Abstract: The instant invention is directed to the preparation of a slurry catalyst composition. The slurry catalyst composition is prepared in a series of steps, involving mixing a Group VIB metal oxide, particularly molybdenum and aqueous ammonia to form an aqueous mixture and sulfiding the mixture to form a slurry. The slurry is then promoted with a Group VIII metal. Subsequent steps involve mixing the slurry with a hydrocarbon oil, and combining the resulting mixture with hydrogen gas (under conditions which maintain the water in a liquid phase) to produce the active slurry catalyst.

Abstract: Applicants have developed a new residuum full hydroconversion slurry reactor system that allows the catalyst, unconverted oil and converted oil to circulate in a continuous mixture throughout an entire reactor with no confinement of the mixture. The mixture is partially separated in between the reactors to remove only the products and hydrogen gas, while permitting the unconverted oil and the slurry catalyst to continue on into the next sequential reactor. A portion of the unconverted oil is then converted to lower boiling point hydrocarbons, once again creating a mixture of unconverted oil, products, hydrogen, and slurry catalyst. Further hydroprocessing may occur in additional reactors, fully converting the oil. Additional oil may be added at the interstage feed inlet, possibly in combination with slurry. The oil may alternately be partially converted, leaving a highly concentrated catalyst in unconverted oil which can be recycled directly to the first reactor.

Abstract: The invention is directed to a method of making a small crystal SSZ-32 zeolite, known as SSZ-32X. The catalyst is suitable for use in a process whereby a feed including straight chain and slightly branched paraffins having 10 or more carbon atoms is dewaxed to produce an isomerized product, with increased yield of isomerized material and decreased production of light ends.

Abstract: The invention is directed to a method of making a catalyst comprising an intermediate pore size molecular sieve, preferably a zeolite of the MTT or TON type. SSZ-32 and ZSM-22 are examples of such molecular sieves. This catalyst is modified with a metal or metals selected from the group consisting of Ca, Cr, Mg, La, Ba, Pr, Sr, K and Nd. The catalyst is additionally loaded with a Group VIII metal or metals for hydrogenation purposes. The catalyst is suitable for use in a process whereby a feed including straight chain and slightly branched paraffins having 10 or more carbon atoms is isomerized.

Abstract: In the refining of crude oil, hydroprocessing units such as hydrotreaters and hydrocrackers are used to remove impurities such as sulfur, nitrogen, and metals from the crude oil. They are also used to convert the feed into valuable products such as naphtha, jet fuel, kerosene and diesel. The current invention provides very high to total conversion of heavy oils to products in a single high-pressure loop, using multiple reaction stages. The second stage or subsequent stages may be a combination of co-current and counter-current operation. The benefits of this invention include conversion of feed to useful products at reduced operating pressures using lower catalyst volumes. Lower hydrogen consumption also results. A minimal amount of equipment is employed. Utility consumption is also minimized.

Abstract: The instant invention is directed to a process for upgrading heavy oils using a slurry composition. The slurry composition is prepared by a series of steps, involving mixing a Group VIB metal oxide and aqueous ammonia to form an aqueous mixture, and sulfiding the mixture to form a slurry. The slurry is then promoted with a Group VIII metal. Subsequent steps involve mixing the slurry with a hydrocarbon oil and combining the resulting mixture with hydrogen gas and a second hydrocarbon oil having a lower viscosity than the first oil. An active catalyst composition is thereby formed.

Abstract: The instant invention is directed to a process for upgrading heavy oils using a slurry composition. The slurry composition is prepared in a series of steps, involving mixing a Group VIB metal oxide with aqueous ammonia to form an aqueous mixture and sulfiding the mixture to form a slurry. The slurry is then promoted with a Group VIII metal compound. Subsequent steps involve mixing the slurry with a hydrocarbon oil, and combining the resulting mixture with hydrogen gas (under conditions which maintain the water in a liquid phase) to produce the active slurry catalyst.

Abstract: The invention is directed to a method of making a catalyst comprising an intermediate pore size molecular sieve, preferably a zeolite of the MTT or TON type. SSZ-32 and ZSM-22 are examples of such molecular sieves. This catalyst is modified with a metal or metals selected from the group consisting of Ca, Cr, Mg, La, Ba, Pr, Sr, K and Nd. The catalyst is additionally loaded with a Group VII metal or metals for hydrogenation purposes. The catalyst is suitable for use in a process whereby a feed including straight chain and slightly branched paraffins having 10 or more carbon atoms is isomerized.

Abstract: This invention relates to a crude oil desulfurization process which comprises hydrodesulfurizing a crude oil feed in a crude desulfurization unit. The desulfurized crude oil is then separated into a light gas oil fraction, a vacuum gas oil fraction and a vacuum residuum fraction. The vacuum gas oil is hydrocracked to form at least one low sulfur fuel product. The light gas oil fraction is hydrotreated. The vacuum gas oil may be hydrocracked in one or more stages. Hydrocracking in the second stage, if present, will convert of at least 20% of the first zone effluent, to create a low sulfur light gas oil fraction. The light gas oil fraction may then be hydrotreated.

