Catalytic Patents (Class 208/113)
  • Patent number: 11446645
    Abstract: A fluid catalytic cracking catalyst composition (FCC catalyst composition) includes a framework-substituted ultra-stable Y-type zeolite (USY zeolite) having one or more transition metals substituted into the framework of a USY zeolite and a FCC zeolite cracking additive. A method for upgrading a hydrocarbon feed includes contacting the hydrocarbon feed with the FCC catalyst composition of the present disclosure at reaction conditions sufficient to upgrade at least a portion of the hydrocarbon feed. A method for upgrading a hydrocarbon feed includes passing the hydrocarbon feed to a fluid catalytic cracking unit, contacting the hydrocarbon feed with a FCC catalyst composition in the fluid catalytic cracking unit under reaction conditions sufficient to cause at least a portion of the hydrocarbon feed to undergo cracking reactions to produce a cracking reaction mixture comprising a used FCC catalyst composition and a cracked effluent comprising one or more olefins.
    Type: Grant
    Filed: July 2, 2020
    Date of Patent: September 20, 2022
    Assignees: Saudi Arabian Oil Company, JGC Catalysts and Chemicals Ltd., Japan Cooperation Center Petroleum
    Inventors: Omer Refa Koseoglu, Yaming Jin, Masaru Ushio, Seiji Arakawa
  • Patent number: 11396002
    Abstract: A plant or refinery may include equipment such as reactors, heaters, heat exchangers, regenerators, separators, or the like. Types of heat exchangers include shell and tube, plate, plate and shell, plate fin, air cooled, wetted-surface air cooled, or the like. Operating methods may impact deterioration in equipment condition, prolong equipment life, extend production operating time, or provide other benefits. Mechanical or digital sensors may be used for monitoring equipment, and sensor data may be programmatically analyzed to identify developing problems. For example, sensors may be used in conjunction with one or more system components to detect and correct maldistribution, cross-leakage, strain, pre-leakage, thermal stresses, fouling, vibration, problems in liquid lifting, conditions that can affect air-cooled exchangers, conditions that can affect a wetted-surface air-cooled heat exchanger, or the like. An operating condition or mode may be adjusted to prolong equipment life or avoid equipment failure.
    Type: Grant
    Filed: March 27, 2018
    Date of Patent: July 26, 2022
    Assignee: UOP LLC
    Inventors: Sanford Allan Victor, Phillip F. Daly, Ian G. Horn
  • Patent number: 11377602
    Abstract: Processes and systems for the conversion of hydrocarbons herein may include separating an effluent from a moving bed reactor, the effluent including reaction product, first particulate catalyst, and second particulate catalyst. The separating may recover a first stream including the reaction product and first particulate catalyst and a second stream including second particulate catalyst. The second stream may be admixed with a regenerated catalyst stream including both first and second particulate catalyst at an elevated temperature. The admixing may produce a mixed catalyst at a relatively uniform temperature less than the elevated regenerated catalyst temperature, where the temperature is more advantageous for contacting light naphtha and heavy naphtha within the moving bed reactor to produce the effluent including the reaction product, the first particulate catalyst, and the second particulate catalyst.
    Type: Grant
    Filed: April 2, 2020
    Date of Patent: July 5, 2022
    Assignee: LUMMUS TECHNOLOGY LLC
    Inventors: Bryan Tomsula, Liang Chen, Peter Loezos, Rama Rao Marri
  • Patent number: 11365886
    Abstract: A chemical plant may include one or more fired heaters for heating of process streams. A fired heater may include a direct-fired heat exchanger that uses the hot gases of combustion to raise the temperature of a process fluid feed flowing through tubes positioned within the heater. Fired heaters may deliver feed at a predetermined temperature to the next stage of the reaction process or perform reactions such as thermal cracking. Systems and methods are disclosed to optimize the performance of fired heaters or reduce energy consumption of fired heaters.
    Type: Grant
    Filed: June 18, 2018
    Date of Patent: June 21, 2022
    Assignee: UOP LLC
    Inventors: Theodore Peter Faiella, Raul A. Ohaco, Colin J. Deller
  • Patent number: 11352573
    Abstract: Methods for operating a system having two downflow high-severity FCC units for producing products from a hydrocarbon feed includes introducing the hydrocarbon feed to a feed separator and separating it into a lesser boiling point fraction and a greater boiling point fraction. The greater boiling point fraction is passed to the first FCC unit and cracked in the presence of a first catalyst at 500° C. to 700° C. to produce a first cracking reaction product and a spent first catalyst. The lesser boiling point fraction is passed to the second FCC unit and cracked in the presence of a second catalyst at 500° C. to 700° C. to produce a second cracking reaction product and a spent second catalyst. At least a portion of the spent first catalyst or the spent second catalyst is passed back to the first FCC unit, the second FCC unit or both.
    Type: Grant
    Filed: October 29, 2020
    Date of Patent: June 7, 2022
    Assignee: Saudi Arabian Oil Company
    Inventors: Sameer A. Al-Ghamdi, Saad Al-Bogami, Abdennour Bourane
  • Patent number: 11339333
    Abstract: A fluidized catalytic cracking unit system includes a fluidized catalytic cracking unit assembly comprising a cracking unit; a reformer-electrolyzer-purifier assembly comprising a reformer-electrolyzer-purifier cell, the reformer-electrolyzer-purifier cell comprising an anode section and a cathode section; and a carbon capture assembly. The anode section of the reformer-electrolyzer-purifier assembly is configured to receive an input stream comprising hydrocarbon gases and water. The cathode section of the reformer-electrolyzer-purifier assembly is configured to produce a cathode exhaust stream comprising oxygen and carbon dioxide. The fluidized catalytic cracking unit assembly is configured to receive the cathode exhaust stream and to produce a flue gas comprising carbon dioxide, water, and less than 5 mole % oxygen.
