Abstract: Systems and methods are provided for integrating a fluidized coking process with a catalyst-enhanced coke gasification process. The catalyst for the gasification process can correspond to calcium oxide, a thermally decomposable calcium salt, a potassium salt such as potassium carbonate, or a combination thereof. Examples of suitable calcium salts can include, but are not limited to, calcium hydroxide, calcium nitrate, and calcium carbonate. The calcium oxide, potassium salts, and/or thermally decomposable calcium salts can be introduced into the integrated system, for example, as part of the feed into the coker. It has been unexpectedly discovered that using catalytic gasification as part of an integrated fluidized coking and gasification process can result in an overhead gas stream from the gasifier with increased energy content and/or overhead gas pressure.

Abstract: Systems and methods are provided for integrating a fluidized coking process, optionally a coke gasification process, and processes for production of additional liquid products from the coking and/or gasification process. In some aspects, the integrated processes can allow for conversion of olefins generated during a fluidized coking process to form additional liquid products. Additionally or alternately, in some aspects the integrated processes can allow for separation of syngas from the flue gas/fuel gas generated by a gasifier integrated with a fluidized coking process. This syngas can then be used to form methanol, which can then be converted in a methanol conversion process to form heavier products. In such aspects, olefins generated during the fluidized coking process can be added to the methanol conversion process to improve the yield.

Abstract: Systems and methods are provided for integrating a fluidized coking process, optionally a coke gasification process, and processes for production of additional liquid products from the coking and/or gasification process. In some aspects, the integrated processes can allow for conversion of olefins generated during a fluidized coking process to form additional liquid products. Additionally or alternately, in some aspects the integrated processes can allow for separation of syngas from the flue gas/fuel gas generated by a gasifier integrated with a fluidized coking process. This syngas can then be used to form methanol, which can then be converted in a methanol conversion process to form heavier products. In such aspects, olefins generated during the fluidized coking process can be added to the methanol conversion process to improve the yield.

Abstract: Systems and methods are provided for improving operation of a fluid catalytic cracker as part of an integrated processing environment including a deasphalting unit and a hydroprocessor. Optionally, a coker can be included in the integrated system to allow for further improvements. The improved processing can be facilitated based on a process configuration where a combination of deasphalting and hydroprocessing are used to perform conversion on more refractory compounds, so that the fluid catalytic cracker can be operated at lower severity conditions. This can allow for improved production of desirable olefins and reduced production of light paraffins and coke. Additionally or alternately, the processing configuration can allow the bottoms fraction from fluid catalytic cracking to be incorporated into a higher value use than the typical regular sulfur fuel oil disposition.

Abstract: Systems and methods are provided for upgrading a mixture of catalytic slurry oil and coker bottoms by hydroprocessing. Optionally, the upgrading can further include deasphalting the mixture of catalytic slurry oil and coker bottoms to form a deasphalted oil and a deasphalter residue or rock fraction. The mixture of catalytic slurry oil and coker bottoms and/or the deasphalted oil can then be hydroprocessed to form an upgraded effluent that includes fuels boiling range products. Optionally, in some aspects where the feed mixture is deasphalted prior to hydroprocessing, the feed mixture can further include a portion of a (sour) vacuum resid.

Abstract: Systems and methods are provided for improving the processing of heavy or challenged feeds in a refinery based on integrated use of deasphalting, coking, and hydroprocessing. An optional fluid catalytic cracking unit can be included in the integrated system to allow for further improvements. The improved processing can be facilitated based on a process configuration where the vacuum resid fractions and/or other difficult fractions are deasphalted to generate a deasphalted oil and a deasphalter residue or rock fraction. The deasphalted oil can be passed into a hydroprocessing unit for further processing. The rock fraction can be used as the feed to a coking unit. Although deasphalter residue or rock is typically a feed with a high content of micro carbon residue, a high lift deasphalting process can allow a portion of the micro carbon residue in the initial feed to remain with the deasphalted oil.

Abstract: A fluid coking unit for converting a heavy oil feed to lower boiling products by thermal has a centrally-apertured annular baffle at the top of the stripping zone below the coking zone to inhibit recirculation of solid particles from the stripping zone to the coking zone. By inhibiting recirculation of the particles from the stripping zone to the coking zone, the temperatures of the two zones are effectively decoupled, enabling the coking zone to be run at a lower temperature than the stripping zone to increase the yield of liquid products.

Abstract: Methods are provided for processing deasphalted gas oils derived from thermally cracked resid fractions to form Group I, Group II, and/or Group III lubricant base oils. The yield of lubricant base oils (optionally also referred to as base stocks) can be increased by thermally cracking a resid fraction at an intermediate level of single pass severity relative to conventional methods. By performing thermal cracking to a partial level of conversion, compounds within a resid fraction that are beneficial for increasing both the viscosity and the viscosity index of a lubricant base oil can be retained, thus allowing for an improved yield of higher viscosity lubricant base oils from a thermally cracked resid fraction.

Abstract: Systems and methods of coking are provided that crack feeds and/or products of the coker to improve liquid yields and/or increase the Conradson carbon residue of the hydrocarbon feed to the coker.

Abstract: A fluid coking unit for converting a heavy oil feed to lower boiling products by thermal has a centrally-apertured annular baffle at the top of the stripping zone below the coking zone to inhibit recirculation of solid particles from the stripping zone to the coking zone. By inhibiting recirculation of the particles from the stripping zone to the coking zone, the temperatures of the two zones are effectively decoupled, enabling the coking zone to be run at a lower temperature than the stripping zone to increase the yield of liquid products.