Abstract: With this invention, high conversion of heavy gas oils and the production of high quality products is possible in a single high-pressure loop with reaction stages operating at different pressure and conversion levels. The flexibility offered is great and will allow the refiner to avoid decrease in product quality while at the same time minimizing capital cost. Feeds with varying boiling ranges can be introduced at different sections of the process, thereby minimizing the consumption of hydrogen and further reducing capital investment.

Abstract: In the refining of crude oil, vacuum gas oil hydrotreaters and hydrocrackers are used to remove impurities such as sulfur, nitrogen, and metals from the crude oil. Typically, the middle distillate boiling material (boiling in the range from 250° F.-735° F.) from VGO hydrotreating or moderate severity hydrocrackers does not meet the smoke point, the cetane number or the aromatic specification. In most cases, this middle distillate is separately upgraded by a middle distillate hydrotreater or, alternatively, the middle distillate is blended into the general fuel oil pool or used as home heating oil. With this invention, the middle distillate is hydrotreated in the same high pressure loop as the vacuum gas oil hydrotreating reactor or the moderate severity hydrocracking reactor.

Abstract: This invention is directed to a process for hydroprocessing vacuum gas oils and other feeds in order to produce unconverted oil suitable for use as base oil feed for white oils, Group III oils, and BMCI (Bureau of Mines Correlation Index) ethylene plant feed. Ammonia, hydrogen sulfide, and light products are removed from the first stage at high pressure in order to produce a higher quality of unconverted oil that is suitable for Group III base oils.

Abstract: The instant invention comprises a hydroprocessing method having at least two stages. The first stage employs a hydroprocessing catalyst which may contain hydrotreating catalyst, hydrocracking catalyst, or a combination of both. The second stage is limited to hydrocracking. Conversion in the second stage may be improved by the addition of multiple reaction zones for hydrocracking, with flash separation zones between the stages. Middle distillate yield is thereby increased and the volume of the recycle stream is reduced. This invention reduces the need for equipment which would normally be required for a large recycle stream.

Abstract: A VGO stream is initially hydrocracked in a hydrocracking reaction zone within an integrated hydroconversion process. Effluent from the hydrocracking reaction zone is combined with a light aromatic-containing feed stream, and the blended stream hydrotreated in a hydrotreating reaction zone. Heat exchange occurs between the hydrocracking reaction zone and the hydrotreating reaction zone, permitting the temperature control of the initial hydrocracking zone. The integrated reaction system provides a single hydrogen supply and recirculation system for use in two reaction processes.

Abstract: An in-extrudate reaction mixture to be effectively crystallized is effectively crystallized to produce zeolitic or non-zeolitic molecular sieves. The reaction mixture is heated within a slowly rotating, double-walled reactor vessel wherein a heated medium is conducted within a space formed between the double walls of the vessel. Thus, the reaction mixture is contacted by a uniformly heated wall while being gently tumbled at low speed. The tumbling action serves to uniformly distribute the heat within the reaction mixture without subjecting the mixture to such shearing that could damage shaped particles. A relatively high quantity of reaction mixture can be handled in that way to maximize the production volumes and reduce production costs.

Abstract: This invention is directed to middle distillate production (e.g., diesel and kerosene products) by means of a reactor hydroprocessing system using two or more reactors (or a single reactor vessel having two or more stages, each stage containing one or more reaction zones). Hydrocracking is preferably performed in the initial reactor, and hydrotreating (and/or further hydrocracking) is preferably performed in the subsequent reactor vessel or stages within a single vessel. Reaction stages are effectively segregated to avoid recracking of products, to dramatically reduce hydrogen consumption in saturating the bottoms product and to carry out aromatic saturation of middle distillates in a clean low-temperature environment.

Abstract: An integrated distillate hydrocracking process produces one or more fuel products and one or more lube products from a first reaction stage. Heavy fractions from the first stage, which are not recovered as lube products, are cracked to fuels in a second reaction stage. This invention is intended to provide a full range of lube streams, over a wide viscosity range and a wide viscosity index range, from a fuels hydrocracker, in addition to high yields of high quality fuels.

Abstract: A base oil feed having a tendency to form a haze at ambient or sub-ambient temperatures is contacted with a solid adsorbent to remove at least a portion of the haze precursors, thereby reducing the haze-forming tendency of the base oil feed.

Abstract: A reactor system and process for hydrotreating a heavy feedstock contaminated with metals sulfur and carbon residue using an upflow fixed bed reactor with at least two catalyst layers having different hydrogenation activity.

Abstract: The present invention relates to new crystalline zeolite SSZ-55 prepared using a phenylcycloalkylmethyl ammonium or N-cyclohexyl-N-(2-methylpropyl)pyrrolidinium cation templating agents.