Abstract: A high pressure two-zone molten iron gasification process for converting solid, liquid and gaseous hydrocarbon feeds into separate substantially hydrogen-rich and carbon monoxide-rich streams at 2 to 200 atmospheres pressure by feeding hydrocarbons into the molten iron in a first zone (4) in which hydrogen-rich gas is formed and then circulating the molten iron into contact with an oxygen containing gas in a second zone (5) in which carbon monoxyide-rich gas is formed. The carbon level in the circulating molten iron is carefully controlled above 0.3 wt. % to minimize formation of FeO. Hydrogen sulfide and other volatile sulfur compounds are removed from the separate gas streams via scrubbing in downstream equipment (12 and 16).

Abstract: Hydrogen sulfide is produced by charging a sulfur containing feed to a molten metal bath containing over 3 wt. % dissolved carbon. Allowing dissolved carbon levels to build up in the bath, preferably by controlling oxygen addition to ensure a large inventory of dissolved carbon, creates a reducing “atmosphere” in the molten metal bath which allows most of the feed sulfur to be converted to H2S, which can be converted to elemental sulfur using a Claus unit or similar technology. Oxygen addition, to burn carbon from the bath, preferably occurs at a different time or place in the bath than the time or place of sulfur containing feed addition.

Abstract: A process for recovering and purifying vanadium found in petroleum coke is disclosed. Coke containing V and sulfur is charged to a molten metal bath and dissolved to form a molten metal bath with dissolved carbon, dissolved V metal and dissolved sulfur. At least a majority of the dissolved sulfur is released as H2S by maintaining reducing conditions in the bed, by maintaining a high concentration of dissolved carbon or addition of steam or hydrogen rich hydrocarbon such as methane or some combination of these approaches.

Abstract: An asphalt blend composition containing an asphalt component and a bottoms fraction from a used motor vaporization process of the above process, and a pavement composition comprising aggregate and the asphalt blend composition. The process comprises directly contacting used lubricating oil with a heated vapor, e.g., steam, under conditions which at least partially decompose the organo-metallic component and provide a desired volume of pumpable bottoms containing organo-metallic compound decomposition products and an overhead comprising gases and distillatable hydrocarbons, with no substantial carryover of metals into the overhead. The process may be carried out under conditions which minimize decomposition of high molecular weight additives such as VI improvers.

Abstract: A low softening point pitch is disclosed. A high melting point (100° C.+) pitch is blended with an aromatic rich liquid hydrocarbon stream to form a pourable pitch mixture having a softening point of 30-50° C. which can be used as a partial or complete replacement for coal tar pitch used in driveway sealer and other sealer and coating applications. Driveway sealer (an emulsion of clay, water and binder) made with this pitch has enhanced durability. The low softening point pitch, even when blended with coal tar pitch, is phase stable on storage.

Abstract: Sequential processing of hydrogen rich and hydrogen deficient feeds (14 and 16) in a heat balanced, single molten metal bath (40) to produce both 90+ mole % hydrogen (90) and one or more lower purity vapor streams (140) is disclosed. The molten metal bath is heated by oxygen addition (18) to burn dissolved carbon from the bath and then cooled by sequential addition of two feeds with differing hydrogen contents. Preferably a 98% hydrogen product with a pressure of at least 2 atm., absolute is obtained, along with a lower purity hydrogen containing stream and a separate carbon oxides flue gas stream.

Abstract: A continuous process for recovering vanadium values from petroleum coke is disclosed. A vanadium containing coke is charged to a molten metal bath to which oxygen containing gas is added in an amount sufficient to heat balance the process and produce off gas. The carbon in the coke dissolves in the molten metal bath as does the vanadium content of the coke. A majority, and preferably all, of the net addition of vanadium to the process is removed in the form of “dust” from the molten metal bath.

Abstract: A process for recovering and purifying vanadium found in petroleum coke is disclosed. Coke containing V and other metals such as Ni is charged to a molten metal bath and dissolved to form a molten metal bath with dissolved carbon, dissolved V metal and dissolved Ni. Oxygen containing gas is added in an amount sufficient to heat balance the process and produce off gas. At least periodically the conditions in the bed are made more severely oxidizing so that a portion of the molten vanadium metal is oxidized to form slag. Oxidation is limited so that a majority of the Ni dissolved in the bath remains as dissolved elemental Ni metal. Oxidized vanadium species are continuously or intermittently withdrawn from the slag layer, by dust formation or by tapping the slag layer.

Abstract: A process for the recovery of vanadium from a petroleum coke or heavy hydrocarbon feed comprising dissolving the feed in a molten metal bath to which oxygen containing gas is added to maintain heat balance and bum off carbon. Preferably the feed is added via a high pressure nozzle as a coke/steam mixture discharged down into a molten metal bath. Preferably the net gas make from the molten metal reactor is quenched and/or cooled to permit dust recovery, with recycle of dust to the molten metal reactor. An iron/vanadium product is withdrawn from the molten metal reactor as a product.

Abstract: A catalytic cracking catalyst comprising zeolite, kaolin, alumina and/or silica, antimony and 100-5,000 wt. ppm Ni is disclosed. The Ni-antimony interact in the environment of a fluidized catalytic cracking reactor to increase the magnetic susceptibility of the catalyst, permitting removal of nickel contaminated catalyst by magnetic separation.

