Abstract: A first hydroprocessed product and a second hydroprocessed product produced from a multi-stage process for upgrading pyrolysis tar, such as steam cracker tar, are provided herein. Fuel blends including the first hydroprocessed product and/or the second hydroprocessed product are also provided herein as well as methods of lowering pour point of a gas oil using the first hydroprocessed product and the second hydroprocessed product.

Abstract: Apparatus and processes herein provide for converting hydrocarbon feeds to light olefins and other hydrocarbons. The processes and apparatus include, in some embodiments, feeding a hydrocarbon, a first catalyst and a second catalyst to a reactor, wherein the first catalyst has a smaller average particle size and is less dense than the second catalyst. A first portion of the second catalyst may be recovered as a bottoms product from the reactor, and a cracked hydrocarbon effluent, a second portion of the second catalyst, and the first catalyst may be recovered as an overhead product from the reactor. The second portion of the second catalyst may be separated from the overhead product, providing a first stream comprising the first catalyst and the hydrocarbon effluent and a second stream comprising the separated second catalyst, allowing return of the separated second catalyst in the second stream to the reactor.

Abstract: A process for converting high boiling hydrocarbon feedstock into lighter boiling hydrocarbon products in which the lighter boiling hydrocarbon products are suitable feedstock for petrochemical processes.

Abstract: A hydroconversion process includes feeding a heavy feedstock containing vanadium and/or nickel, a catalyst emulsion containing at least one group 8-10 metal and at least one group 6 metal, hydrogen and an organic additive to a hydroconversion zone under hydroconversion conditions to produce an upgraded hydrocarbon product and a solid carbonaceous material containing the group 8-10 metal, the group 6 metal, and the vanadium and/or nickel.

Abstract: The invention relates to an oil-derived hydrocarbon converter comprising a catalytic cracking vessel (1) in the presence of catalyst particles in fluidized phase and a regenerator, for regenerating said catalyst particles by burning off the coke deposited on them, said catalyst circulating between said cracking vessel and said regenerator, said regenerator being a reactor (2) integrated into a combustion installation for steam generation comprising carbon dioxide capture.

Abstract: A process for dewaxing a waxy component-containing hydrocarbon feedstock comprises contacting the feedstock under dewaxing conditions with a catalyst system comprising ZSM-48 and a molecular sieve of the MTT framework type.

Abstract: The instant invention relates to a process to produce low sulfur distillate products through the hydrotreating of distillate boiling range feedstreams in the presence of a bulk metal hydrotreating catalyst.

Abstract: A process for dewaxing a waxy component-containing hydrocarbon feedstock comprises contacting the feedstock under dewaxing conditions with a catalyst system comprising ZSM-48 and a molecular sieve of the MTT framework type.

Abstract: A process for the fluid catalytic cracking of mixed hydrocarbon feeds from different sources is described, such as feeds A and B of different crackability, the process being especially directed to obtaining light fractions such as LPG and comprising injecting feed A in the base of the riser reactive section and feed B, of lower crackability, at a height between 10% and 80% of the riser, with feed B comprising between 5% and 50% of the total processed feed. The process requires that the feeds present differences in the contaminant content, improved dispersion of feeds A and B and feed B injection temperature same or higher than that of feed A.

Abstract: A fluidized-bed reactor is disclosed. The fluidized-bed reactor steadies the gas flow through the fluidized bed chamber of the reactor. The swirl chamber of the reactor consists of a conical housing in which a conical insert is also situated. This creates an annular gap between the housing and the insert, which acts as the swirl chamber and which, according to the geometry of the two components, causes a velocity of the gas flow which remains the same along the height, which increases or which decreases. Such a reactor can also be called a constant annular-gap reactor.

Abstract: This invention provides a resid cracking apparatus comprising a riser, reactor, stripper cum separator with adjustable outlets in flow communication with adsorbent and catalyst regenerators for converting hydrocarbon residues containing higher concentration of conradson carbon content, poisonous metals such as nickel & vanadium and basic nitrogen etc., into lighter and valuable products and a process thereof.

Abstract: A composition for controlling NOx emissions during FCC processes comprises (i) an acidic oxide support, (ii) cerium oxide, (iii) a lanthanide oxide other than ceria such as praseodymium oxide, and (iv), optionally, an oxide of a metal from Groups Ib and IIb such as copper, silver and zinc.