    Type: Grant
    Filed: April 19, 2017
    Date of Patent: May 24, 2022
    Assignee: FuelCell Energy, Inc.
    Inventor: Fred C. Jahnke
  • Patent number: 11306258
    Abstract: Systems and methods for steam and catalytic cracking of a hydrocarbon inlet stream comprising hydrocarbons. Systems and methods can include a catalyst feed stream, where the catalyst feed stream comprises a fluid and a heterogeneous catalyst, the heterogeneous catalyst operable to catalyze cracking of the hydrocarbons on surfaces of the heterogeneous catalyst a steam feed stream, where the steam feed stream is operable to effect steam cracking of the hydrocarbons, and where the steam feed stream decreases coking of the heterogeneous catalyst; and a downflow reactor, where the downflow reactor is operable to accept and mix the hydrocarbon inlet stream, the catalyst feed stream, and the steam feed stream, where the downflow reactor is operable to produce light olefins by steam cracking and catalytic cracking, and where the downflow reactor is operable to allow the heterogeneous catalyst to flow downwardly by gravity.
    Type: Grant
    Filed: July 29, 2020
    Date of Patent: April 19, 2022
    Assignee: SAUDI ARABIAN OIL COMPANY
    Inventors: Musaed Salem Al-Ghrami, Wei Xu, Aaron Chi Akah
  • Patent number: 11260357
    Abstract: A process and apparatus for fluidizing a catalyst cooler with fluidization gas fed to the cooler below the catalyst bed is disclosed. Fluidization headers extend through an outlet manifold and deliver fluidization gas through distributors protruding through an outlet tube sheet defining said outlet manifold. The outlet manifold collects heated water vapor from the catalyst cooler and discharges it from the catalyst cooler.
    Type: Grant
    Filed: December 21, 2017
    Date of Patent: March 1, 2022
    Assignee: UOP LLC
    Inventor: Kevin J. Brandner
  • Patent number: 11261143
    Abstract: In an FCC apparatus in which swirl arms are used to discharge gas and catalyst from a riser, the swirling movement of the catalyst particles is inhibited while impeding the catalyst particles and gaseous products from exiting the disengaging chamber and entering a reactor annulus. The catalyst particles and gaseous products pass through a tunnel comprising a vertical wall to enter the reactor annulus. The vertical wall presents a face that is opposed to the angular direction in which the catalyst particles and gaseous products swirl. A baffle may be located at the intersection between the reactor annulus and the disengaging chamber to deflect catalyst laterally in a stripping section after exiting the reactor annulus. The baffle may be equipped with openings to fluidize the large proportion of catalyst passing over this region to effectively pre-strip this catalyst before it enters a stripping section.
    Type: Grant
    Filed: April 2, 2020
    Date of Patent: March 1, 2022
    Assignee: UOP LLC
    Inventors: Mohammad Reza Mostofi-Ashtiani, Lev Davydov, Robert Mehlberg
  • Patent number: 11253832
    Abstract: A catalytic cracking system in which liquid hydrocarbon and bio-oil are directed into a reactor riser of a fluid catalytic cracking unit by separate feed spray nozzle assemblies. To protect liquid bio-oil directed through the liquid bio-oil feed nozzle assembly from high temperature degradation, an insulating layer is provided between a central bio-oil feed tube in a concentrically surrounding atomizing gas passageway. Cooling channels also may be provided in the spray tip of the bio-oil feed nozzle assembly.
    Type: Grant
    Filed: July 10, 2020
    Date of Patent: February 22, 2022
    Assignee: Spraying Systems Co.
    Inventors: Bandish Patel, Digna Boatman, Eusebius Anku Gbordzoe
  • Patent number: 11230672
    Abstract: According to one more embodiments, petrochemical products may be produced from a hydrocarbon material by a process that may comprise separating the hydrocarbon material into at least a lesser boiling point fraction, a medium boiling point fraction, and a greater boiling point fraction. The process may further comprise cracking at least a portion of the lesser boiling point fraction and the medium boiling point fraction in a second reactor unit in the presence of a second catalyst at a reaction temperature of from 500° C. to 700° C. to produce a second cracking reaction product, wherein the lesser boiling point fraction enters the second reactor unit upstream of wherein the medium boiling point fraction enters the second reactor.
    Type: Grant
    Filed: September 1, 2020
    Date of Patent: January 25, 2022
    Assignee: Saudi Arabian Oil Company
    Inventors: Mansour Ali Al Herz, Abdennour Bourane, Ali Al Jawad, Alberto Lozano Ballesteros
  • Patent number: 11224864
    Abstract: The invention is directed to a CO to CO2 combustion promoter comprising microsphere sized porous silica and/or alumina comprising particles further comprising on or more Group VIII noble metals wherein the noble metal is distributed in the particle as an eggshell such that a higher content of noble metal is present in the outer region of the particle as compared to the content of noble metal in the center of the particle.
