Abstract: Systems and methods are provided for improving the integration of fluidized coking systems that include an associated gasifier with other refinery and/or chemical plant processes. The improved integration can be based on one or more types of integration improvements. In some aspects, the integration can allow for improved carbon capture. In other aspects, the integration can allow for production of higher quality synthesis gas, which can then facilitate production of various chemicals, such as ammonia or urea. In still other aspects, the integration can allow for incorporation of H2S generated during the fluidized coking and gasification into a fertilizer product. In yet other aspects, the integration can allow the fluidized coking system to continue to operate even when the associated refinery and/or chemicals production processes are off-line.

Abstract: A novel process/system for flexibly producing chemicals and fuels from a petroleum feed such as crude comprise a flashing drum, a first cracker (e.g., a fluidized bed pyrolysis cracker or an oxidative cracker), and an olefin-to-gasoline reaction zone. The process/system can also include a steam cracker and a hydrotreater. The process/system can convert crude oil into hydrogen, C2-C4 olefins, gas oil and distillates with various amounts by adjusting the cut point of the bottoms effluent exiting the flashing drum.

Abstract: Systems and methods are provided for integrating a fluidized coking operation, a reverse osmosis operation, a coke gasification operation and/or processes for production of compounds from the synthesis gas generated during the coke gasification. Conventional FLEXICOKING™ processes may produce carbon dioxide emissions and low Joule Flexigas, as well as waste water containing metals and poor quality coke containing metals, which may be expensive to process, or may require sending to other facilities for further processing. The systems and methods described herein address these issues in an advantageous and economical manner, with improved carbon capture, waste upgrade and chemicals production, while providing high value ash (e.g., for recovery of metals such as vanadium, nickel, sodium, iron, and mixtures thereof) and upgraded coke streams.

Abstract: A method for upgrading olefin-containing naphtha can include injecting a hydrocarbon stream containing an olefin-containing naphtha comprising olefins and diolefins in a reforming reactor at temperatures of from about 700° F. to about 1200° F. and pressures of from about 10 psig to about 500 psig to produce a reformate stream, which is then contacted with an atmosphere comprising hydrogen in a hydrotreating reactor to produce a product stream, wherein the reformate stream comprises at least 50% less diolefins than the hydrocarbon stream and the product stream comprises at least 99% less diolefins than the hydrocarbon stream. A system for upgrading olefin-containing naphtha may include a reforming reactor configured to receive a hydrocarbon stream containing an olefin-containing naphtha comprising olefins and diolefins, which produces a reformate stream, and a hydrotreating reactor configured to receive the reformate stream.

Abstract: Provided are novel process for upgrading naphtha and increasing the yield of reformate. Olefinic naphtha and light paraffins are combined and fed to a catalytic fluidized bed reactor maintained at a temperature about 775° F. and about 1250° F. and an operating pressure between about 10 psig and about 500 psig to produce a product comprising at least 1 wt. % higher C5+ hydrocarbon than the combined feed and at least 55 wt. % aromatics.

Abstract: The present disclosure provides processes for converting a hydrocarbon feedstock to a hydrocarbon product stream. A process may include introducing the hydrocarbon feedstock to a reactor including a catalyst to form a reactor effluent having a temperature of from about 700° F. to about 1300° F. The catalyst may include a crystalline microporous material. The process may also include cooling the reactor effluent to a temperature of from about 350° F. to about 550° F. to form a condensate and a vapor stream. The condensate and vapor stream may be separated in a first separation system. Additionally, the vapor stream may be introduced to a second separation system to form a hydrocarbon product stream and a light hydrocarbon stream. The present disclosure also relates to apparatuses including a reactor, a vapor-liquid separator, a heat exchanger, and a separation system.

Abstract: Methanol-to-gasoline conversion may be performed using a heavy gasoline treatment, followed by a separation operation. Methanol may be converted into a first product mixture comprising dimethyl ether (DME) under DME formation conditions. In a methanol-to-gasoline (MTG) reactor, the first product mixture may be converted under MTG conversion conditions to produce a second product mixture comprising light gasoline hydrocarbons and untreated heavy gasoline hydrocarbons. The untreated heavy gasoline hydrocarbons may be separated from the light gasoline hydrocarbons and transferred to a heavy gasoline treatment (HGT) reactor. The untreated heavy gasoline hydrocarbons may be catalytically reacted in the HGT reactor to form a third product mixture. A heavy hydrocarbon fraction may be separated from the third product mixture. The heavy hydrocarbon fraction includes heavy gasoline hydrocarbons having a lower boiling endpoint than does the untreated heavy gasoline hydrocarbons.

Abstract: Processes for converting an organic-material-containing feed comprising contacting the feed with a plurality of fluidized hot particles in a pyrolysis zone to product a first pyrolysis effluent, optionally contacting the first pyrolysis effluent with a quenching stream to impart additional pyrolysis of organic materials contained in the quenching stream, separating at least a portion of the particles and feeding them to a combustion zone where the particles are heated to an elevated temperature, optionally contacting the combustion zone effluent with a second organic-material-containing stream to produce, e.g., syngas, and feeding at least a portion of the heated particles to the pyrolysis zone.

Abstract: A method for identifying sensor drift can include: setting an autocorrelation threshold for a sensor in a long-short term memory (LSTM) model developed based on historical process measurements from an analogous sensor to a sensor; collecting measured data from the sensor; applying the LSTM model to the measured data from the sensor, wherein applying the LSTM model comprises: applying the LSTM model to the measured data from the sensor to yield LSTM predicted data; calculating key performance indicators (KPIs) of the LSTM data based on an accumulated slow drift error (ASDE) model, wherein the KPIs comprise an error, an accumulated prediction error, an accumulated slow-drift error, and an estimated autocorrelation; and identifying sensor drift when the estimated autocorrelation violates the autocorrelation threshold.