Abstract: A composition for controlling NOx emissions during FCC processes comprises (i) an acidic oxide support, (ii) cerium oxide, (iii) a lanthanide oxide other than ceria such as praseodymium oxide, and (iv), optionally, an oxide of a metal from Groups Ib and IIb such as copper, silver and zinc.

Abstract: A sequential processing for heavy petroleum residues is disclosed which uses a separate mixture of catalyst and adsorbent. The solid adsorbent and FCC (fluids catalytic cracking) catalyst particles differ significant at least on particle size or density or both. The adsorbent preferably consist of calcined coke or metal oxides of Al, Si, or Mg having enhanced ability of selectively capture different impurities of the residual oil. The adsorbent particles first treat the residual hydrocarbons in the riser bottom end subsequently the actual catalyst tales care of catalytic cracking in the upper section of the riser. The spent solid mixture is fed to the catalyst separator which uses steam at sufficiently high velocity but at lower temperature to lift the catalyst particles out of the separator. Such a novel low temperature faster separation minimizes Vanadium mobility and deactivation of the catalyst. A net coke stream is withdrawn from the separator/burner especially while processing residues above 5 wt % CCR.

Abstract: A method, and a reactor, for hydroprocessing a hydrocarbon feed stream through multistage moving catalyst beds contained within a single onstream reactor vessel, with separate catalyst addition and withdrawal systems for each of the multistages of moving catalyst beds. The reactor contains two or more different and distinct moving catalyst beds for any hydroprocessing application. The method includes serially passing, without leaving the reactor vessel, at least a partially treated hydrocarbon stream from one hydroconversion reaction zone containing a moving catalyst bed with a first set of catalytic characteristics to another hydroconversion reaction zone containing a moving catalyst bed with a second set of catalytic characteristics that differ in catalytic abilities from the first set of catalytic characteristics.

Abstract: A process for catalytically cracking a heavy feed in an FCC unit, with large amounts of shape selective cracking additive is disclosed. The catalyst inventory preferably contains at least 10 wt % additive, of 12-40% ZSM-5 on an amorphous support, equivalent to more than 3.0 wt % ZSM-5 crystal circulating with equilibrium catalyst. Large yields of light olefins are produced, without excessive production of aromatics, or loss of gasoline yield. Operating with large amounts of additives allows yields of butadiene and/or methane to be suppressed, and production of a cracked gasoline fraction with an unusually low olefin content, and high ratio of cyclic unsaturates to normal unsaturates.

Abstract: Hydrocarbonaceous feedstocks admixed with a flow-through catalyst and hydrogen are hydroprocessed in a hydroprocessing reactor containing a captive hydroprocessing catalyst. The flow-through catalyst is continually withdrawn with the hydroprocessed feed from the hydroprocessing reactor. The flow-through catalyst may be an FCC, hydrocracking, isomerization or ring-opening catalyst. In a preferred embodiment, the captive hydroprocessing catalyst contains Co, Ni and/or Mo on an alumina base and the flow-through catalyst is an FCC zeolitic catalyst which is withdrawn with the hydroprocessed feed from the hydroprocessing reactor and then sent to an FCC unit.

Abstract: Disclosed is a process for converting olefinic hydrocarbons using spent FCC catalysts which comprises using spent FCC catalysts, optionally containing spent FCC additives, in the reactor/stripper part of the FCCU, instead of or in addition to a separate olefin upgrader, to upgrade C.sub.2 -C.sub.8 oligomerizable olefins, preferably propylene and ethylene, into C.sub.4 /C.sub.5 olefins and isoparaffins as well as gasoline, wherein feedstock can be product streams of the FCCU containing propylene/ethylene such as, for example, the absorber and depropanizer overheads.

Abstract: Process for the hydrotreating of a hydrocarbon feedstock, wherein the feedstock is passed through a fixed bed catalyst system of a hydrotreating catalyst comprising a physical mixture of high void catalyst particles and low void catalyst particles, which particles are mixed in different amounts in different layers of the catalyst bed so as to obtain within the fixed bed catalyst system a layered structure with different layers having different mixing ratios of the high and low void particles.

