Abstract: The present invention is a process for regenerating a sulfur-contaminated, highly selective, large-pore zeolite catalyst. It comprises a multistep process involving exposure of the catalyst to a combination of oxidizing conditions, reducing conditions and treatment with a halogen acid gas. These conditions are effective to agglomerate a Group VIII metal and remove sulfur. Thereafter, the catalyst is oxychlorinated to redisperse the Group VIII metal over the catalyst surface. A carbon removal step is optionally included.

Abstract: A multi-stage catalytic reforming process using a catalyst having a high rhenium to platinum ratio in the first stage or stages and a catalyst having a still higher rhenium to platinum ratio for the last stage. The process comprises:(a) contacting a naphtha feed with a first stage catalyst comprising rhenium and platinum, and having a rhenium to platinum weight ratio of at least 1.7, under catalytic reforming conditions in one or more first reforming stages of a reforming unit to obtain intermediate reformate; and(b) contacting the intermediate reformate, under catalytic reforming conditions in a last stage of the reforming unit, with a last stage catalyst comprising rhenium and 0.2 to 2.0 weight percent platinum, and having sufficient rhenium so that the last stage catalyst has at least 0.5 weight percent rhenium beyond that necessary to attain a 1.7 rhenium to platinum weight ratio.

Abstract: A reactor vessel for maintaining a staged moving bed of solids, in the presence of countercurrently flowing gas stream, having a diameter of at least one meter and a pressure drop across the body of solids approximately equal to that of a fully fluidized bed and a method for using same to thermally process a granular solid composed of a broad distribution of particle sizes.

Abstract: A method is provided for preparing a porous catalyst carrier having a pore volume of at least 0.5 cc/g, a content of micropores in which the pore diameter is between 80 and 150 A. which constitutes at least 70% of the pore volume and a content of macropores which constitutes less than 3% of the pore volume. In the method, a powdered solid comprised of predominantly alpha-alumina monohydrate and sized in the range below 500 microns is treated with a particular amount of a monobasic acid. The acid in the resulting mixture is then at least partially neutralized by admixing with a nitrogen base such as aqueous ammonia. The treated and neutralized feed is converted into a catalyst carrier by shaping as desired, drying, and calcining. Further aspects of the invention are a hydrodesulfurization catalyst prepared using the present carrier and a hydrodesulfurization process for metals-contaminated hydrocarbon feeds using the catalyst.

Abstract: Disclosed is a preferred baffle system for a staged turbulent bed retort. The system preferably comprises a plurality of at least 4 vertically spaced, horizontally disposed perforated baffles, each of said baffles having an open area in the range of 30-70% of the baffle cross-sectional area.

Abstract: Process for burning a pyrolyzed carbon containing solid in a staged turbulent bed to provide hot heat transfer material for use in pyrolyzing additional carbon containing solids.

Abstract: Disclosed is an improved process for retorting oil shale in a staged turbulent bed retort wherein the raw shale feed particles are classified and deaerated into first and second fractions, said first fraction containing substantially only shale particles above about 25 mesh. The first fraction is then preheated with hot shale fines in a dilute phase lift pipe prior to retorting.

Abstract: A continuous process is disclosed for the retorting of shale and other similar hydrocarbon-containing solids of a broad particle size distribution in which the solids to be retorted are introduced into an upper portion of an elongated vessel with a solid heat transfer material at an elevated temperature. The hydrocarbon-containing solids and heat transfer material, a portion of each being fluidized, pass downwardly through the retort under substantially plug-flow conditions, countercurrent to an upwardly flowing stripping gas. Retorted solids and heat transfer material are withdrawn from the bottom of the retort vessel and a product stream of hydrocarbon vapors mixed with stripping gas is recovered overhead.

Abstract: A method is provided for preparing a porous catalyst carrier having a pore volume of at least 0.5 cc/g, a content of micropores in which the pore diameter is between 80 and 150 A. which constitutes at least 70% of the pore volume and a content of macropores which constitutes less than 3% of the pore volume. In the method, a powdered solid comprised of predominantly alpha-alumina monohydrate and sized in the range below 500 microns is treated with a particular amount of a monobasic acid. The acid in the resulting mixture is then at least partially neutralized by admixing with a nitrogen base such as aqueous ammonia. The treated and neutralized feed is converted into a novel catalyst carrier by shaping as desired, drying, and calcining. Further aspects of the invention are a catalytic reforming catalyst containing the present carrier and a reforming process using this catalyst.

Abstract: Disclosed is a process for the retorting of shale and other similar hydrocarbon-containing solids in which the solids to be retorted are mixed with a solid heat-transfer material to provide the necessary heat for retorting. The shale is retorted in a spouted bed of the shale and heat-transfer solids. Preferably, molecular oxygen is excluded from the retorting zone.

Abstract: Disclosed is a process for the retorting of shale and other similar hydrocarbon-containing solids in which the solids to be retorted are mixed with a solid heat transfer material to rapidly heat the hydrocarbon-containing solids to a high temperature. The shale and heat-transfer material are entrained in a high-velocity gaseous stream and conveyed upward in a vertical dilute phase lift pipe retorting vessel whereby the hydrocarbon-containing solids are rapidly heated to an elevated temperature vaporizing a minor portion of the hydrocarbons in the solid. The hydrocarbon-containing solids then pass into a disengaging zone wherein the gas and solids are separated. The partially retorted solids then pass into a gravitating bed retort and flow downward countercurrent to the flow of a stripping gas. The process is characterized by a high liquid yield and a minimum gas yield along with minimal amounts of volatile components being left in the retorted solids.

Abstract: A method is provided for preparing a porous catalyst carrier having a pore volume of at least 0.5 cc/g, a content of micropores in which the pore diameter is between 80 and 150 A. which constitutes at least 70% of the pore volume and a content of macropores which constitutes less than 3% of the pore volume. In the method, a powdered solid comprised of predominantly alpha-alumina monohydrate and sized in the range below 500 microns is treated with a particular amount of a monobasic acid. The acid in the resulting mixture is then at least partially neutralized by admixing with a nitrogen base such as aqueous ammonia. The treated and neutralized feed is converted into a novel catalyst carrier by shaping as desired, drying, and calcining. Further aspects of the invention are a catalytic reforming catalyst containing the present carrier.

Abstract: Heavy oil feedstocks containing at least 20 ppm metals, particularly residuum feedstocks, are hydrodesulfurized using a catalyst prepared by impregnating Group VIb and Group VIII metals or metal compounds into a support comprising alumina wherein the support has at least 70 volume percent of its pore volume in pores having a diameter between 80 and 150 Angstroms and less than 3 volume percent of its pore volume in pores having a diameter above 1000 Angstroms. The catalyst preferably has at least 80 volume percent of its pore volume in pores having a diameter between 80 and 150 Angstroms and less than 1.5 volume percent of its pore volume in pores having a diameter above 1000 Angstroms.

Abstract: The present invention is a process for regenerating a sulfur-contaminated, highly selective, large-pore zeolite catalyst. It comprises a multistep process involving exposure of the catalyst to a combination of oxidizing conditions, reducing conditions and treatment with a halogen acid gas. These conditions are effective to agglomerate a Group VIII metal and remove sulfur. Thereafter, the catalyst is oxychlorinated to redisperse the Group VIII metal over the catalyst surface. A carbon removal step is optionally included.