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: 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: Methods, catalysts, and corresponding catalyst precursors are provided for performing dewaxing of diesel or distillate boiling range fractions. The dewaxing methods, catalysts, and/or catalyst precursors can allow for production of diesel boiling range fuels with improved cold flow properties at desirable yields. The catalysts and/or catalyst precursors can correspond to supported metal catalysts and/or catalyst precursors that include at least one noble metal, such as Pt, at least one Group 8-10 base metal, preferably a non-noble Group 8-10 base metal, such as Ni and/or Co along with a Group 6 metal, such as Mo and/or W as supported metals along. The support can include a zeolitic framework structure. The catalyst precursors can be formed, for example, by impregnating a support including a zeolitic framework structure with impregnation solution(s) that also includes a dispersion agent.

Abstract: Compositions and methods of preparing the compositions are disclosed for sorbents and other surfaces that can adsorb and desorb carbon dioxide. A sorbent or surface can include a metal compound such as an alkali or alkaline earth compound and a support. The sorbent can be prepared by several methods, including an incipient wetness technique. The sorbents have a CO2 adsorption and desorption profile. A sorbent having high levels of a metal compound and adsorbed CO2 is disclosed.

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: A method for making catalyst materials is disclosed in which active metal ingredients of the final catalyst are added to a mixture for extruding the catalyst material that includes a binder, one or more precursors of one or more base metals and/or one or more noble metals, and a crystal of a zeolite. The extruded catalyst material is then pre-calcined and ion-exchanged and then a final calcining step is applied. The catalyst materials made by such a method are also disclosed as is a method for treating a hydrocarbon stream using the catalysts.

Abstract: Methods are provided for making base metal catalysts with improved activity. After forming catalyst particles based on a support comprising a zeolitic molecular sieve, the catalyst particles can be impregnated with a solution comprising a) metal salts (or other precursors) for a plurality of base metals and b) an organic dispersion agent comprising 2 to 10 carbons. The impregnated support particles can be dried to form a base metal catalyst, and then optionally sulfided to form a sulfided base metal catalyst. The resulting (sulfided) base metal catalyst can have improved activity for cloud point reduction and/or for improved activity for heteroatom removal, relative to a base metal dewaxing catalyst prepared without the use of a dispersion agent.

Abstract: Methods for regenerating and/or rejuvenating catalysts, particularly dewaxing catalysts, as well as methods for performing dewaxing of diesel or distillate boiling range feeds with the regenerated and/or rejuvenated catalyst are provided herein. The regeneration and/or rejuvenation methods can include calcining spent catalyst followed by contacting the calcined catalyst with a solution comprising a complexing agent, which can restore hydrotreatment (HDT) activity and dewaxing activity of the spent catalyst such that it may be reused during hydroprocessing.

Abstract: Methods, catalysts, and corresponding catalyst precursors are provided for performing dewaxing of diesel or distillate boiling range fractions. The dewaxing methods, catalysts, and/or catalyst precursors can allow for production of diesel boiling range fuels with improved cold flow properties at desirable yields. The catalysts and/or catalyst precursors can correspond to supported base metal catalysts and/or catalyst precursors that include at least two Group 8-10 base metals supported on the catalyst, such as a catalyst/catalyst precursor including both Ni and Co as supported metals along with a Group 6 metal (i.e., Mo and/or W). The support can correspond to a support including a zeolitic framework structure. The catalyst precursors can be formed, for example, by impregnating a support including a zeolitic framework structure with an impregnation solution that also includes a dispersion agent.

Abstract: Disclosed is a process for the conversion of acyclic C5 feedstock to a product comprising cyclic C5 compounds, including cyclopentadiene, and formulated catalyst compositions for use in such process. The process comprises contacting the feedstock and, optionally, hydrogen under acyclic C5 conversion conditions in the presence of a catalyst composition to form the product. The catalyst composition comprises a microporous crystalline metallosilicate, a Group 10 metal or compound thereof, a binder, optionally, a metal selected from the group consisting of rare earth metals, metals of Groups 8, 9, or 11, mixtures or combinations thereof, or a compound thereof, in combination with a Group 1 alkali metal or a compound thereof and/or a Group 2 alkaline earth metal or a compound thereof.

Abstract: Disclosed are processes for conversion of a feedstock comprising C8+ aromatic hydrocarbons to lighter aromatic products in which the feedstock and optionally hydrogen are contacted in the presence of the catalyst composition under conversion conditions effective to dealkylate and transalkylate said C8+ aromatic hydrocarbons to produce said lighter aromatic products comprising benzene, toluene and xylene. The catalyst composition comprises a zeolite, a first metal, and a second metal, and is treated with a source of sulfur and/or a source of steam.