Abstract: This invention relates to an improved catalytic process for carrying out heavy hydrocarbon conversion, usually, but not necessarily, in the presence of nickel and vanadium on the catalyst and in the feedstock, by catalytic cracking gas oils and heavy carbometallic oils to lighter molecular weight fractions. The process is facilitated by the continuous addition of one or more heavy rare earth additives, including gadolinum, terbium, dysprosium, holmium, erbium, and thulium, all having exceptionally high paramagnetic properties, which as they accumulate on aged catalyst, are used to achieve enhanced magnetic separation of aged catalyst. These additives are unusual in that they not only act dramatically as magnetic hooks to assist in removing old, nickel and vanadium poisoned catalyst, but also act to achieve increased activity and improve selectivity of the remaining catalyst, and of equal importance, tend to resist catalyst deactivation.

Abstract: A catalytic cracking composition comprising a physical blend of a cracking catalyst component with alcohol treated Sr(OH).sub.2 and alcohol is used to crack hydrocarbon-containing feedstocks that further contain quantities of vanadium.

Abstract: An improved catalytic process for heavy hydrocarbon conversion, (usually, but not necessarily, in the presence of nickel and vanadium on the catalyst and in the feedstock.) to produce lighter molecular weight fractions. Manganese, which has paramagnetic properties, is added so it progressively accumulates on aged catalyst, and enhances magnetic separation of aged catalyst, to increase activity and improve selectivity of remaining catalyst which is recycled. Manganese acts as a "magnetic hook" to separate more magnetic, older, less catalytically active and less selective, higher-metals-containing catalyst particulates from less-magnetically-active, lower-metal-containing, more catalytically active and selective catalysts fractions, which are then recycled back to the unit.

Abstract: This invention relates to an improved catalytic process for carrying out heavy hydrocarbon conversion, usually, but not necessarily, in the presence of nickel and vanadium on the catalyst and in the feedstock, by catalytic cracking gas oils and heavy carbometallic oils to lighter molecular weight fractions. The process is facilitated by the continuous addition of one or more heavy rare earth additives, including gadolinum, terbium, dysprosium, holmium, erbium, and thulium, all having exceptionally high paramagnetic properties, which as they accumulate on aged catalyst, are used to achieve enhanced magnetic separation of aged catalyst. These additives are unusual in that they not only act dramatically as magnetic hooks to assist in removing old, nickel and vanadium poisoned catalyst, but also act to achieve increased activity and improve selectivity of the remaining catalyst, and of equal importance, tend to resist catalyst deactivation.

Abstract: An improvement in iso-olefin production without substantial decrease in overall yield is obtained in an integrated process combining a fluidized catalytic cracking reaction and a fluidized catalyst olefin interconversion reaction when crystalline medium pore shape selective zeolite catalyst particles are withdrawn in partially deactivated form from the interconversion reaction stage and added as part of the active catalyst in the FCC reaction.

Abstract: A catalytic process for cracking vanadium-containing oils employs a physical mixture of (a) zeolite embedded in an inorganic matrix material and (b) magnesium oxide on alumina support.

Abstract: A method for prolonging a hydroconversion catalyst life-time is provided. An additive functional to partially redirect the deposition of catalytic poisoning agents on the catalyst is utilized. The additive may comprise a chemically inert, porous carbonaceous material or ferruginous clay.

Abstract: By continuously or intermittently adding amounts of magnetically active moieties, e.g. iron compounds, over time so that the moiety deposits on a catalyst or sorbent in a fluid catalytic cracker or similar circulating hydrocarbon conversion unit, older catalyst, being more magnetic, can be readily separated from catalyst which has been in the system a shorter time. Separation is readily accomplished by passing the catalyst and/or sorbent through a magnetic field and discarding the more magnetic 50% by wt. or more preferably 20% by wt., while recycling the remainder back to the hydrocarbon conversion unit.

Abstract: Emission of noxious nitrogen oxides with the flue gas from the regenerator of a fluid catalytic cracking plant are reduced by incorporating into the circulating inventory of cracking catalyst separate additive particles that contain a copper-loaded zeolite material having a characteristic structure with a defined X-ray diffraction pattern. The preferred material of this type is zeolite MCM-22. The copper may be exchanged onto the zeolite or impregnated into the catalyst. In addition, the catalyst may include titanium or zirconium to provide stability and further improvements in stability may be obtained with the addition of rareearth metal cations, especially cerium or yttrium. NOX and CO emissions from the regenerator are reduced, and the gasoline produced in the unit may have an improved octane number.

