Abstract: A process for the conversion of a petroleum feed to light olefins may comprise pretreating the petroleum feed to form one or more pretreated petroleum feeds and fractionating the one or more pretreated petroleum feeds to form a methane stream, an ethane stream, a C3-C4 stream, a light liquid fraction, and a heavy liquid fraction. The process may further comprise methane cracking the methane stream to form hydrogen, steam cracking the ethane stream to form a steam cracking product; dehydrogenating the C3-C4 stream to form a dehydrogenated stream; and steam enhanced catalytic cracking (SECC) the light liquid fraction and the heavy liquid fraction to form an SECC product.

Abstract: In accordance with one or more embodiments herein, an integrated process for upgrading a hydrocarbon oil feed stream utilizing a gasification unit, steam enhanced catalytic cracker, and an aromatics complex includes solvent deasphalting the hydrocarbon oil stream; processing the heavy residual hydrocarbons in a gasification unit to form syngas and gasification residue; hydrotreating the deasphalted oil stream to form a light C5+ hydrocarbon stream and a heavy C5+ hydrocarbon stream; steam enhanced catalytically cracking the light C5+ hydrocarbon stream; steam enhanced catalytically cracking the heavy C5+ hydrocarbon stream; passing at least a portion of the light steam enhanced catalytically cracked stream, the heavy steam enhanced catalytically cracked stream, or both to a product separator to produce a olefin product stream, a naphtha product stream, and a BTX product stream; and processing the naphtha product stream in the aromatics complex to produce benzene and xylenes.

Abstract: An integrated process for upgrading a hydrocarbon oil feed stream includes solvent deasphalting the hydrocarbon oil stream; processing the heavy residual hydrocarbons in a gasification unit to form syngas and gasification residue; hydrotreating the deasphalted oil stream to form a C3-C4 hydrocarbon stream, a light C5+ hydrocarbon stream, and a heavy C5+ hydrocarbon stream; dehydrogenating the C3-C4 hydrocarbon stream to form propylene and butylene; steam enhanced catalytically cracking the light C5+ hydrocarbon stream; steam enhanced catalytically cracking the heavy C5+ hydrocarbon stream; passing at least a portion of the light steam enhanced catalytically cracked stream, the heavy steam enhanced catalytically cracked stream, or both to a product separator to produce a olefin product stream, a naphtha product stream, and a BTX product stream; and processing the naphtha product stream in the aromatics complex to produce benzene and xylenes.

Abstract: An integrated process for upgrading a hydrocarbon oil feed stream utilizing a delayed coker, steam enhanced catalytic cracker, and an aromatics complex includes solvent deasphalting the hydrocarbon oil stream; delayed coking the heavy residual hydrocarbons; hydrotreating the delayed coker product stream and the deasphalted oil stream to form a C3-C4 hydrocarbon stream, a light C5+ hydrocarbon stream, and a heavy C5+ hydrocarbon stream; dehydrogenating the C3-C4 hydrocarbon stream to form propylene and butylene; steam enhanced catalytically cracking the light C5+ hydrocarbon stream; steam enhanced catalytically cracking the heavy C5+ hydrocarbon stream; passing at least a portion of the light steam enhanced catalytically cracked stream, the heavy steam enhanced catalytically cracked stream, or both to a product separator to produce a olefin product stream, a naphtha product stream, and a BTX product stream; and processing the naphtha product stream in the aromatics complex to produce benzene and xylenes.

Abstract: This disclosure relates to methods of forming a zeolite composition, the method comprising calcining one or more clay mineral compositions to form metakaolin, wherein the one or more clay mineral compositions may comprise greater than or equal to 10 wt. % halloysite, forming a slurry by combining at least the metakaolin, a shape selective zeolite, a basic compound, silica particles, and a templating agent, hydrothermally treating the slurry to form a hydrothermal product, calcining the hydrothermal product to form a zeolite product, combining the zeolite product and at least one metal precursor, wherein the at least one metal precursor may comprise a manganese precursor, a phosphorous precursor, or both a manganese precursor and a phosphorous precursor to form a zeolite composition comprising manganese, phosphorus, or both manganese and phosphorous.