Abstract: A slipstream of high pressure, cooled isobutane recycle from within an alkylation process unit is used to withdraw hydrofluoric acid from a storage vessel by means of an eductor and discharges the same into a reactor section of the unit. The eductor is preferably constructed of HASTELLOY “C” which provides both corrosion resistance to HF acid and has excellent surface hardness to withstand the highly erosive eductor application. This eductor eliminates potential release of HF acid due to failure of conventional rotating equipment seals or sealing systems, is low cost, has no moving parts, and is fireproof (will not lose containment during a fire).

Abstract: Two, preferably three or more gasoline (or other fuel) blending components are delivered to a point adjacently point of sale to the motorist and are blended by an apparatus which proportions the flow of individual components in response to signals indicative of the gasoline quality variables, octane, Reid vapor pressure, percent alcohol, etc. (The preferred octane for control purposes is motor octane, but pump octane or research octane or any combination of these three may be utilized.

Abstract: A sulfur in oil in asphalt blend is disclosed. A polymer-free slurry of solid, elemental, sulfur in liquid oil is used to add sulfur to asphalt. Addition of a slurry of solid sulfur in oil, or oil containing sulfur compounds, permits rapid and effective dispersion of the sulfur component in the asphalt. Uneven mixing, which can occur when sulfur is separately added as a solid, or in molten forms to the asphalt, is avoided. The method is safer because formation of explosive clouds of sulfur dust is avoided.

Abstract: Reformulated gasoline (RFG) testing recently required by EPA involves measuring sulfur, olefin, aromatic contents, Reid Vapor Pressure (RVP), and benzene, distillation properties, plus total air pollutants (TAPs), volatile organic carbon (VOC), and nitrogen oxides (NOx). Measuring driveability, although not required, is desirable. All of these tests can be conducted by spectrometer, preferably in the IR range, more preferably in the NIR range, and most preferably by a single instrument operating at high-correlation wavelengths. Importantly, VOC, TAP, NOx, and RVP may be correlated to IR absorbance at certain bands. Statistical methods including PLS, MLR, PCR, and neural networks can be used and derivatives of first, particularly second, or other orders can be used. Results can be displayed on a single screen.

Abstract: A sulfur in oil in asphalt and polymer blend is disclosed. An asphalt and polymer blend is first prepared and then a slurry of solid sulfur in liquid oil added. Addition of a slurry of solid sulfur in oil or oil containing sulfur compounds, permits rapid and effective uniform dispersion of the sulfur component in the asphalt/polymer blend. Uneven mixing, which can occur when sulfur is separately added as a solid to the asphalt blend, is avoided. Polymer use is optimized because polymer matrix development (digestion/swelling) can be completed before cross-linking occurs. The method is safer because formation of explosive clouds of sulfur dust is avoided.

Abstract: A process in which a high-purity, high-pressure hydrogen-rich gas stream and a high-purity, high-pressure carbon monoxide-rich gas stream are simultaneously produced separately and continuously using a molten metal gasifier that contains at least two zones, thereby avoiding the need to separate or compress the gases in down-stream equipment.

Abstract: Asphaltene concentration of a hydrocarbon feed is measured by IR spectroscopy using mid-range IR frequencies between 3800 cm.sup.-1 and 650 cm.sup.-1 (corresponding to wavelengths between 2630 nanometers (nm) and 15,380 nm) together with mathematical techniques and statistical techniques in which measurements of absorption are made, and combines these with multiple regression analysis, or other statistical technique and modeling to determine asphaltene concentration. The output signal can be used to control refinery and chemical processes, e.g., atmospheric crude column, vacuum distillation column, solvent deasphalting and visbreaking.

Abstract: A process is provided for recovering lube oil base stocks from used lubricating oil formulations containing base oil stock and organo-metallic component which obviates preseparation of water and light hydrocarbons contaminants. The process comprises directly contacting used lubricating oil with a heated vapor, e.g., steam, under conditions which at least partially decompose the organo-metallic component and provide a desired volume of pumpable bottoms containing organo-metallic compound decomposition products and an overhead comprising gases and distillatable hydrocarbons, with no substantial carryover of metals into the overhead. The process may be carried out under conditions which minimize decomposition of high molecular weight additives such as VI improvers, to provide a bottoms fraction which may be added to asphalt or fuel oil.

Abstract: A method is provided for improving high temperature performance grade properties of asphalt which comprises i) heating an asphalt cement to 200 to 500.degree. F. (93 to 260.degree. C.), ii) adding 1 to 10 wt. % crosslinkable polymer, e.g., styrene-butadiene-styrene triblock copolymer based on weight of said asphalt cement, iii) adding a useful temperature index (UTI) improving amount of dioxime(s) of 1,4-benzoquinone and its derivatives and optionally, free radical initiator, e.g., organic peroxide, and iv) mixing the resulting blend, thereby providing a paving asphalt having a greater useful temperature index (UTI) than a corresponding blend to which no dioxime is added. The invention further relates to asphalt compositions thus made and paving compositions containing these asphalt compositions.