Abstract: A catalytic composition for use in fluid catalytic cracking has an effective heat capacity of at least about 0.29 BTU/lb. .degree.F. over the range from 950.degree. F. to 1300.degree. F. The composition may include microspheres containing in situ crystallized Y-faujasite and fluidizable particles consisting essentially of dimagnesium borate. The catalytic composition may include a heat retention component selected from the group consisting of dimagnesium borate, aluminum borate, magnesium tetraborate, magnesium orthoborate, lithim aluminum borate, lithium magnesium borate, lithium aluminum silicate, and lithium aluminate.

Abstract: The present invention features the use of a particulate sorbent and a particulate FCC catalyst, which are physically separable, sequentially in the same FCC riser, followed by separation of commingled spent catalyst and sorbent particles from vapors, and the subsequent primary partial regeneration and heat up of spent sorbent particles and catalysts particles in an oxygen deficient burning zone, followed by physical separation of partially regenerated catalyst and sorbent particles, preferably using a cyclonic classifier to effect the separation. This is followed by secondary regeneration of the resulting segregated partially regenerated sorbent and catalyst streams in oxygen rich combustion zones to fully regenerate sorbent and catalyst particles.

Abstract: Oxides of nitrogen (NO.sub.x) emissions from an FCC regenerator are reduced by adding a DeNO.sub.x catalyst to the FCC regenerator in a form whereby the DeNO.sub.x catalyst remains segregated within the FCC regenerator. This permits use of a DeNO.sub.x catalyst without regard to the effect of the DeNO.sub.x catalyst on the catalytic cracking reaction. Floating hollow spheres, or catalyst fines, containing the DeNO.sub.x catalyst are preferred.

Abstract: A process and apparatus are disclosed for the catalytic conversion of hydrocarbons in a transport or sub-transport fluidized bed reaction zone. Inert particles are used to transfer heat to the reaction zone. The particles may be heated separately from the catalyst in a combustion zone or together with the catalyst in a regenerator. Fuel is fired to heat the inert particles or a mixture of catalyst and inert particles. Hydrogen deficient fuels such as charcoal or coke are preferred.

Abstract: A process for regeneration of cracking catalyst while minimizing NO.sub.x emissions is disclosed. A Group IIIB based DeNO.sub.x additive is present in an amount and in a form which reduces NO.sub.x emissions. Relatively small amounts of lanthanum or yttrium oxides, or lanthanum titanate, preferably impregnated on a separate support are effective to reduce NO.sub.x produced in the regenerator. The additive converts NO.sub.x to nitrogen even when Pt CO combustion promoter and some excess oxygen are present in the regenerator.

Abstract: A process is disclosed wherein a regenerator is operated in an incomplete mode of combustion to regenerate FCC catalyst to burn coke contained thereon in the presence of a CO oxidation promoter. The quantity of the CO oxidation promoter is regulated so that there is at least two and preferably at least three times the minimum quantity of CO oxidation promoter present than necessary to prevent temperature excursions in the dilute phase caused by afterburn combustion of CO to CO.sub.2. The regeneration zone is maintained in an incomplete mode of combustion defined by having a CO content greater than 1.0 percent and preferably from 1 to 10 percent.

Abstract: The invention provides a catalyst composition useful in treating hydrocarbons contaminated with vanadium residues, the catalyst comprising a zeolite, a matrix and certain heavier alkaline earth metal oxides.

Abstract: Oxides of nitrogen (NO.sub.x) emissions are catalytically reduced by contacting a flue gas contain NO.sub.x with a carbonaceous substance, preferably sponge coke or coal, in the presence of a catalyst effective for promoting the reduction of NO.sub.x in the presence of such carbonaceous substances.

Abstract: A process for reducing sulfur oxides production during an FCC cracking operation comprises the steps of:(a) passivating metal contaminants on an FCC catalyst by contacting the FCC catalyst with a sulfur-containing compound under conditions that enable association of the sulfur with the metal contaminants;(b) cracking hydrocarbons with the passivated FCC catalyst in an FCC cracking zone;(c) oxidatively regenerating the catalyst in a regeneration zone whereby the carbonaceous material deposited on the catalyst in step (b) is burned off and the sulfur deposited on the FCC catalyst in step (a) is converted to sulfur oxides;(d) reacting the sulfur oxides with a sulfur oxide adsorption additive capable of adsorbing the sulfur oxides under sulfur oxide adsorbing conditions;(e) converting the adsorbed sulfur oxides from step (d) to hydrogen sulfide by contacting the adsorbed sulfur oxides in a separate treatment vessel with a reducing gas before the regenerated FCC catalyst and sulfur oxides adsorption additive enter

Abstract: A process for regeneration of cracking catalyst while minimizing NO.sub.x emissions is disclosed. A zinc-based DeNO.sub.x catalyst is present in an amount and in a form which reduces NO.sub.x emissions. Relatively small amounts of zinc oxides impregnated on a separate support having little or no cracking activity are preferred. The zinc NO.sub.x reduction catalyst can be a separate particle additive, or can be made in situ by adding a solution or dispersion of zinc or a compound thereof to the cracking unit, or to the hydrocarbon feed to the cracking unit.

