Abstract: A method of producing bifunctional catalysts by extrusion may include mixing an acid catalyst, a metal catalyst, optionally a binder, and a fluid to produce a dough; extruding the dough to form an extrudate; producing a powder from the extrudate; and calcining the powder to produce an acid/metal bifunctional catalyst. Such acid/metal bifunctional catalysts may be useful in, among other things, converting syngas to dimethyl ether in a single reactor.

Abstract: Systems and methods are provided for partial upgrading of heavy hydrocarbon feeds to meet transport specifications, such as pipeline transport specifications. The systems and methods can allow for one or more types of improvement in heavy hydrocarbon processing prior to transport. In some aspects, the systems and methods can produce a partially upgraded heavy hydrocarbon product that satisfies one or more transport specifications while incorporating an increased amount of vacuum gas oil and a reduced amount of pitch into the partially upgraded heavy hydrocarbon product. In other aspects, the systems and methods can allow for increased incorporation of hydrocarbons into the fraction upgraded for transport, thereby reducing or minimizing the amount of hydrocarbons requiring an alternative method of disposal or transport.

Abstract: An upgraded crude composition is provided, along with systems and methods for making such a composition. The upgraded crude composition can include an unexpectedly high percentage of vacuum gas oil boiling range components while having a reduce or minimized amount of components boiling above 593° C. (1100° F.). In some aspects, based in part on the hydroprocessing used to form the upgraded crude composition, the composition can include unexpectedly high contents of nitrogen. Still other unexpected features of the composition can include, but are not limited to, an unexpectedly high nitrogen content in the naphtha fraction; and an unexpected vacuum gas oil fraction including an unexpectedly high content of polynuclear aromatics, an unexpectedly high content of waxy, paraffinic compounds, and/or an unexpectedly high content of n-pentane asphaltenes.

Abstract: A method of producing bifunctional catalyst systems that include a carbon-coated metal catalyst may comprise: coating a metal catalyst particle with a carbon-containing small molecule to produce a coated metal catalyst particle; carbonizing the carbon-containing small molecule on the coated metal catalyst particle to produce a carbon-coated metal catalyst particle; and mixing the carbon-coated metal catalyst particle with an acid catalyst particle to produce an acid/metal bifunctional catalyst system.

Abstract: Methods of producing metal catalysts can include mixing two or more metal salts and an aluminum salt in water to produce a metal catalyst precursor solution; mixing the metal catalyst precursor solution and an alkali metal buffer solution to produce a precipitate; ion exchanging the alkali metal in the precipitate for a non-alkali cation to produce a low-alkali metal precipitate comprising 3 wt % or less alkali metal by weight of the precipitate on a dry basis; producing a powder from the low-alkali metal precipitate; and calcining the powder to produce a metal catalyst. Such metal catalysts may be useful in producing bifunctional catalyst systems that are useful in, among other things, converting syngas to dimethyl ether in a single reactor.

Abstract: Methods of producing metal catalysts can include mixing two or more metal salts and an aluminum salt in water to produce a metal catalyst precursor solution having a pH of about 2.5 to about 4.0; mixing the metal catalyst precursor solution and a basic solution having a pH of about 10 to about 13 to produce a mixture with a pH of about 6 to about 7 and a precipitate; producing a powder from the precipitate; and calcining the powder to produce a metal catalyst. Such metal catalysts may be useful in producing bifunctional catalyst systems that are useful in, among other things, converting syngas to dimethyl ether in a single reactor.

Abstract: A method of producing a acid/metal bifunctional catalyst may include: mixing an acid catalyst, a metal catalyst, and a fluid to produce a slurry, wherein the acid catalyst is present at 50 wt % or less relative to a total catalyst weight in the slurry; heating the slurry; producing a powder from the slurry; and calcining the powder to produce the acid/metal bifunctional catalyst. Such acid/metal bifunctional catalyst would be useful in the direct conversion of syngas to dimethyl ether as well as other reactions.

Abstract: An upgraded crude composition is provided, along with systems and methods for making such a composition. The upgraded crude composition can include an unexpectedly high percentage of vacuum gas oil boiling range components while having a reduce or minimized amount of components boiling above 593° C. (1100° F.). In some aspects, based in part on the hydroprocessing used to form the upgraded crude composition, the composition can include unexpectedly high contents of nitrogen. Still other unexpected features of the composition can include, but are not limited to, an unexpectedly high nitrogen content in the naphtha fraction; and an unexpected vacuum gas oil fraction including an unexpectedly high content of polynuclear aromatics, an unexpectedly high content of waxy, paraffinic compounds, and/or an unexpectedly high content of n-pentane asphaltenes.

Abstract: Systems and methods are provided for partial upgrading of heavy hydrocarbon feeds to meet transport specifications, such as pipeline transport specifications. The systems and methods can allow for one or more types of improvement in heavy hydrocarbon processing prior to transport. In some aspects, the systems and methods can produce a partially upgraded heavy hydrocarbon product that satisfies one or more transport specifications while incorporating an increased amount of vacuum gas oil and a reduced amount of pitch into the partially upgraded heavy hydrocarbon product. In other aspects, the systems and methods can allow for increased incorporation of hydrocarbons into the fraction upgraded for transport, thereby reducing or minimizing the amount of hydrocarbons requiring an alternative method of disposal or transport.