Abstract: A process for converting a hydrocarbon feed includes contacting a hydrocarbon feed with steam in the presence of a cracking catalyst under steam enhanced catalytic cracking conditions. The contacting the hydrocarbon feed with the steam in the presence of the cracking catalyst causes at least a portion of the hydrocarbon feed to undergo steam catalytic cracking reactions to produce a cracked effluent comprising C2 to C4 olefins, C6 to C10 aromatic compounds, or both. The cracking catalyst is a nanoparticle. The nanoparticle has a core and a shell. The core includes at least one zeolite particle, where the at least one zeolite particle includes ZSM-5 zeolites, Beta zeolites, Y-zeolites, or combinations of these zeolites. The shell is mesoporous and incudes silica (SiO2), alumina (Al2O3), or silica and alumina.

Abstract: A method of preparing a cracking catalyst includes converting one or more clay mineral compositions to metakaolin; synthesizing an intermediate ZSM-5 zeolite from the metakaolin, a silica source, and ZSM-5 zeolite seeds; and forming a cracking catalyst comprising a hierarchical mesoporous ZSM-5 zeolite through disintegration and recrystallization of the intermediate ZSM-5 zeolite. A cracking catalyst for steam enhanced catalytic cracking of hydrocarbons includes a hierarchical mesoporous ZSM-5 zeolite impregnated with manganese, zirconium, or manganese and zirconium, where the cracking catalyst has a mesopore volume of at least 0.30 cubic centimeters per gram (cm3/g). A process for upgrading crude oil through steam enhanced catalytic cracking includes contacting the crude oil with steam in the presence of a cracking catalyst, where the cracking catalyst comprises a hierarchical mesoporous ZSM-5 zeolite impregnated with manganese, zirconium, or both manganese and zirconium.

Abstract: A process for upgrading a hydrocarbon feed comprises contacting the hydrocarbon feed with steam in the presence of a cracking catalyst composition at reaction conditions sufficient to cause at least a portion of hydrocarbons in the hydrocarbon feed to undergo one or more cracking reactions to produce a steam catalytic cracking effluent comprising light olefins, light aromatic compounds, or both, where: the cracking catalyst composition comprises a cracking additive comprising a ZSM-5 zeolite, a first metal species, and a second metal species, where the first metal species and the second metal species are impregnated onto the ZSM-5 zeolite, the first metal species comprises a metal or metal oxide comprising a first metal, the second metal species comprises a metal or metal oxide comprising a second metal, and the second metal is different from the first metal.

Abstract: A process for upgrading a hydrocarbon feed comprises contacting the hydrocarbon feed with steam in the presence of a cracking catalyst composition at reaction conditions sufficient to cause at least a portion of hydrocarbons in the hydrocarbon feed to undergo one or more cracking reactions to produce a steam catalytic cracking effluent comprising light olefins, light aromatic compounds, or both, where the cracking catalyst composition comprises a cracking additive comprising metal species impregnated on a ZSM-5 zeolite, where the metal species comprises a metal selected from the group consisting of chromium, vanadium, iron, platinum, molybdenum, cerium, and nickel.

Abstract: A process for converting a hydrocarbon feed may comprise contacting a hydrocarbon feed with steam in the presence of a cracking catalyst under steam enhanced catalytic cracking conditions. The contacting the hydrocarbon feed with the steam in the presence of the cracking catalyst may cause at least a portion of the hydrocarbon feed to undergo steam catalytic cracking reactions to produce a cracked effluent comprising C2 to C4 olefins, C6 to C10 aromatic compounds, or both. The cracking catalyst may be a nanoparticle comprising: a core and a shell. The core may comprise one or more ZSM-5 zeolite particles and have an outer surface. The shell may comprise a plurality of fibers extending radially outward from the outer surface of the core. The plurality of fibers may comprise silica.

