olefins and aromatics as well as to any fractions and downstream products thereof like monomers, polymers, or polymer products.

Further embodiments of the different aspects of the invention are described by the combination of any and each of the above definitions and embodiments with one another.

The following set of preferred embodiments further illustrates, but in no way restricts the present disclosure as described herein. Being directed to preferred embodiments, it represents a suitably structured part of the description and thus supports but does not represent the claims of the present disclosure.

Preferred Embodiments

1. A process for producing olefins, the process comprising the steps

A) providing at least one raw material stream comprising bio-oil;

C) subjecting said at least one raw material stream comprising bio-oil to catalytic hydrotreatment, wherein said hydrogen is used, to obtain hydrotreated intermediates and separating said hydrotreated intermediates to obtain at least one first intermediate stream comprising bionaphtha; and

D) subjecting said at least one first intermediate stream comprising bio-naphtha to hydrocarbon cracking to obtain cracking products and separating said cracking products to obtain at least one first product stream comprising olefins, optionally at least one second product stream comprising aromatics, and to obtain at least one first by-product stream comprising hydrogen, optionally at least one second by-product stream comprising low-boiling alkanes.

2. The process according to any of the preceding embodiments, wherein step A) comprises the substeps of

A1) providing biomass; and

A2) processing said biomass into at least one raw material stream comprising bio-oil. 3. The process according to any of the preceding embodiments, wherein in step B), the mass fraction of said hydrogen that is of fossil origin is < 90 %, preferably < 80 %, more preferably < 70 % more preferably < 60 % more preferably < 50 % more preferably < 40 % more preferably < 30 %, more preferably < 20 %, more preferably < 10 %, most preferably said hydrogen is exclusively of non-fossil origin.

4. The process according to any of the preceding embodiments, wherein in step C), at least one second intermediate stream comprising one or more of renewable diesel and/or renewable jet fuel is obtained; and/or step C) further comprises the substeps C1), C2), and/or C3)

C1) optionally combining said at least one second intermediate stream comprising one or more of renewable diesel and/or renewable jet fuel with said at least one raw material stream comprising bio-oil to obtain a combined raw material stream,

C2) subjecting said at least one raw material stream comprising bio-oil, said combined raw material stream, and/or said at least one second intermediate stream comprising one or more of renewable diesel and/or renewable jet fuel to cracking, especially to hydrocracking, preferably to increase the yield of bio-naphtha;

C3) subjecting said at least one raw material stream comprising bio-oil, said combined raw material stream, and/or said at least one first intermediate stream comprising bio-naphtha to isomerization, especially to hydroisomerization, preferably to form iso-paraffins.

5. The process according to any of the preceding embodiments, wherein step C) further comprises the substep C4b) C4b) blending said at least one first intermediate stream comprising bio-naphtha with at least one diluent like fossil naphtha and/or with at least one recycled feedstock like waste-derived pyrolysis oil to obtain a cracker feedstock blend and wherein preferably in substep C4b), the mass fraction of said at least one first intermediate stream comprising bio-naphtha in the cracker feedstock blend is > 2 %, preferably > 5 %, more preferably > 10 %, more preferably > 20 %, more preferably > 30 %, more preferably > 40 %, more preferably > 50 %, more preferably > 60 %, more preferably > 70 %, more preferably > 80 %, most preferably > 90 %.

6. The process according to any of the preceding embodiments, wherein in step D), said hydrocarbon cracking is carried out by thermal cracking in a moving bed reactor, preferably in an electric heat-integrated moving bed reactor.

7. The process according to any of embodiments 1 to 5, wherein in step D), said hydrocarbon cracking is carried out by steam cracking, preferably wherein at least one of the steam cracking furnaces is heated electrically.

8. The process according to any of the preceding embodiments, wherein in step C), at least one second intermediate stream comprising bio-Ci-4-HCs is obtained; and/or in step D), at least one second by-product stream comprising low-boiling alkanes, in particular methane, is obtained; and wherein the process further comprises step E)

E) subjecting at least a part of said at least one second intermediate stream comprising bio-Cu-HCs and/or at least a part of said at least one second by-product stream comprising low-boiling alkanes, in particular methane, to hydrogen production to obtain a stream comprising hydrogen.

9. The process according to embodiment 8, wherein in step B), at least a part of said hydrogen originates from step E).

10. The process according to any of embodiments 8 to 9, wherein in step E), said hydrogen production is carried out by hydrocarbon reforming, in particular by steam reforming, partial oxidation, or autothermal reforming, preferably by steam reforming, and preferably comprises the substeps E1), E2), and E3)

11. The process according to any of embodiments 8 to 10, wherein in step E), said hydrogen production is carried out by hydrocarbon pyrolysis and preferably comprises the substeps E4), E5), and E6)

E4) hydrocarbon decomposition to obtain a first gas stream comprising hydrogen;

12. The process according to any of the preceding embodiments, the process further comprising step F)

F) controlling the hydrogen supply, and wherein preferably step F) comprises the substeps

F1) determining the hydrogen demand of step C);

F3) controlling supply means for providing said at least one second intermediate stream comprising bio-Cu-HCs and/or said at least one second by-product stream comprising Ci-6-alkanes to step E), controlling steps D) and E), controlling hydrogen release from hydrogen carriers, and controlling supply means for providing hydrogen from steps D), E), and from said hydrogen release to step B), so that a total amount of hydrogen is provided that is sufficient to meet the hydrogen demand as determined in substep F1). 13. A process for producing at least one downstream product, the process comprising the process according to any of the preceding embodiments and further comprising step G)

14. A system for producing olefins, the system comprising the units

IV) a hydrocarbon cracking unit for receiving said at least one first intermediate stream comprising bio-naphtha from unit III), for cracking said at least one first intermediate stream comprising bio-naphtha to cracking products, and for separating said cracking products into at least one first product stream comprising olefins and at least one first by-product stream comprising hydrogen.

