Abstract: A hydrocarbon feed stream may be processed by a method that may include catalytically cracking a hydrocarbon feed stream in a counter-current reactor to produce a first effluent stream, and processing a portion or all of the first effluent stream by at least one or more separations. The at least one or more separations may form at least a second effluent stream including at least 95 wt. % C4-C6 hydrocarbons, and a third effluent stream including at least 95 wt. % of ethane, propane, or a combination thereof. In some embodiments, the method may further include catalytically cracking a portion or all of the second effluent stream in a second reactor to form a second reactor effluent stream, combining a portion of all of the second reactor effluent stream with the first effluent stream, steam cracking a portion or all of the third effluent stream to form a steam cracked effluent stream, and combining a portion or all of the steam cracked effluent stream with the first effluent.

Abstract: A multi-zoned fluidized bed reactor system may include a multi-zoned fluidized bed reactor and at least one catalyst regeneration loop. The multi-zoned fluidized bed reactor comprising a housing, a fluid bed distributor plate positioned at the bottom of the housing, a fluidized catalyst bed disposed vertically above the fluid bed distributor plate and a condensation zone disposed vertically above the fluidized catalyst bed. The at least one catalyst regeneration loop may be fluidly coupled to the stripping zone and a reaction zone. The at least one catalyst regeneration loop may be operable to withdraw a portion of spent catalyst from the stripping zone, regenerate the portion of spent catalyst to produce regenerated catalyst, and return the regenerated catalyst to the reaction zone. A method of regenerating catalyst in a multi-zoned fluidized bed reactor may include passing a portion of spent catalyst from a stripping zone to a catalyst regeneration loop.

Abstract: A hydrocarbon feed stream may be processed by a method that may include catalytically cracking a hydrocarbon feed stream in a counter-current reactor to produce a first effluent stream, and processing a portion or all of the first effluent stream by at least one or more separations. The at least one or more separations may form at least a second effluent stream including at least 95 wt. % C4-C6 hydrocarbons, and a third effluent stream including at least 95 wt. % of ethane, propane, or a combination thereof. In some embodiments, the method may further include catalytically cracking a portion or all of the second effluent stream in a second reactor to form a second reactor effluent stream, combining a portion of all of the second reactor effluent stream with the first effluent stream, steam cracking a portion or all of the third effluent stream to form a steam cracked effluent stream, and combining a portion or all of the steam cracked effluent stream with the first effluent.

Abstract: A method for making a metal carbide based catalyst for crude oil cracking includes mixing a clay with a phosphorous based stabilizer material to obtain a liquid slurry; adding an aluminosilicate zeolite and an ultrastable Y zeolite to the liquid slurry; adding Al2Cl(OH)5 to the liquid slurry; adding metal carbide particles, having a given diameter, to the liquid slurry to obtain a mixture; and spray drying the mixture to obtain the metal carbide based catalyst. The metal carbide particles are coated with the aluminosilicate zeolite and the ultrastable Y zeolite.

Abstract: A multi-zoned fluidized bed reactor system may include a multi-zoned fluidized bed reactor and at least one catalyst regeneration loop. The multi-zoned fluidized bed reactor comprising a housing, a fluid bed distributor plate positioned at the bottom of the housing, a fluidized catalyst bed disposed vertically above the fluid bed distributor plate and a condensation zone disposed vertically above the fluidized catalyst bed. The at least one catalyst regeneration loop may be fluidly coupled to the stripping zone and a reaction zone. The at least one catalyst regeneration loop may be operable to withdraw a portion of spent catalyst from the stripping zone, regenerate the portion of spent catalyst to produce regenerated catalyst, and return the regenerated catalyst to the reaction zone. A method of regenerating catalyst in a multi-zoned fluidized bed reactor may include passing a portion of spent catalyst from a stripping zone to a catalyst regeneration loop.

Abstract: A method of continuously producing a polyol includes: (i) feeding a solid catalyst into a continuous stirred tank reactor (CSTR); (ii) contacting a reaction mixture comprising one or more epoxides and carbon dioxide with the solid catalyst and a chain transfer agent comprising a plurality of sites capable of initiating copolymerization of epoxides and carbon dioxide in the CSTR; (iii) allowing polymerization reaction to proceed until a desired molecular weight polyol has formed; and (iv) terminating the polymerization reaction.

Abstract: An integrated method for mesophase pitch and petrochemicals production. The method including supplying crude oil to a reactor vessel; heating the crude oil in the reactor vessel to a predetermined temperature for a predetermined amount of time; reducing asphaltene content in the crude oil by allowing polymerization reactions to occur in the reactor vessel at an elevated pressure in the absence of oxygen; producing a three-phase upgraded hydrocarbon product comprising gas, liquid, and solid hydrocarbon components, where the liquid hydrocarbon component comprises deasphalted oil and the solid hydrocarbon component comprises mesophase pitch; separating the gas, liquid, and solid hydrocarbon components; directly utilizing the liquid hydrocarbon component for petrochemicals production; and directly utilizing the solid hydrocarbon component for carbon artifact production.