Abstract: Systems and methods are provided for partial upgrading of heavy hydrocarbon feeds to meet transport specifications, such as pipeline transport specifications. The systems and methods can allow for one or more types of improvement in heavy hydrocarbon processing prior to transport. In some aspects, the systems and methods can produce a partially upgraded heavy hydrocarbon product that satisfies one or more transport specifications while incorporating an increased amount of vacuum gas oil and a reduced amount of pitch into the partially upgraded heavy hydrocarbon product. In other aspects, the systems and methods can allow for increased incorporation of hydrocarbons into the fraction upgraded for transport, thereby reducing or minimizing the amount of hydrocarbons requiring an alternative method of disposal or transport.

Abstract: Systems and methods are provided for partial upgrading of heavy hydrocarbon feeds to meet transport specifications, such as pipeline transport specifications. The systems and methods can allow for one or more types of improvement in heavy hydrocarbon processing prior to transport. In some aspects, the systems and methods can produce a partially upgraded heavy hydrocarbon product that satisfies one or more transport specifications while incorporating an increased amount of vacuum gas oil and a reduced amount of pitch into the partially upgraded heavy hydrocarbon product. In other aspects, the systems and methods can allow for increased incorporation of hydrocarbons into the fraction upgraded for transport, thereby reducing or minimizing the amount of hydrocarbons requiring an alternative method of disposal or transport.

Abstract: Methods of producing metal catalysts can include mixing two or more metal salts and an aluminum salt in water to produce a metal catalyst precursor solution having a pH of about 2.5 to about 4.0; mixing the metal catalyst precursor solution and a basic solution having a pH of about 10 to about 13 to produce a mixture with a pH of about 6 to about 7 and a precipitate; producing a powder from the precipitate; and calcining the powder to produce a metal catalyst. Such metal catalysts may be useful in producing bifunctional catalyst systems that are useful in, among other things, converting syngas to dimethyl ether in a single reactor.

Abstract: A method of producing bifunctional catalysts by extrusion may include mixing an acid catalyst, a metal catalyst, optionally a binder, and a fluid to produce a dough; extruding the dough to form an extrudate; producing a powder from the extrudate; and calcining the powder to produce an acid/metal bifunctional catalyst. Such acid/metal bifunctional catalysts may be useful in, among other things, converting syngas to dimethyl ether in a single reactor.

Abstract: Methods of producing metal catalysts can include mixing two or more metal salts and an aluminum salt in water to produce a metal catalyst precursor solution; mixing the metal catalyst precursor solution and an alkali metal buffer solution to produce a precipitate; ion exchanging the alkali metal in the precipitate for a non-alkali cation to produce a low-alkali metal precipitate comprising 3 wt % or less alkali metal by weight of the precipitate on a dry basis; producing a powder from the low-alkali metal precipitate; and calcining the powder to produce a metal catalyst.

Abstract: A method of producing a acid/metal bifunctional catalyst may include: mixing an acid catalyst, a metal catalyst, and a fluid to produce a slurry, wherein the acid catalyst is present at 50 wt % or less relative to a total catalyst weight in the slurry; heating the slurry; producing a powder from the slurry; and calcining the powder to produce the acid/metal bifunctional catalyst. Such acid/metal bifunctional catalyst would be useful in the direct conversion of syngas to dimethyl ether as well as other reactions.

Abstract: A method of producing bifunctional catalyst systems that include a carbon-coated metal catalyst may comprise: coating a metal catalyst particle with a carbon-containing small molecule to produce a coated metal catalyst particle; carbonizing the carbon-containing small molecule on the coated metal catalyst particle to produce a carbon-coated metal catalyst particle; and mixing the carbon-coated metal catalyst particle with an acid catalyst particle to produce an acid/metal bifunctional catalyst system.

Abstract: Systems and methods are provided for conversion of gas phase reactants including CO and H2 to C2+ products using multiple catalysts in a single reactor while reducing or minimizing deactivation of the catalysts. Separate catalysts can be used that correspond to a first catalyst, such as a catalyst for synthesis of methanol from synthesis gas, and a second catalyst, such as a catalyst for conversion of methanol to a desired C2+ product. The separate catalysts can be loaded into the reactor in distinct layers that are separated by spacer layers. The spacer layers can correspond to relatively inert particles, such as silica particles. Optionally, the spacer layer can include an adsorbent, such as boron supported on alumina or boron carbide particles. The adsorbent can be suitable for selective adsorption of the one or more reaction products (such as one or more reaction by-products), to allow for further reduction or minimization of the deactivation of the conversion catalysts.

Abstract: Systems and methods are provided for conversion of gas phase reactants including CO and H2 to C2+ products using multiple catalysts in a single reactor while reducing or minimizing deactivation of the catalysts. Separate catalysts can be used that correspond to a first catalyst, such as a catalyst for synthesis of methanol from synthesis gas, and a second catalyst, such as a catalyst for conversion of methanol to a desired C2+ product. The separate catalysts can be loaded into the reactor in distinct layers that are separated by spacer layers. The spacer layers can correspond to relatively inert particles, such as silica particles. Optionally, the spacer layer can include an adsorbent, such as boron supported on alumina or boron carbide particles. The adsorbent can be suitable for selective adsorption of the one or more reaction products (such as one or more reaction by-products), to allow for further reduction or minimization of the deactivation of the conversion catalysts.