15. The system according to embodiment 14, the system further comprising unit V)

V) a hydrogen production unit for receiving at least one second intermediate stream comprising bio-Cu-HCs from unit III) and/or at least one second by-product stream comprising Ci-6-alkanes, in particular methane, from unit IV) and for producing hydrogen from said at least one second intermediate stream and/or from said at least one second by-product stream; and the system optionally further comprising unit VI)

VI) a hydrogen supply control unit for controlling the hydrogen supply

Claims

1. A process for producing olefins, the process comprising the steps

A) providing at least one raw material stream comprising bio-oil;

D) subjecting said at least one first intermediate stream comprising bio-naphtha to hydrocarbon cracking, wherein said hydrocarbon cracking is carried out by thermal cracking in a moving bed reactor, preferably in an electric heat-integrated moving bed reactor, to obtain cracking products and separating said cracking products to obtain at least one first product stream comprising olefins, optionally at least one second product stream comprising aromatics, and to obtain at least one first by-product stream comprising hydrogen, optionally at least one second by-product stream comprising low-boiling alkanes.

2. The process according to the preceding claim, wherein in step B), the mass fraction of said hydrogen that is of fossil origin is < 90 %, preferably < 80 %, more preferably < 70 % more preferably < 60 % more preferably < 50 % more preferably < 40 % more preferably < 30 %, more preferably < 20 %, more preferably < 10 %, most preferably said hydrogen is exclusively of non-fossil origin.

3. The process according to any of the preceding claims, wherein in step C), at least one second intermediate stream comprising one or more of renewable diesel and/or renewable jet fuel is obtained; and step C) further comprises the substeps C1), and one or both of C2) and C3)

C1) combining said at least one second intermediate stream comprising one or more of renewable diesel and/or renewable jet fuel with said at least one raw material stream comprising bio-oil to obtain a combined raw material stream,

C2) subjecting said combined raw material stream and/or said at least one second intermediate stream comprising one or more of renewable diesel and/or renewable jet fuel to cracking, especially to hydrocracking, preferably to increase the yield of bio-naphtha;

C3) subjecting said combined raw material stream, and/or said at least one first intermediate stream comprising bio-naphtha to isomerization, especially to hydroisomerization, preferably to form iso-paraffins.

4. The process according to any of the preceding claims, wherein in step C), at least one second intermediate stream comprising bio-Cu-hydrocarbons is obtained; and step D) further comprises

D1) subjecting at least a part of said at least one second intermediate stream comprising bio-Ci-4- hydrocarbons to said hydrocarbon cracking.

5. The process according to any of the preceding claims, wherein in step D), at least one second by-product stream comprising low-boiling alkanes, in particular methane, is obtained; and step D) further comprises

D2) subjecting at least a part of said at least second by-product stream comprising low-boiling alkanes to said hydrocarbon cracking.

6. The process according to any of the preceding claims, wherein in step D), at least one third product stream comprising solid carbon is obtained.

7. The process according to any of the preceding claims, wherein in step C), at least one second intermediate stream comprising bio-Cu-hydrocarbons is obtained; and/or in step D), at least one second by-product stream comprising low-boiling alkanes, in particular methane, is obtained; and wherein the process further comprises step E)

E) subjecting at least a part of said at least one second intermediate stream comprising bio-Cu-hydrocarbons and/or at least a part of said at least one second by-product stream comprising low-boiling alkanes, in particular methane, to hydrogen production to obtain a stream comprising hydrogen.

8. The process according to claim 7, wherein in step B), at least a part of said hydrogen originates from step E).

9. The process according to any of claims 7 to 8, wherein in step E), said hydrogen production is carried out by hydrocarbon pyrolysis and preferably comprises the substeps E4), E5), and E6)

E4) hydrocarbon decomposition to obtain a first gas stream comprising hydrogen;

10. The process according to any of the preceding claims, the process further comprising step F)

F) controlling the hydrogen supply, and wherein preferably step F) comprises the substeps F1) determining the hydrogen demand of step C);

11. A process for producing at least one downstream product, the process comprising the process according to any of the preceding claims and further comprising step G)

12. A system for producing olefins, the system comprising the units

IV) a hydrocarbon cracking unit, comprising a moving bed reactor subunit, for receiving said at least one first intermediate stream comprising bio-naphtha from unit III), for cracking said at least one first intermediate stream comprising bio-naphtha to cracking products, and for separating said cracking products into at least one first product stream comprising olefins and at least one first by-product stream comprising hydrogen.

13. The system according to claim 12, the system further comprising unit V)

VI) a hydrogen supply control unit for controlling the hydrogen supply.