    Type: Grant
    Filed: February 16, 2021
    Date of Patent: January 18, 2022
    Assignee: COCHISE TECHNOLOGY, LLC
    Inventor: Guido William Aru
  • Patent number: 11214741
    Abstract: A fluid catalytic cracking (FCC) process for cracking multiple feedstocks in a FCC apparatus comprising a first set of feed distributors having first distributor tips and a second set of feed distributors having second distributor tips is provided. A first feed is injected into the riser from first distributor tips. A second feed is injected into the riser from second distributor tips. The first distributor tips and the second distributor tips are positioned at different radii in the riser. The first feed and the second feed are cracked in the riser in the presence of an FCC catalyst to provide a cracked effluent stream. The first distributor tips and the second distributor tips are located into a region of lower catalyst density and a region of higher catalyst density respectively in the riser.
    Type: Grant
    Filed: February 25, 2020
    Date of Patent: January 4, 2022
    Assignee: UOP LLC
    Inventors: Lev Davydov, Robert Mehlberg, Matthew R. Wojtowicz, Patrick D. Walker, Sakthivelan Maadasamy Durai, Sathit Kulprathipanja
  • Patent number: 11194317
    Abstract: Catalysts used for catalytic reforming are treated with organic chloride to condition the catalysts. Chloride treaters may be located in the product streams to remove the chloride contaminants. The continuous catalyst reforming process, including the catalyst reformer unit and chloride treaters, may be monitored in order to predict when adsorbent replacement or regeneration is needed. For example, one or more sensors and measurement devices may be used to monitor certain conditions or parameters. A system may be configured to take one or more actions in response to certain conditions or parameters being met.
    Type: Grant
    Filed: October 1, 2018
    Date of Patent: December 7, 2021
    Assignee: UOP LLC
    Inventors: Jorge Charr, Dean E. Rende, Bryan James Egolf, Yue Zhu, Mary Wier, Guy Woodle
  • Patent number: 11185834
    Abstract: An injection device is described herein, which is configured to atomize a liquid into droplets using a gas. The injection device has a body with walls defining a recess, a liquid inlet orifice being formed laterally in the walls, and a gas injection assembly in which there is formed a passage for the circulation of gas between a gas inlet orifice at one end of the recess and a gas outlet orifice situated inside the recess. The assembly defines, with the walls of the body, a space for the circulation of liquid from the liquid inlet orifice to the constriction. The walls of the body define a constriction having a throat, downstream of the gas outlet orifice, and the injection device is arranged in such a way that the stream of gas at the outlet orifice covers a wall portion in close proximity to the throat.
    Type: Grant
    Filed: September 19, 2019
    Date of Patent: November 30, 2021
    Assignee: TOTAL RAFFINAGE CHIMIE
    Inventor: Romain Lesage
  • Patent number: 11130111
    Abstract: A plant or refinery may include equipment such as reactors, heaters, heat exchangers, regenerators, separators, or the like. Types of heat exchangers include shell and tube, plate, plate and shell, plate fin, air cooled, wetted-surface air cooled, or the like. Operating methods may impact deterioration in equipment condition, prolong equipment life, extend production operating time, or provide other benefits. Mechanical or digital sensors may be used for monitoring equipment, and sensor data may be programmatically analyzed to identify developing problems. For example, sensors may be used in conjunction with one or more system components to detect and correct maldistribution, cross-leakage, strain, pre-leakage, thermal stresses, fouling, vibration, problems in liquid lifting, conditions that can affect air-cooled exchangers, conditions that can affect a wetted-surface air-cooled heat exchanger, or the like. An operating condition or mode may be adjusted to prolong equipment life or avoid equipment failure.
    Type: Grant
    Filed: March 27, 2018
    Date of Patent: September 28, 2021
    Assignee: UOP LLC
    Inventors: Sanford Allan Victor, Phillip F. Daly, Ian G. Horn
  • Patent number: 11117108
    Abstract: A process where external fuel oil is used to wash entrained catalyst from a fluidized-bed propane dehydrogenation reactor effluent, where the fuel oil and catalyst mixture is returned to the reactor to provide the net fuel required for catalyst regeneration. Optionally the fluidized-bed propane dehydrogenation reactor effluent and the fuel oil are contacted in a direct contact inline device before entering a flash zone in the reactor vessel.
    Type: Grant
    Filed: September 13, 2019
    Date of Patent: September 14, 2021
    Assignee: Kellogg Brown & Root LLC
    Inventors: Rian Reyneke, Jose Manuel Urquiaga, Truc Vu, Jeffrey Donald Caton
  • Patent number: 11105787
    Abstract: An apparatus includes at least one processor configured to obtain inline measurements of one or more properties of crude oil, translate the measurements into a set of process and control parameters, and apply the process and control parameters to process equipment. The process and control parameters configure the process equipment to process the crude oil having the one or more properties. The one or more properties of the crude oil may include at least one of: density, specific gravity, viscosity, carbon residue, and sulfur content of the crude oil. The process and control parameters could be applied to one or more controllers associated with a blending unit in a refinery or to one or more controllers associated with a crude oil distillation column in the refinery.
    Type: Grant
    Filed: September 25, 2018
    Date of Patent: August 31, 2021
    Assignee: HONEYWELL INTERNATIONAL INC.