Abstract: In accordance with one or more embodiments herein, an integrated process for upgrading a hydrocarbon oil feed stream utilizing a delayed coker, steam enhanced catalytic cracker, and an aromatics complex includes solvent deasphalting the hydrocarbon oil stream; delayed coking the heavy residual hydrocarbons; hydrotreating the delayed coker product stream and the deasphalted oil stream to form a light C5+ hydrocarbon stream and a heavy C5+ hydrocarbon stream; steam enhanced catalytically cracking the light C5+ hydrocarbon stream; steam enhanced catalytically cracking the heavy C5+ hydrocarbon stream; passing at least a portion of the light steam enhanced catalytically cracked stream, the heavy steam enhanced catalytically cracked stream, or both to a product separator to produce a olefin product stream, a naphtha product stream, and a BTX product stream; and processing the naphtha product stream in the aromatics complex to produce benzene and xylenes.

Abstract: A process of producing a mesoporous beta zeolite includes mixing a crystalline beta zeolite with one or more solvents, cetyltrimethylammonium bromide, and metal hydroxide to produce a solution, heating the solution at a temperature of from 50° C. to 150° C. to convert the crystalline beta zeolite to a non-crystalline material with reduced silica content relative to the crystalline beta zeolite, cooling the solution to a temperature of from 25° C. to 40° C., adjusting the pH of the solution to from 8 to 10 by adding an acid, and aging the solution at a temperature of from 50° C. to 150° C. for a time period sufficient to crystalize the non-crystalline material to produce beta zeolite particles.

Abstract: An integrated process and associated system for conversion of crude oil to value added petrochemicals. The process includes separating crude oil into light and heavy crude fractions and processing the heavy fraction in a solvent deasphalting unit and a delayed coker unit, and then providing the light fraction and selected effluents of the solvent deasphalting unit and the delayed coker unit to a hydrotreater. The process further includes separating the effluent of the hydrotreater to generate a C1 fraction passed to a methane cracker, a C2 fraction passed to an ethane steam cracker, a C3-C4 fraction passed to a dehydrogenation reactor, a hydrotreated light fraction passed to an aromatization unit, and a hydrotreated heavy fraction passed to a steam enhanced catalytic cracking unit. The process further includes separating effluents of the various unit operations into product streams including a BTX stream and a light olefin stream.

Abstract: Methods and systems for producing aromatics and light olefins from a mixed plastics stream are described. The method may include feeding a plastic feedstock to a dechlorination operation to melt the plastic feedstock to release HCl and generate a liquid plastic stream; feeding the liquid plastic stream to a pyrolysis reactor, the pyrolysis reactor to generate hydrocarbon vapors; feeding the hydrocarbon vapors to an acid gas removal reactor with a solid inorganic alkali salt disposed within the reaction vessel to remove residual HCl and sulfur-containing compounds from the hydrocarbon vapors to generate a plastic derived oil; and feeding the plastic derived oil to a fluid catalytic cracking reactor to generate a product stream comprising light olefins having a carbon number of C2-C4 and aromatics. The associated system for processing mixed plastics into aromatics and light olefins is also described.

Abstract: In accordance with one or more embodiments herein, an integrated process for upgrading a hydrocarbon oil feed stream utilizing a delayed coker, steam enhanced catalytic cracker, and an aromatics complex includes solvent deasphalting the hydrocarbon oil stream; delayed coking the heavy residual hydrocarbons; hydrotreating the delayed coker product stream and the deasphalted oil stream to form a light C5+ hydrocarbon stream and a heavy C5+ hydrocarbon stream; steam enhanced catalytically cracking the light C5+ hydrocarbon stream; steam enhanced catalytically cracking the heavy C5+ hydrocarbon stream; passing at least a portion of the light steam enhanced catalytically cracked stream, the heavy steam enhanced catalytically cracked stream, or both to a product separator to produce a olefin product stream, a naphtha product stream, and a BTX product stream; and processing the naphtha product stream in the aromatics complex to produce benzene and xylenes.

Abstract: An integrated process and associated system for conversion of crude oil to value added petrochemicals. The process includes separating crude oil into light and heavy crude fractions and processing the heavy fraction in a solvent deasphalting unit and a delayed coker unit, and then providing the light fraction and selected effluents of the solvent deasphalting unit and the delayed coker unit to a hydrotreater. The process further includes separating the effluent of the hydrotreater to generate a C1 fraction passed to a methane cracker, a C2 fraction passed to an ethane steam cracker, a C3-C4 fraction passed to a dehydrogenation reactor, a hydrotreated light fraction passed to an aromatization unit, and a hydrotreated heavy fraction passed to a steam enhanced catalytic cracking unit. The process further includes separating effluents of the various unit operations into product streams including a BTX stream and a light olefin stream.

