Abstract: A system for steam cracking a whole crude that may include a volatilization device, a control system, a separator, and a steam pyrolysis reactor. The volatilization device may be configured to separate a vapor phase from a liquid phase. The control system may be configured to maintain a flow rate of the whole crude and steam, at an initial relative velocity of less than 30 m/s. The separator may be fluidly connected to the volatilization device and configured to separate the liquid phase into a second vapor phase, and a second liquid phase. The steam pyrolysis reactor may include a convection section and a steam pyrolysis heater section, the convection section configured to heat the vapor phase, the liquid phase, and the second vapor phase, and the steam pyrolysis heater section configured to steam crack hydrocarbons in the vapor phase thereby generating a cracked hydrocarbon product.

Abstract: Catalysts and catalytic methods are provided. The catalysts and methods are useful in a variety of catalytic reactions, for example, the oxidative coupling of methane.

Abstract: A process for dehydrogenating a paraffinic feedstock, producing olefins and/or dienes. The process includes feeding a paraffinic hydrocarbon feedstock comprising one or more C2+ paraffinic hydrocarbons and a fuel gas stream to a dehydrogenation reactor preheater, combusting the fuel gas stream in the dehydrogenation reactor preheater and heating the paraffinic hydrocarbon feedstock to a temperature in the range of 500-650° C., producing a heated paraffinic feedstock, feeding the heated paraffinic feedstock to a first dehydrogenation reactor operating in a reaction mode and containing an active dehydrogenation catalyst and at least one first electrical heating element, heating the heated paraffinic feedstock in the first dehydrogenation reactor using the at least one first electrical heating element, and contacting the heated paraffinic feedstock with the active dehydrogenation catalyst and the at least one electrical heating element thereby producing an olefinic product stream comprising one or more olefins.

Abstract: A process and system for producing bio or fossil fuels is provided. The process includes: feeding mixed hydrocarbon to a fixed-bed reactor system containing a zeolite catalyst; operating the fixed-bed reactor system for oligomerization of one or more C3-C8 hydrocarbons to form an oligomerized effluent; separating the oligomerized effluent into a C3-fraction, a gas stream, and a liquid stream in a gas/liquid separation unit; feeding at least a first portion of the liquid stream to a distillation unit; recycling at least a second portion of the liquid stream to the fixed-bed reactor system; separating the first portion of the liquid stream in the distillation unit into, a light fraction and a heavy fraction; and recycling the light fraction to the fixed-bed reactor system.

Abstract: Processes and systems for recovering hydrogen include feeding a gas stream, comprising hydrogen and additional gases, to a pressure swing adsorption (PSA) system and feeding a membrane permeate stream comprising hydrogen to the PSA system. In the PSA system, a portion of the hydrogen is separated from the additional gases to recover a hydrogen product stream and a PSA tail gas stream comprising unseparated hydrogen and the additional gases. The PSA tail gas stream is fed to a membrane separation unit for separating hydrogen from the additional gases and to recover (i) the membrane permeate stream comprising hydrogen fed to the PSA system and (ii) a membrane tail gas stream comprising the additional gases. Processes and systems herein may additionally include a refrigeration system for partially condensing one or both of the feed gas stream and the PSA tail gas stream, enhancing the efficiency of the membrane separation unit.

Abstract: Systems and processes for the production of a high purity isobutylene stream, a high purity isooctene stream or for the co-production of a high purity isobutylene and a high purity isooctene. The systems and processes advantageously process mixed C4 hydrocarbon streams via etherification, back cracking, isomerization, and/or dimerization, along with various separation systems, to produce the desired high purity streams.

Abstract: Systems and processes for the flexible production of gasoline and jet fuel via alkylation of C4 and C5 olefins.

Abstract: Processes and systems for converting a hydrocarbon mixture to produce olefins including a first preheater, one or more separation systems, a secondary transferline exchanger, a thermal cracking heater, a primary transferline exchanger, and a flow line. The process includes preheating a hydrocarbon feed, separating the preheated hydrocarbon stream, heating the vaporized hydrocarbon, and heating the liquid hydrocarbon stream. The process includes cracking the heated hydrocarbon stream and the second vaporized hydrocarbon stream, feeding the cracked hydrocarbon product stream to a primary transferline exchanger, and feeding the cooled hydrocarbon product stream to the secondary transferline exchanger.

Abstract: Systems and processes for converting light or very light sweet crudes and condensates to chemicals and petrochemicals. The process includes providing a hydrocarbon feedstock comprising a crude oil or condensate having an API gravity of at least 35, a sulfur content of less than 0.2 wt %, and less than 10 wt % of hydrocarbons having a normal boiling point above 575° C. The hydrocarbon feedstock is heated and separated to recover a light fraction, a middle fraction, and optionally a heavy fraction. The light fraction is steam cracked to produce a cracked light fraction and the middle fraction is separately steam cracked to produce a cracked middle fraction. The cracked light fraction and the cracked middle fraction are then separated to recover one or more product fractions including an ethylene fraction and a propylene fraction.

Abstract: A process including preheating a hydrocarbon feed, feeding the preheated hydrocarbon stream to a second preheat zone for cracking, and feeding the cracking feed stream to one or more coils in a radiant section to recover a cracked hydrocarbon product. The process includes injecting excess air and cooling the cracked hydrocarbon product in a transfer line exchanger. The system includes a pyrolysis heater, a first and second preheat zone of the convection heating zone, and one or more coils in the radiant heating zone. The system includes one or more inlets for injecting an amount of excess air, one or more electrical heating elements in the radiant heating zone, and a feedline for directing the cracked hydrocarbon product to a transfer line exchanger.