    Inventors: Dinesh Kumar KN, Soumendra Mohan Banerjee
  • Patent number: 11098255
    Abstract: The invention provides an improved system for separation technology intended to reduce unwanted catalyst/thermal reactions by minimizing contact of the hydrocarbons and the catalyst within the reactor.
    Type: Grant
    Filed: January 7, 2020
    Date of Patent: August 24, 2021
    Assignee: MARATHON PETROLEUM COMPANY LP
    Inventors: Nikolas Larsen, Jeff Sexton
  • Patent number: 11078434
    Abstract: Disclosed is a process and system for upgrading low-quality oils. The upgrading process comprises: (1) subjecting a low-quality oil to a conversion reaction in the presence of hydrogen and optionally in the presence of a conversion catalyst to obtain a conversion product, (2) processing the conversion product to obtain a first processed product, wherein the first processed product comprises a specific amount of a special component, and (3) subjecting the first processed product to extraction separation to obtain an upgraded oil and a pitch. The upgrading process and the upgrading system have the advantages of stable operation, high upgrading efficiency, environmental friendliness, low coke yield or high yield of upgraded oil.
    Type: Grant
    Filed: September 11, 2017
    Date of Patent: August 3, 2021
    Assignees: CHINA PETROLEUM & CHEMICAL CORPORATION, RESEARCH INSTITUTE OF PETROLEUM PROCESSING, SINOPEC
    Inventors: Jun Long, Huandi Hou, Zijun Wang, Haiping Shen, Ming Dong, Lishun Dai, Jianhong Gong, Jiguang Li, Shuhong Zhang, Cuihong Wang, Yucheng She, Yuzhang Wang, Mengying Tao
  • Patent number: 11071960
    Abstract: The invention relates to a reaction container for stabilizing the temperature of a liquid mixture substances, the reaction container comprising an upper container part and a lower container part, in which the lower container part has an inner direct means of refrigeration and an outer indirect means of refrigeration in addition to an inner, direct means of heating and an outer, indirect means of heating.
    Type: Grant
    Filed: April 11, 2018
    Date of Patent: July 27, 2021
    Assignee: INNOIL AG
    Inventors: Kurt Böhme, Pierre Freymond
  • Patent number: 11059013
    Abstract: A method for processing a chemical stream includes contacting a feed stream with a catalyst in an upstream reactor section of a reactor having the upstream reactor section and a downstream reactor section, passing an intermediate product stream to the downstream reactor section, and introducing a riser quench fluid into the downstream reactor section, upstream reactor section, or transition section and into contact with the intermediate product stream and the catalyst to slow or stop the reaction. The method includes separating at least a portion of the catalyst from the product stream, passing the product stream to a product processing section, cooling the product stream, and separating a portion of the riser quench fluid from the product stream. The riser quench fluid separated from the product stream may be recycled back to the downstream reactor section, upstream reactor section, or transition section as the riser quench fluid.
    Type: Grant
    Filed: June 13, 2018
    Date of Patent: July 13, 2021
    Assignee: Dow Global Technologies LLC
    Inventor: Matthew T. Pretz
  • Patent number: 11052366
    Abstract: An erosion monitoring system of components exposed to wear for use in systems equipped with a fluidized catalyst comprising a bundle of fiber optic sensors, said optical fibers being provided with one or more Bragg gratings, a processing unit and the fiber optic sensors depart off from the bundle and are positioned transversely to the wall exposed to erosion wear due to the erosion of the components to be monitored.
    Type: Grant
    Filed: October 15, 2018
    Date of Patent: July 6, 2021
    Assignee: Remosa S.r.l.
    Inventor: Cristian Argiolas
  • Patent number: 11042170
    Abstract: A process and apparatus for reducing pressure of a flue gas stream including passing a pressurized flue gas stream to a vessel and through a bed of particulates in the vessel to reduce the pressure of the flue gas stream. The flue gas passes from the vessel at a lower pressure than at which it entered. The bed of particulates is disposed in the vessel between the outlet end of the inlet conduit and the inlet end of the outlet conduit. If deposits develop in the bed of particulates, the particulates can be replaced with fresh particulates to avoid excessive pressure drop. Data may be received from a stream in fluid communication with the foregoing process and apparatus.
    Type: Grant
    Filed: July 24, 2018
    Date of Patent: June 22, 2021
    Assignee: UOP LLC
    Inventors: Sujay R. Krishnamurthy, Paolo Palmas, Thomas W. Lorsbach
  • Patent number: 11022963
    Abstract: A petrochemical plant or refinery may include equipment such as pumps, compressors, valves, exchangers, columns, adsorbers, or the like. Some petrochemical plants or refineries may include one or more sensors configured to collect operation information of the equipment in the plant or refinery. A faulty condition of a process of the petrochemical plant may be diagnosed based on the operation of the plant equipment. A diagnostic system, which may receive operation information from the one or more sensors, may include a detection platform, an analysis platform, a visualization platform, and/or an alert platform.
    Type: Grant
    Filed: January 18, 2019
    Date of Patent: June 1, 2021
    Assignee: UOP LLC
    Inventors: Christophe Romatier, Ian G. Horn, Paul Kowalczyk, Zak Alzein, David Rondeau
  • Patent number: 10967351
    Abstract: A fluid catalytic cracking unit (FCCU) for production of petrochemical feedstock fractions comprises a first reactor to receive a stream of desalinated crude oil and produce a first cracked product stream; a second reactor to receive a stream of light cracked naphtha (LCN) and produce a second cracked product stream; a third reactor to receive a bottom stream and produce a third cracked product stream; and a fractionating column and gas concentration section to separate components of the first cracked product stream, the second cracked product stream, and the third cracked product stream to produce, upon further fractionation, Ethylene, Propylene, Butylene, Benzene, Toluene and Xylene as the petrochemical feedstock fractions.