Abstract: A method of crude oil fractionation without using a vacuum distillation unit can include: introducing a crude oil feed having been preheated to an atmospheric distillation tower; introducing steam according to one of: (a) into the atmospheric heater at a weight ratio of 0.1:1 to 5:1 of the steam to the crude oil feed, (b) into the atmospheric distillation tower at a weight ratio of 0.1:1 to 5:1 of the steam to the crude oil feed, or (c) both (a) and (b); and distilling the crude oil feed in the atmospheric distillation tower into a plurality of cuts including an atmospheric bottoms cut having a boiling point of 800+° F. to 950+° F.

Abstract: Systems and processes are provided for upgrading a crude oil. In some examples, a heated crude oil can be introduced into an atmospheric distillation column where an overhead gas product comprising C4? hydrocarbons can be recovered and recycled back to the atmospheric distillation column to decrease the partial pressure of the C5+ hydrocarbons in the distillation column allowing higher boiling point fractions of crude oil to be vaporized and recovered.

Abstract: Systems and methods are provided for performing steam cracking on a feed while using direct heating of the reaction environment. The heating of the reaction environment can be achieved in part by transporting heat transfer particles from a heating zone to cracking zone. This can be performed in a fluidized bed reactor, a moving bed reactor, a riser reactor, or another type of reactor that can allow for catalyst movement and regeneration during operation.

Abstract: Methanol-to-gasoline (MTG) conversion may be performed with a methanol recycling. Methanol may be fed to a first reactor where it may be catalytically converted under dimethyl ether formation conditions in the presence of a first catalyst to form a product mixture comprising dimethyl ether (DME), methanol, and water. The DME may be separated from the methanol and the water and delivered to a second reactor. In the second reactor, the DME may be catalytically converted under MTG conversion conditions in the presence of a second catalyst to form a second product mixture comprising gasoline hydrocarbons and light hydrocarbon gas. The methanol and the water from the first reactor may be separated further to obtain substantially water-free methanol, which may be returned to the first reactor. The separation of methanol from the water may be performed using the light hydrocarbon gas to effect stripping of the methanol.

Abstract: Methanol-to-gasoline (MTG) conversion may be performed with forward methanol processing. Methanol may be fed to a first reactor where it may be catalytically converted under dimethyl ether formation conditions in the presence of a first catalyst to form a product mixture comprising dimethyl ether (DME), methanol, and water. The DME may be separated from the methanol and the water and delivered to a second reactor. In the second reactor, the DME may be catalytically converted under MTG conversion conditions in the presence of a second catalyst to form a second product mixture comprising gasoline hydrocarbons and light hydrocarbon gas. The methanol and the water from the first reactor may be separated further to obtain substantially water-free methanol, which may be delivered to the second reactor. The separation of methanol from the water may be performed using the light hydrocarbon gas to effect stripping of the methanol.

Abstract: A novel process/system for flexibly producing chemicals and fuels from a petroleum feed such as crude comprise a flashing drum, a first cracker (e.g., a fluidized bed pyrolysis cracker or an oxidative cracker), and an olefin-to-gasoline reaction zone. The process/system can also include a steam cracker and a hydrotreater. The process/system can convert crude oil into hydrogen, C2-C4 olefins, gas oil and distillates with various amounts by adjusting the cut point of the bottoms effluent exiting the flashing drum.

Abstract: Systems and processes for removing organic acids from liquid hydrocarbon product streams are provided. The systems and processes can include injecting an ammoniated water wash into a liquid hydrocarbon product stream, such as an effluent stream from a methanol conversion process, and subsequently separating the treated liquid hydrocarbon product stream from the wash water. The addition of ammonia can reduce the amount of water wash by an unexpected amount.

Abstract: Systems and methods are provided for using an oxygen-containing gas as at least part of the stripping gas for the stripping zone or section in a fluidized coker. By using an oxygen-containing gas as the stripping gas, heat can be added to the stripping zone selectively based on combustion of coke and/or hydrocarbons with the oxygen in the stripping gas. This can allow the temperature of the stripping zone to be increased relative to the temperature of the coking zone of a fluidized coking system. The flow of oxygen can be controlled to achieve a desirable temperature in the stripper while the reactor temperature is independently set by preheating of the feed and/or hot coke circulation to the reaction zone.

Abstract: Systems and methods are provided for using an oxygen-containing gas as at least part of the stripping gas for the stripping zone or section in a fluidized coker. By using an oxygen-containing gas as the stripping gas, heat can be added to the stripping zone selectively based on combustion of coke and/or hydrocarbons with the oxygen in the stripping gas. This can allow the temperature of the stripping zone to be increased relative to the temperature of the coking zone of a fluidized coking system. The flow of oxygen can be controlled to achieve a desirable temperature in the stripper while the reactor temperature is independently set by preheating of the feed and/or hot coke circulation to the reaction zone.

Abstract: Systems and methods are provided for catalyst regeneration using a stoichiometric amount or less air for coke combustion.

Abstract: Methods and systems are provided for making gasoline. The method includes converting a resid-containing feed to a first fuel gas and a fluid coke in a fluidized bed reactor; gasifying the fluid coke with steam and air to produce a second fuel gas, said second fuel gas comprising a syngas; contacting the first fuel gas with a first conversion catalyst under first effective conversion conditions to form an effluent comprising C5+ hydrocarbon compounds; and converting the syngas to gasoline boiling range hydrocarbons by converting the syngas to a methanol intermediate product.