Abstract: An electrical heater system includes a heater block, a plurality of heating element holes transversing the heater block, a plurality of radiant coil holes transversing the heater block, a plurality of electrical heating elements disposed within the plurality of heating element holes, and a plurality of radiant coils disposed within the plurality of radiant coil holes. A process for olefin production includes heating a plurality of radiant coils using an electrical heater, feeding a hydrocarbon mixture into a plurality of inlet tubes, controlling a temperature of a plurality of electrical heating elements to heat a heater block to a desired temperature, cracking the hydrocarbon mixture in the plurality of radiant coils to produce a cracked effluent, collecting the cracked effluent through a plurality of outlet tubes, and cooling the cracked effluent using a heat exchanger.

Abstract: Systems and processes for external combustion air preheating for providing preheated combustion air to a furnace. The furnace systems convective heating section includes multiple heating coils for waste heat recovery. The heating coils may be used for preheating a feed (feed preheat coils), heating a boiler feed water, superheating steam, or heating or superheating a feed stream prior to the feed being fed to the radiant coil. The waste heat in the combustion gas is also used to heat a heat transfer fluid, which may be used to pre-heat combustion air or for other purposes within the plant.

Abstract: Systems and methods for flexibly converting crude oil to chemicals and fuels. The systems include unit operations configured to provide flexibility between operating in two different modes for two periods of time. A method includes separating a crude oil, distillate hydrotreating a medium oil fraction resulting from the separation, and operating in a max chemicals mode of operation for a first period of time and in a chemicals plus fuels mode for a second period of time. The method may further include conditioning and hydroprocessing, collectively separating, recovering an unconverted oil fraction, and feeding a light oil fraction, first hydrocarbon fraction, and a diesel fuel fraction or jet fuel fraction to a steam cracker. The system includes a separation unit, a low pressure distillate hydrotreating unit, a separation unit, a steam cracker unit, a separation system, a flow system, and a control system.

Abstract: Systems and processes for pyrolyzing waste plastics, including, in one or more heating stages, heating a waste plastic from an initial temperature to a peak pyrolysis temperature, and, in a final pyrolysis stage, providing heat input sufficient to maintain a temperature of the waste plastic at a pyrolysis reaction temperature less than the peak pyrolysis temperature and maintaining the waste plastic at the pyrolysis reaction temperature for a time period to convert a portion of the waste plastic to a pyrolyzed product and a pitch. The process further includes recovering the pyrolyzed product and recovering the pitch.

Abstract: A process including heating a hydrogen manufacturing unit feedstock producing a heated hydrogen manufacturing unit feedstock. The process includes stripping a wide boiling range hydrocarbon mixture with heated hydrogen manufacturing unit feedstock producing an overheads stream, separating the overheads stream to recover a non-condensed stream, and feeding the non-condensed stream to a hydrogen manufacturing unit.

Abstract: Systems herein separate an inlet gas stream containing methane, C2 components, C3 components and optionally heavier hydrocarbons into a volatile gas fraction containing methane and a less volatile hydrocarbon fraction containing C2+ components. The system may include piping, valving, and controls configured to flexibly allow the system to operate in a high ethane recovery mode, a high throughput mode, or in some embodiments, a high propane recovery mode.

Abstract: A process for recovering propane from a hydrocarbon stream including cooling a feed gas, separating the feed gas into a vapor and a liquid, expanding the vapor to produce a feed gas, feeding the feed gas to an absorber and recovering an absorber bottoms product, an absorber liquid draw, and an absorber overheads fraction; feeding the absorber bottoms product to a deethanizer and producing a deethanizer liquid fraction comprising propane and heavier components and a deethanizer overhead vapor fraction comprising ethane and lighter components. The absorber liquid draw, absorber overheads fraction, and deethanizer overhead vapor fraction are brought into indirect heat exchange to produce an absorber reboil stream and to partially condense the deethanizer overheads vapor product.

Abstract: Processes and systems for converting a hydrocarbon mixture to produce olefins. The process and systems include preheating a hydrocarbon feed in one or multiple preheaters to a preheat temperature, producing a preheated hydrocarbon stream. The preheated hydrocarbon stream are separated in one or more separation systems, producing a vaporized hydrocarbon stream and a liquid hydrocarbon stream. The vaporized hydrocarbon stream is heated in a secondary transfer line exchanger, producing a heated hydrocarbon stream that is further heated in a convective electric preheater, producing a second heated hydrocarbon stream. The second heated hydrocarbon stream is then cracked, using a radiant electric thermal cracking heater, producing a cracked hydrocarbon product stream, which is fed to a primary transfer line exchanger for quenching the cracked hydrocarbon product stream and recovering a cooled hydrocarbon product stream.

Abstract: A heat exchanger assembly including an elongated tubular heat exchanger enclosure defining an interior chamber. A tube sheet is positioned within the interior chamber of the heat exchanger enclosure separating the interior chamber into a shell side and a channel side. The interior portion is configured to removably receive a tube bundle positioned within the shell side of the interior chamber. An annular sleeve member is positioned within the channel side of the interior chamber of the heat exchanger enclosure. An annular elastic torsion member is positioned within the channel side of the interior chamber of the heat exchanger such that the sleeve member is positioned between the tube sheet and the elastic torsion member. The elastic torsion member has an inner circumference deflectable relative to its outer circumference for torsioning the elastic torsion member.

Abstract: Catalysts, catalytic materials having catalysts present on supports and catalytic methods are provided. The catalysts, catalytic material and methods are useful in a variety of catalytic reactions, for example, the oxidative coupling of methane.