    Type: Grant
    Filed: May 28, 2018
    Date of Patent: April 6, 2021
    Assignee: Hindustan Petroleum Corporation Limited
    Inventors: Pramod Kumar, Hrishikesh Shriram Shidhaye, Peddy Vendata Chalapathi Rao, Sri Ganesh Gandham
  • Patent number: 10962302
    Abstract: A plant or refinery may include equipment such as reactors, heaters, heat exchangers, regenerators, separators, or the like. Types of heat exchangers include shell and tube, plate, plate and shell, plate fin, air cooled, wetted-surface air cooled, or the like. Operating methods may impact deterioration in equipment condition, prolong equipment life, extend production operating time, or provide other benefits. Mechanical or digital sensors may be used for monitoring equipment, and sensor data may be programmatically analyzed to identify developing problems. For example, sensors may be used in conjunction with one or more system components to detect and correct maldistribution, cross-leakage, strain, pre-leakage, thermal stresses, fouling, vibration, problems in liquid lifting, conditions that can affect air-cooled exchangers, conditions that can affect a wetted-surface air-cooled heat exchanger, or the like. An operating condition or mode may be adjusted to prolong equipment life or avoid equipment failure.
    Type: Grant
    Filed: March 27, 2018
    Date of Patent: March 30, 2021
    Assignee: UOP LLC
    Inventors: Sanford Allan Victor, Phillip F. Daly, Ian G. Horn
  • Patent number: 10953386
    Abstract: An activated carbon-based media for efficient removal of chloramines as well as chlorine and ammonia from an aqueous stream is presented, and a method for making the same. The method involves preparing activated carbon that removes chloramines efficiently from chloramine-rich aqueous media. In particular, this application relates to the use of high performance catalytically active carbon for an efficient removal of chloramine from drinking water in the form of a solid carbon block or granular carbon media. The activated carbon is treated with a nitrogen-rich compound, such as, melamine.
    Type: Grant
    Filed: December 27, 2018
    Date of Patent: March 23, 2021
    Assignee: Mannon Water (Singapore) PTE. LTD.
    Inventors: Nabin Kumar Pal, Ramachandra Swamy, Sridhar Chowdasandra, Jola Solomon
  • Patent number: 10953377
    Abstract: A chemical plant or a petrochemical plant or a refinery may include one or more pieces of equipment that process one or more input chemicals to create one or more products. For example, catalytic dehydrogenation can be used to convert paraffins to the corresponding olefin. A delta temperature controller may determine and control differential temperature across the reactor, and use a delta temperature to control a set point for a heater temperature controller. By doing so, the plant may ramp up a catalytic dehydrogenation unit faster and ensure it does not coke up the catalyst and/or foul a screens too quickly. Catalyst activity may be taken into account and allow the plant to have better control over production and run length of the unit.
    Type: Grant
    Filed: December 10, 2018
    Date of Patent: March 23, 2021
    Assignee: UOP LLC
    Inventors: Louis A. Lattanzio, Christopher Schindlbeck
  • Patent number: 10940460
    Abstract: An intercalated, modified and calcined smectite clay comprising (a) pillars comprising aluminum and: (i) at least one rare earth or lanthanide group metal; or (ii) at least one rare earth or lanthanide group metal and gallium; and (b) at least one ion-exchanged metal selected from the group consisting of aluminum, barium, beryllium, calcium, cerium, cesium, copper, chromium, gadolinium, gallium, germanium, hafnium, holmium, iron (II and III), lanthanum, lithium, magnesium, manganese, neodymium, potassium, praseodymium, rubidium, samarium, silver, selenium, sodium, strontium, tellurium, terbium, thallium, thorium, tin, titanium, uranium, ytterbium, yttrium, zinc and zirconium; wherein the clay is characterized by a basal d001 spacing equal to or greater than about 18.5 angstroms; and processes for making.
    Type: Grant
    Filed: May 9, 2016
    Date of Patent: March 9, 2021
    Assignee: W. R. Grace & Co.-Conn.
    Inventors: Michael D. Jensen, John Robert McCauley, Andrew G. Singleton, Demetrius Michos
  • Patent number: 10913905
    Abstract: Systems and methods are disclosed for managing the operation of a plant, such as a chemical plant or a petrochemical plant or a refinery, and more particularly for enhancing system performance of a catalyzed reaction system by, among other features, detecting catalyst deactivation and cycle length. Plants may include those that provide hydrocarbon cracking or other process units. A plant may include a reactor, a heater, a catalyst bed, a separator, and other equipment. The equipment may use catalyst to treat feed products to remove compounds and produce different products. Catalysts used in the various reactors in these processes become deactivated over time. Systems and methods are disclosed for extending catalyst life and thereby improving efficiency of the plant.