Abstract: Catalysts for experimentation are produced having a controlled matrix pore structure. The manufacturing process utilizes tape casting in the drying procedure in which a catalyst slurry is cast on a substrate and dried at a temperature of between about 50° C. to 200° C. for a period of time of about 0.1 to 1.0 hour. The dried catalyst particles can be removed from the substrate by several techniques, including scraping, burning, and deforming the substrate material, The resulting catalytic particles can be produced in an amount of about ca. 3 g to 300 g from slurries with volumes between 5 cc to 500 cc, which are suitable for small scale FCC reactors and for high throughput experimentation.

Abstract: An improved, fouling-resistant configuration for the stripper sheds of fluid coking units comprises an inverted, open-bottomed channel with apertures spaced along the length of the channel and spaced from the apex of the channel. Preferably, the channels are of an inverted-V configuration with a downwardly extending lip provided on each side of the channel, extending from the bottom edge of each side of the channel. The stripper sheds may be positioned parallel to one another in the stripper section of the reactor vessel or, alternatively, the sheds in different tiers in the stripper section may be disposed so that the longitudinal axes of the sheds are rotated angularly relative to the sheds in other rows.

Abstract: Catalysts for experimentation are produced having a controlled matrix pore structure. The manufacturing process utilizes tape casting in the drying procedure in which a catalyst slurry is cast on a substrate and dried at a temperature of between about 50° C. to 200° C. for a period of time of about 0.1 to 1.0 hour. The dried catalyst particles can be removed from the substrate by several techniques, including scraping, burning, and deforming the substrate material. The resulting catalytic particles can be produced in an amount of about ca. 3 g to 300 g from slurries with volumes between 5 cc to 500 cc, which are suitable for small scale FCC reactors and for high throughput experimentation.

Abstract: In a process for producing a para-xylene enriched product from a gaseous mixture comprising at least para-xylene, meta-xylene and ortho-xylene, the gaseous mixture is contacted with an adsorbent capable of selectively adsorbing para-xylene and comprising a crystalline molecular sieve having an average crystal size between about 0.5 micron and about 20 microns. The contacting is conducted at a temperature and pressure such that at least part of the para-xylene in the mixture is adsorbed by the adsorbent to produce a para-xylene-depleted effluent stream. The para-xylene is then desorbed from said adsorbent and collected to form a para-xylene enriched stream. The adsorption and desorption steps are repeated for a plurality of cycles, such that the time between successive contacting steps is no more than 10 seconds.

Abstract: A method is provided for converting oxygenates, e.g., methanol, to olefins, e.g., ethylene and propylene, comprising contacting said oxygenates and an aromatics co-feed, e.g., xylenes, with a framework gallium-containing molecular sieve catalyst comprising pores having a size ranging from about 5.0 Angstroms to about 7.0 Angstroms, e.g., ZSM-5, under production conditions effective to produce olefins. A catalyst composition is also provided, comprising a ZSM-5 zeolite-bound ZSM-5 zeolite having a bound zeolite of framework Ga-containing zeolite having a Si/Ga molar ratio ranging from 5 to 500 and a binder of Ga-modified, e.g., Ga-exchanged and/or Ga-impregnated, zeolite having a Si/Ga molar ratio ranging from 5 to ?.

Abstract: Catalysts for experimentation are produced having a controlled matrix pore structure. The manufacturing process utilizes tape casting in the drying procedure in which a catalyst slurry is cast on a substrate and dried at a temperature of between about 50° C. to 200° C. for a period of time of about 0.1 to 1.0 hour. The dried catalyst particles can be removed from the substrate by several techniques, including scraping, burning, and deforming the substrate material. The resulting catalytic particles can be produced in an amount of about ca. 3g to 300g from slurries with volumes between 5 cc to 500 cc, which are suitable for small scale FCC reactors and for high throughput experimentation.

Abstract: In a process for producing a para-xylene enriched product from a gaseous mixture comprising at least para-xylene, meta-xylene and ortho-xylene, the gaseous mixture is contacted with an adsorbent capable of selectively adsorbing para-xylene and comprising a crystalline molecular sieve having an average crystal size between about 0.5 micron and about 20 microns. The contacting is conducted at a temperature and pressure such that at least part of the para-xylene in the mixture is adsorbed by the adsorbent to produce a para-xylene-depleted effluent stream. The para-xylene is then desorbed from said adsorbent and collected to form a para-xylene enriched stream. The adsorption and desorption steps are repeated for a plurality of cycles, such that the time between successive contacting steps is no more than 10 seconds.

Abstract: A catalyst system that exhibits a ratio of ethylene saturation to aromatics ring saturation of greater than 3,500. The catalyst system comprises two components and each component comprises a crystalline molecular sieve having a Constraint Index of from about 1 to about 12 and an effective amount of Group VIII metal. The catalyst system finds particular application in ethylbenzene conversion/xylenes isomerization reactions. The catalyst system can be prepared by incorporating the Group VIII metal into the molecular sieves by competitive ion exchange.

Abstract: A catalyst system that exhibits a ratio of ethylene saturation to aromatics ring saturation of greater than 3,500. The catalyst system comprises two components and each component comprises a crystalline molecular sieve having a Constraint Index of from about 1 to about 12 and an effective amount of Group VIII metal. The catalyst system finds particular application in ethylbenzene conversion/xylenes isomerization reactions. The catalyst system can be prepared by incorporating the Group VIII metal into the molecular sieves by competitive ion exchange.

Abstract: This invention relates to a process for the selective alkylation of toluene and/or benzene with an oxygen-containing alkylation agent. In particular, the process uses a selectivated molecular sieve which has been modified by the addition of a hydrogenation component, wherein at least one of the following conditions is met: (a) the selectivated molecular sieve has an alpha value of less than 100 prior to the addition of the hydrogenation component, or (b) the selectivated and hydrogenated catalyst has an alpha value of less than 100. The process of this invention provides high selectivity for the alkylated product while reducing catalyst degradation.