Abstract: Disclosed are processes for conversion of a feedstock comprising C8+ aromatic hydrocarbons to lighter aromatic products in which the feedstock and optionally hydrogen are contacted in the presence of a first and a second catalyst composition under conversion conditions effective to produce said lighter aromatic products comprising benzene, toluene and xylene. In the process, the C8+ aromatic hydrocarbons are dealkylated to form C6-C7 aromatic hydrocarbon and the C2+ olefins formed are saturated. The remaining C8+ aromatic hydrocarbons are transalkylated with the C6-C7 aromatic hydrocarbon. The first and second catalyst compositions each comprise a zeolite, a first metal, and optionally a second metal, and are treated with a source of sulfur and/or a source of steam.

Abstract: A method of producing a hydrogenation catalyst, for example, a phthalate hydrogenation catalyst, comprising contacting a silica support having a medium pore size of at least about 10 nm with an acid to produce a treated silica support, and depositing a noble metal, preferably ruthenium, on the treated silica support to produce a noble metal-containing silica support, and optionally contacting the noble metal-containing silica support with a chelating agent to form the hydrogenation catalyst; a hydrogenation catalyst prepared by that method; and a method of hydrogenating unsaturated hydrocarbons, such as, phthalates, in which an unsaturated hydrocarbon is contacted with hydrogen gas in the presence of the hydrogenation catalyst of the invention.

Abstract: Methods and systems for converting hydrocarbons including exposing a portion of a hydroperoxide-containing feed including tert-butyl hydroperoxide to a solid deperoxidation catalyst under decomposition conditions to form an oxidation effluent comprising tert-butyl alcohol, wherein the solid deperoxidation catalyst comprises a manganese oxide octahedral molecular sieve, are provided herein. Further methods and systems for converting the oxidation effluent to an alkylation product are also provided herein.

Abstract: Methods are provided for performing selective hydrodesulfurization on a naphtha boiling range stream naphtha boiling range portion of a feed. It has been unexpectedly discovered that hydrodesulfurization with improved octane retention can be performed by using a catalyst that comprises CoMo supported on a catalyst support that includes a zeotype framework. By using a catalyst support including a zeotype framework, an unexpectedly high amount of octane in the naphtha boiling range portion of the hydrodesulfurized effluent is maintained.

Abstract: Systems and methods are provided for hydroconversion of a heavy oil feed under slurry hydroprocessing conditions and/or solvent assisted hydroprocessing conditions. The systems and methods for slurry hydroconversion can include the use of a configuration that can allow for improved separation of catalyst particles from the slurry hydroprocessing effluent. In addition to allowing for improved catalyst recycle, an amount of fines in the slurry hydroconversion effluent can be reduced or minimized. This can facilitate further processing or handling of any “pitch” generated during the slurry hydroconversion. The systems and methods for solvent assisted hydroprocessing can include processing of a heavy oil feed in conjunction with a high solvency dispersive power crude.

Abstract: Systems and methods are provided for hydroconversion of a heavy oil feed under slurry hydroprocessing conditions and/or solvent assisted hydroprocessing conditions. The systems and methods for slurry hydroconversion can include the use of a configuration that can allow for improved separation of catalyst particles from the slurry hydroprocessing effluent. In addition to allowing for improved catalyst recycle, an amount of fines in the slurry hydroconversion effluent can be reduced or minimized. This can facilitate further processing or handling of any “pitch” generated during the slurry hydroconversion. The systems and methods for solvent assisted hydroprocessing can include processing of a heavy oil feed in conjunction with a high solvency dispersive power crude.

Abstract: Bulk metallic catalyst precursors are provided that include a Group VIB metal, such as Ni, a Group VIII metal, such as Mo or W, an organic-compound based component, and an organo-metalloxane polymer or gel. The catalyst precursors can further include a binder. Amorphous sulfided catalysts formed from the catalyst precursors are also provided. The catalyst precursor can have a surface area of about 50 m2/g or less.

Abstract: Systems and methods are provided for hydroconversion of a heavy oil feed under slurry hydroprocessing conditions and/or solvent assisted hydroprocessing conditions. The systems and methods for slurry hydroconversion can include the use of a configuration that can allow for improved separation of catalyst particles from the slurry hydroprocessing effluent. In addition to allowing for improved catalyst recycle, an amount of fines in the slurry hydroconversion effluent can be reduced or minimized. This can facilitate further processing or handling of any “pitch” generated during the slurry hydroconversion. The systems and methods for solvent assisted hydroprocessing can include processing of a heavy oil feed in conjunction with a high solvency dispersive power crude.