    Type: Grant
    Filed: June 18, 2018
    Date of Patent: February 9, 2021
    Assignee: UOP LLC
    Inventors: Mahesh Kumar Gellaboina, Michael Terry, Seth Huber, Danielle Schindlbeck
  • Patent number: 10901403
    Abstract: Methods, systems, and apparatuses for developing linear process models to improve performance of components that make up operations in a plant are described herein. In some arrangements, a system may leverage one or more sensors and/or measurement devices to identify rates and compositions of feed and yield. The system may use one or more stoichiometric matrices and/or differential equations to identify molar and mass solutions for each feed component and predict the yield for reaction rates on a component-by-component basis. The system may further adjust the reaction rate coefficients to minimize the deviation between the yield results and the yield identified by system sensors and/or measuring devices. The resulting linear process models may be utilized to optimize plant processes in order to minimize reaction waste and maximize reaction yield.
    Type: Grant
    Filed: February 20, 2018
    Date of Patent: January 26, 2021
    Assignee: UOP LLC
    Inventor: Joel Joshua Kaye
  • Patent number: 10899972
    Abstract: A method for fluid catalytic cracking (FCC) of petroleum oil feedstock includes reacting the petroleum oil feedstock with a catalyst mixture in a reaction zone of an FCC unit to obtain a product stream including desulfurized hydrocarbon product, unreacted petroleum oil feedstock, and spent catalyst. During the reacting a process control system develops a process model based on data collected during the reacting, the process model characterizing a relationship among the feed rate of the base cracking catalyst, the feed rate of the FCC additive, the operating conditions, the composition of the product stream, and emissions from the reaction; and one or more of (i) a target feed rate of the base cracking catalyst, (ii) a target feed rate of the FCC additive, and (iii) one or more target operating conditions of the reaction in the reaction zone to reduce the emissions from the FCC unit and to increase a yield of the desulfurized hydrocarbon product in the product stream are determined.
    Type: Grant
    Filed: December 18, 2019
    Date of Patent: January 26, 2021
    Assignee: Saudi Arabian Oil Company
    Inventors: Saeed Al-Alloush, Othman Taha
  • Patent number: 10889768
    Abstract: Systems and processes are disclosed for producing petrochemical products, such as ethylene, propene and other olefins from crude oil in high severity fluid catalytic cracking (HSFCC) units. Processes include separating a crude oil into a light fraction and a heavy fraction, cracking the light fraction and heavy fraction in separation cracking reaction zones, and regenerating the cracking catalysts in a two-zone regenerator having a first regeneration zone for the first catalyst (heavy fraction) and a second regeneration zone for the second catalyst (light fraction) separate from the first regeneration zone. Flue gas from the first catalyst regeneration zone is passed to the second regeneration zone to provide additional heat to raise the temperature of the second catalyst of the light fraction side. The disclosed systems and processes enable different catalysts and operating conditions to be utilized for the light fraction and the heavy fraction of a crude oil feed.
    Type: Grant
    Filed: January 10, 2019
    Date of Patent: January 12, 2021
    Assignee: Saudi Arabian Oil Company
    Inventors: Abdennour Bourane, Raed Abudawoud, Ibrahim Abba
  • Patent number: 10870802
    Abstract: Methods for operating a system having two downflow high-severity FCC units for producing products from a hydrocarbon feed includes introducing the hydrocarbon feed to a feed separator and separating it into a lesser boiling point fraction and a greater boiling point fraction. The greater boiling point fraction is passed to the first FCC unit and cracked in the presence of a first catalyst at 500° C. to 700° C. to produce a first cracking reaction product and a spent first catalyst. The lesser boiling point fraction is passed to the second FCC unit and cracked in the presence of a second catalyst at 500° C. to 700° C. to produce a second cracking reaction product and a spent second catalyst. At least a portion of the spent first catalyst or the spent second catalyst is passed back to the first FCC unit, the second FCC unit or both.
    Type: Grant
    Filed: April 4, 2018
    Date of Patent: December 22, 2020
    Assignee: Saudi Arabian Oil Company
    Inventors: Sameer A. Al-Ghamdi, Saad Al-Bogami, Abdennour Bourane
  • Patent number: 10865744
    Abstract: Methods and systems are provided for a mixer. In one example, a system may include an EGR mixing having a downstream surface with a plurality of venturi tubes extending therefrom.
    Type: Grant
    Filed: November 15, 2018
    Date of Patent: December 15, 2020
    Assignee: Ford Global Technologies, LLC
    Inventor: Xiaogang Zhang
  • Patent number: 10851041
    Abstract: Disclosed herein is a fouling-resistant system for the manufacture of a compound by distillation, the system including a reactant heating zone; a distillation column in fluid communication with the reactant heating zone wherein the distillation column comprises a plurality of distillation trays for removing by-products from the reactants, and wherein at least 20% of the plurality of distillation trays are baffle trays arranged in a staggered configuration; where each tray contacts an opposing portion of an inner wall of the distillation column from a portion contacted by a tray located above the tray and below the tray; and wherein the baffle trays are disposed in a lower portion of the distillation column.
    Type: Grant
    Filed: June 26, 2014
    Date of Patent: December 1, 2020
    Assignee: Dow Global Technologies LLC
    Inventors: Bruce S. Holden, John W. Wilchek, Jr.
  • Patent number: 10844294
    Abstract: An integrated process catalytically cracks whole light crude oil into light olefins, especially propylene and ethylene. The process is integrated with an adjacent conventional fluid catalytic cracking unit whereby the heavy liquid product mixture (light and heavy cycle oils) from whole crude oil cracking is mixed with vacuum gas oil (VGO) for further processing. The process comprises recycling total product fraction of light cracked naphtha (LCN) and mixing with fresh crude oil feed. High propylene and ethylene yields are obtained by cracking the whole light crude oil and LCN in an FCC configuration using a mixture of FCC catalyst and ZSM-5 additive at a temperature between, that of conventional FCC and steam cracking.