Abstract: An integrated method for mesophase pitch and petrochemicals production. The method including supplying crude oil to a reactor vessel; heating the crude oil in the reactor vessel to a predetermined temperature for a predetermined amount of time; reducing asphaltene content in the crude oil by allowing polymerization reactions to occur in the reactor vessel at an elevated pressure in the absence of oxygen; producing a three-phase upgraded hydrocarbon product comprising gas, liquid, and solid hydrocarbon components, where the liquid hydrocarbon component comprises deasphalted oil and the solid hydrocarbon component comprises mesophase pitch; separating the gas, liquid, and solid hydrocarbon components; directly utilizing the liquid hydrocarbon component for petrochemicals production; and directly utilizing the solid hydrocarbon component for carbon artifact production.

Abstract: An integrated method for mesophase pitch and petrochemicals production. The method including supplying crude oil to a reactor vessel; heating the crude oil in the reactor vessel to a predetermined temperature for a predetermined amount of time; reducing asphaltene content in the crude oil by allowing polymerization reactions to occur in the reactor vessel at an elevated pressure in the absence of oxygen; producing a three-phase upgraded hydrocarbon product comprising gas, liquid, and solid hydrocarbon components, where the liquid hydrocarbon component comprises deasphalted oil and the solid hydrocarbon component comprises mesophase pitch; separating the gas, liquid, and solid hydrocarbon components; directly utilizing the liquid hydrocarbon component for petrochemicals production; and directly utilizing the solid hydrocarbon component for carbon artifact production.

Abstract: Methods of chemical looping include introducing a hydrocarbon-containing feed stream into a first reaction zone. The first reaction zone includes a moving catalyst bed reactor. The moving catalyst bed reactor includes a heterogeneous catalyst, and the heterogeneous catalyst includes a heat-generating metal oxide component. The method further includes cracking the hydrocarbon-containing feed stream in the presence of the heterogeneous catalyst of the moving catalyst bed reactor, reducing the metal oxide heat-generating component of the heterogeneous catalyst with hydrogen from a product stream to generate heat, and utilizing the heat to drive additional cracking of the hydrocarbon-containing feed stream. A chemical looping system includes at least one reduction reactor, which includes a moving catalyst bed reactor and a heterogeneous catalyst, and at least one oxidation reactor fluidly coupled to the reduction reactor.

Abstract: An integrated method for mesophase pitch and petrochemicals production. The method including supplying crude oil to a reactor vessel; heating the crude oil in the reactor vessel to a predetermined temperature for a predetermined amount of time; reducing asphaltene content in the crude oil by allowing polymerization reactions to occur in the reactor vessel at an elevated pressure in the absence of oxygen; producing a three-phase upgraded hydrocarbon product comprising gas, liquid, and solid hydrocarbon components, where the liquid hydrocarbon component comprises deasphalted oil and the solid hydrocarbon component comprises mesophase pitch; separating the gas, liquid, and solid hydrocarbon components; directly utilizing the liquid hydrocarbon component for petrochemicals production; and directly utilizing the solid hydrocarbon component for carbon artifact production.

Abstract: Methods of chemical looping include introducing a hydrocarbon-containing feed stream into a first reaction zone. The first reaction zone includes a moving catalyst bed reactor. The moving catalyst bed reactor includes a heterogeneous catalyst, and the heterogeneous catalyst includes a heat-generating metal oxide component. The method further includes cracking the hydrocarbon-containing feed stream in the presence of the heterogeneous catalyst of the moving catalyst bed reactor, reducing the metal oxide heat-generating component of the heterogeneous catalyst with hydrogen from a product stream to generate heat, and utilizing the heat to drive additional cracking of the hydrocarbon-containing feed stream. A chemical looping system includes at least one reduction reactor, which includes a moving catalyst bed reactor and a heterogeneous catalyst, and at least one oxidation reactor fluidly coupled to the reduction reactor.

Abstract: A method of cracking a hydrocarbon feed which includes introducing vaporizing a hydrocarbon feed and a heat generating material (HGM) stream comprising at least one aldehyde or ketone to a cracking reactor. The hydrocarbon feed and the HGM stream are vaporized and may be vaporized prior or subsequent to introduction to the cracking reactor. The addition of the HGM to the endothermic cracking process provides the heat needed for cracking and helps the overall process to achieve thermal neutrality. The method includes cracking the hydrocarbon feed to produce a cracking product, where the cracking product comprises C1-C4 hydrocarbons and C5+ hydrocarbons.