Abstract: A process for upgrading a hydrocarbon feed includes contacting the hydrocarbon feed with steam in the presence of a cracking catalyst at reaction conditions sufficient to cause at least a portion of hydrocarbons in the hydrocarbon feed to undergo one or more cracking reactions to produce a steam catalytic cracking effluent comprising light olefins, light aromatic compounds, or both. The cracking catalyst is hierarchical mesoporous ZSM-5 zeolite. The hierarchical mesoporous ZSM-5 zeolite is made by providing a starting ZSM-5 zeolite, disintegrating the a portion of the starting ZSM-5 in the presence of a surfactant using sodium hydroxide, and then recrystallizing the zeolite constituents in the presence of the surfactant to produce recrystallized ZSM-5 zeolite. The recrystallized ZSM-5 zeolite is then recovered and calcined to produce the hierarchical mesoporous ZSM-5 zeolite.

Abstract: An integrated process for upgrading a hydrocarbon oil feed stream utilizing a gasification unit and steam enhanced catalytic cracker includes solvent deasphalting the hydrocarbon oil stream to form at least a deasphalted oil stream and heavy residual hydrocarbons, the heavy residual hydrocarbons including at least asphaltenes; processing the heavy residual hydrocarbons in a gasification unit to form syngas and gasification residue; hydrotreating the deasphalted oil stream to form a light C5+ hydrocarbon stream, and a heavy C5+ hydrocarbon stream; steam enhanced catalytically cracking the light C5+ hydrocarbon stream to form a light steam enhanced catalytically cracked product stream including olefins, benzene, toluene, xylene, naphtha, or combinations thereof; and steam enhanced catalytically cracking the heavy C5+ hydrocarbon stream to form a heavy steam enhanced catalytically cracked product including olefins, benzene, toluene, xylene, naphtha, or combinations thereof.

Abstract: An integrated process for upgrading a hydrocarbon oil feed stream utilizing a delayed coker, steam enhanced catalytic cracker, and an aromatics complex includes solvent deasphalting the hydrocarbon oil stream; delayed coking the heavy residual hydrocarbons; hydrotreating the delayed coker product stream and the deasphalted oil stream to form a C3-C4 hydrocarbon stream, a light C5+ hydrocarbon stream, and a heavy C5+ hydrocarbon stream; dehydrogenating the C3-C4 hydrocarbon stream to form propylene and butylene; steam enhanced catalytically cracking the light C5+ hydrocarbon stream; steam enhanced catalytically cracking the heavy C5+ hydrocarbon stream; passing at least a portion of the light steam enhanced catalytically cracked stream, the heavy steam enhanced catalytically cracked stream, or both to a product separator to produce a olefin product stream, a naphtha product stream, and a BTX product stream; and processing the naphtha product stream in the aromatics complex to produce benzene and xylenes.

Abstract: An integrated process for upgrading a hydrocarbon oil feed stream includes solvent deasphalting the hydrocarbon oil stream to form at least a deasphalted oil stream and heavy residual hydrocarbons, delayed coking the heavy residual hydrocarbons to form petroleum coke and a delayed coker product stream; hydrotreating the delayed coker product stream and the deasphalted oil stream to form a C3-C4 hydrocarbon stream, a light C5+ hydrocarbon stream, and a heavy c5+ hydrocarbon stream; dehydrogenating the C3-C4 hydrocarbon stream to form propylene and butylene; steam enhanced catalytically cracking the light C5+ hydrocarbon stream to form a light steam enhanced catalytically cracked product stream including olefins, benzene, toluene, xylene, naphtha, or combinations thereof; and steam enhanced catalytically cracking the heavy C5+ hydrocarbon stream to form a heavy steam enhanced catalytically cracked product including olefins, benzene, toluene, xylene, naphtha, or combinations thereof.