    Type: Grant
    Filed: March 14, 2019
    Date of Patent: November 24, 2020
    Assignee: King Fahd University of Petroleum and Minerals
    Inventors: Abdullah Mohammed Aitani, Sulaiman Saleh Al-Khattaf, Akram Abdulhakeem Al-Absi
  • Patent number: 10839115
    Abstract: A cleansing system for improving operation of a petrochemical plant or refinery. The petrochemical plant or refinery may include a fractionation column, a condenser, and a pump. Equipment, such as condensers, receivers, reboilers, feed exchangers, and pumps may be divided into subsections. Temperatures, pressures, flows, and other plant operations may be used for optimizing plant performance. A cleansing unit performs an enhanced cleansing process, which may allow early detection and diagnosis of the plant operating conditions based on one or more environmental factors.
    Type: Grant
    Filed: December 22, 2017
    Date of Patent: November 17, 2020
    Assignee: UOP LLC
    Inventors: Ian G. Horn, Christophe Romatier, Paul Kowalczyk, Zak Alzein
  • Patent number: 10807076
    Abstract: This application discloses a mesoporous catalyst formed by combining a matrix precursor treated with a polyphosphate, and a metallic oxide treated with a cationic electrolyte. The combined treatment with the polyphosphate and cationic polyelectrolyte yields unexpected improvements in attrition resistance, while maintaining high overall pore volume, even as the ratio of meso pore volume to macro pore volume of the formed FCC catalyst increases.
    Type: Grant
    Filed: December 3, 2018
    Date of Patent: October 20, 2020
    Assignee: BASF Corporation
    Inventors: Michael Sigman, Charles Keweshan, Mitchell Willis
  • Patent number: 10794644
    Abstract: A plant or refinery may include equipment such as reactors, heaters, heat exchangers, regenerators, separators, or the like. Types of heat exchangers include shell and tube, plate, plate and shell, plate fin, air cooled, wetted-surface air cooled, or the like. Operating methods may impact deterioration in equipment condition, prolong equipment life, extend production operating time, or provide other benefits. Mechanical or digital sensors may be used for monitoring equipment, and sensor data may be programmatically analyzed to identify developing problems. For example, sensors may be used in conjunction with one or more system components to detect and correct maldistribution, cross-leakage, strain, pre-leakage, thermal stresses, fouling, vibration, problems in liquid lifting, conditions that can affect air-cooled exchangers, conditions that can affect a wetted-surface air-cooled heat exchanger, or the like. An operating condition or mode may be adjusted to prolong equipment life or avoid equipment failure.
    Type: Grant
    Filed: March 27, 2018
    Date of Patent: October 6, 2020
    Assignee: UOP LLC
    Inventors: Sanford Allan Victor, Phillip F. Daly, Ian G. Horn
  • Patent number: 10781377
    Abstract: A process and apparatus for catalytically cracking fresh heavy hydrocarbon feed to produce cracked products is disclosed. A fraction of the cracked products can be obtained to re-crack it in a downer reactor. The downer reactor may produce high selectivity to light olefins. Spent catalyst from both reactors can be regenerated in the same regenerator.
    Type: Grant
    Filed: November 30, 2017
    Date of Patent: September 22, 2020
    Assignee: UOP LLC
    Inventors: James M. Bell, Dharmesh C. Panchal
  • Patent number: 10754359
    Abstract: A plant or refinery may include equipment such as condensers, regenerators, distillation columns, pumps, slide valves, or the like. Different operating methods may impact deterioration in equipment condition, thereby prolonging equipment life, extending production operating time, or providing other benefits. Mechanical or digital sensors may be used for monitoring equipment to determine whether problems are developing. Specifically, sensors may be used in conjunction with one or more system components to predict and detect slide valve sticking. A shielded, tube skin thermocouple assembly may provide a temperature profile for a slide valve. Tomography may be used to image a slide valve. An operating condition of the plant or refinery may be adjusted to prolong equipment life or avoid equipment failure.
    Type: Grant
    Filed: December 21, 2017
    Date of Patent: August 25, 2020
    Assignee: UOP LLC
    Inventors: Louis A. Lattanzio, Alex Green, Matthew R. Wojtowicz, Ian G. Horn
  • Patent number: 10752845
    Abstract: A plant or refinery may include equipment such as condensers, regenerators, distillation columns, rotating equipment, compressors, pumps, turbines, or the like. Different operating methods may impact deterioration in equipment condition, thereby prolonging equipment life, extending production operating time, or providing other benefits. Mechanical or digital sensors may be used for monitoring equipment to determine whether problems are developing. For example, sensors may be used in conjunction with one or more system components to perform invariant mapping, monitor system operating characteristics, and/or predict pressure, volume, surges, reactor loop fouling, gas quality, or the like. An operating condition (e.g., of one or more pieces of equipment in the plant or refinery) may be adjusted to prolong equipment life or avoid equipment failure.
    Type: Grant
    Filed: March 26, 2018
    Date of Patent: August 25, 2020
    Assignee: UOP LLC
    Inventors: Michael Van de Cotte, Ian G. Horn
  • Patent number: 10751684
    Abstract: A counter-current catalyst regenerator with at least two stages of counter-current contact along with a regenerator riser is proposed. Each stage may comprise a permeable barrier that allows upward passage of oxygen-containing gas and downward passage of coked catalyst into each stage, but inhibits upward movement of catalyst to mitigate back mixing and approximate true counter-current contact and efficient combustion of coke from catalyst. The regenerator riser may provide a passage to transport the catalyst and may serve as a secondary stage for coke combustion to provide the regenerated catalyst.
    Type: Grant
    Filed: November 30, 2017
    Date of Patent: August 25, 2020
    Assignee: UOP LLC
    Inventors: Lev Davydov, Michael S. Sandacz, Paolo Palmas, Zhihao Fei, Matthew Lippmann
  • Patent number: 10739798
    Abstract: Systems and methods are disclosed for detecting temperature excursion in a chemical plant or petrochemical plant or refinery. Aspects of the disclosure provide an enhanced control system for a reactor, such as in hydroprocessing. The enhanced control system may provide early warnings of impending undesirable events, directly or indirectly manipulate certain process variables to reduce undesirable outcomes, and/or directly or indirectly manipulate of certain process variables so as to place a reactor unit in a “safe park” state. This may avoid a high temperature trip, depressuration, associated operating risks, allow for faster recovery from temperature excursions, and/or avoid unplanned emergency shutdowns of the reactor, chemical process, plant, or refinery.
    Type: Grant
    Filed: May 7, 2018
    Date of Patent: August 11, 2020
    Assignee: UOP LLC
    Inventors: Jorge Charr, Donald Eizenga, Raul A. Ohaco, Ralph P. Davis, Christina L. Haasser, James W. Harris, Kevin Carnes, Daliah Papoutsis
  • Patent number: 10737990
    Abstract: Disclosed is an olefin production method which includes: (a) providing the regenerated catalyst and the hydrocarbon including not less than 90 wt % of LPG into Riser of Fast Fluidization Regime, and dehydrogenating in the presence of an alumina type catalyst; (b) separating an effluent from the dehydrogenation reaction into the catalyst and propylene mixture; (c) stripping to remove the hydrocarbon compound included in the catalyst separated at stage (b); (d) mixing the catalyst stripped at stage (c) with the gas including oxygen, and continuously regenerating it; (e) recycling the catalyst regenerated at stage (d) to stage (a), and providing it again into Riser; and (f) producing propylene product by cooling, compressing and separating propylene mixture of the reaction product separated at stage (b).
    Type: Grant
    Filed: May 1, 2018
    Date of Patent: August 11, 2020
    Assignees: SK GAS CO., LTD., KOREA RESEARCH INSTITUTE OF CHEMICAL TECHNOLOGY
    Inventors: Deuk Soo Park, Ung Gi Hong, Hyeongchan Ahn, Won Choon Choi, Yong Ki Park
  • Patent number: 10734098
    Abstract: Methods, systems, and apparatuses for monitoring health of a catalyst in a plant by retrieving plant data, comparing the plant data to equilibrium conditions, and sending a notification comprising an indication of the health of the catalyst. A plant may be configured to produce a product using a catalyst. A plant monitoring computing platform may be configured to receive, from sensors and/or computing devices of the plant, plant data and/or lab data corresponding to the catalyst. The plant monitoring computing platform may determine equilibrium conditions corresponding to the plant. Based on a comparison of the plant data, the equilibrium conditions, and/or target equilibrium conditions, the plant monitoring computing platform may send a notification. The notification may comprise an indication of the performance of the catalyst.
    Type: Grant
    Filed: March 25, 2019
    Date of Patent: August 4, 2020
    Assignee: UOP LLC
    Inventors: Louis A. Lattanzio, Abhishek Pednekar
  • Patent number: 10688477
    Abstract: A process to react an oxygen containing regenerated catalyst stream prior to use in a fluidized bed reactor comprising providing a regenerated catalyst stream which comprises at least 0.001 wt % oxygen; reacting the regenerated catalyst stream with a fuel source thereby forming oxides and reducing the amount of oxygen in the regenerated catalyst stream to produce a usable regenerated catalyst stream; and injecting the usable regenerated catalyst stream into a hydrocarbon fluidized bed reactor is provided.
    Type: Grant
    Filed: May 5, 2017
    Date of Patent: June 23, 2020
    Assignee: Dow Global Technologies LLC
    Inventors: Matthew T. Pretz, Liwei Li
  • Patent number: 10684631
    Abstract: A plant or refinery may include equipment such as condensers, regenerators, distillation columns, pumps, slide valves, or the like. Different operating methods may impact deterioration in equipment condition, thereby prolonging equipment life, extending production operating time, or providing other benefits. Mechanical or digital sensors may be used for monitoring equipment to determine whether problems are developing. Specifically, sensors may be used in conjunction with one or more system components to predict and detect slide valve hot spots. A shielded, tube skin thermocouple assembly may provide a temperature profile for a slide valve. Tomography may be used to image a slide valve. An operating condition of the plant or refinery may be adjusted to prolong equipment life or avoid equipment failure.
    Type: Grant
    Filed: December 21, 2017
    Date of Patent: June 16, 2020
    Assignee: UOP LLC
    Inventors: Louis A. Lattanzio, Alex Green, Matthew R. Wojtowicz, Ian G. Horn