Abstract: An improvement in gasoline octane without substantial decrease in overall yield is obtained in an integrated process combining a fluidized catalytic cracking reaction and a low severity fluidized catalyst olefin oligomerization reaction when crystalline medium pore shape selective zeolite catalyst particles are withdrawn in partially deactivated form from the oligomerization reaction stage and added as part of the active catalyst in the FCC reaction.

Abstract: This invention provides a fixed bed of nonuniformly sized grade catalyst particles for hydrocracking or hydrodesulfurization. The graded particles are arranged with the largest particles in either the upstream or the downstream portion of the bed. In either case, when compared with the conventional bed of uniformly sized particles, the graded bed of this invention shows enhanced hydrocarbon conversion activity for heavy oils over a useful range of conversion. Such catalyst bed is particularly useful in moderate hydrocracking operating at less than 1000 psig (7000 kPa) pressure.

Abstract: Controlling sulfur oxide emissions from FCC regenerator flue gas by mixing a sulfur sorbent in the circulating inventory and having present in the regeneration zone a chromium/tin sulfur dioxide oxidation promoter.

Abstract: A process for performing catalytic reactions with intensive heat of reaction, in which a reaction mixture is conducted through a catalyst bed, from which the reaction heat is removed or to which it is fed by indirect heat exchange with a heat exchange medium. The catalyst bed adjoins at least one bed of a catalytically inert material, which also is in indirect heat exchange with the heat exchange medium.

Abstract: A process for regeneration of cracking catalyst while minimizing NO.sub.x emissions is disclosed. A DeNOx additive is present in an amount and in a form which reduces NO.sub.x emissions, but does not passivate metals (such as Ni and V) deposited on the catalyst during the cracking reaction nor CO combustion promoter which may be present. Relatively small amounts of antimony oxides impregnated on a separate support having little or no cracking activity are preferred.

Abstract: Oxides of nitrogen (NO.sub.x) emissions are catalytically reduced by contacting a flue gas containing NO.sub.x with ammonia or an ammonia precursor in the presence of a catalyst effective for promoting the reduction of NO.sub.x with ammonia in oxidizing atmospheres, such as those in FCC catalyst regenerators. Bismuth oxides on a support are the preferred NO.sub.x reduction catalyst. The process is especially useful in reducing NO.sub.x emissions from fluidized catalytic cracking units.

Abstract: Emission of noxious nitrogen oxides with the flue gas from the regenerator of a fluid catalytic cracking plant are reduced by incorporating into the circulating inventory of cracking catalyst separate additive particles that contain a copper-loaded zeolite. A particularly effective additive is provided by ion-exchanging ZSM-5 zeolite with cupric ion. With such preferred additive, CO emissions also are reduced, and the recovered gasoline has enhanced octane number.

Abstract: A catalytic cracking process is provided wherein a phosphorous containing alumina or an alkaline earth phosphorous containing alumina is added to a catalytic cracking zone for admixture with a zeolite containing cracking catalyst.

Abstract: Emission of noxious nitrogen oxides with the flue gas from the regenerator of a fluid catalytic cracking plant are reduced by incorporating into the circulating inventory of cracking catalyst separate additive particles that contain a copper-loaded zeolite. A particularly effective additive is provided, for example, by treating a ZSM-5 zeolite in a matrix consisting predominantly of titania, zirconia or a mixture thereof with a solution containing both copper and rare earth cations to incorporate both of these elements with the zeolitic composition.

Abstract: In a catalytic cracking process which includes contacting a hydrocarbon feedstock in a contacting zone in the presence of solid composition containing molecular sieve-containing catalyst capable of promoting hydrocarbon cracking at conditions effective to crack the hydrocarbon feedstock to lower boiling components, the improvement comprising conducting the contacting in the presence of at least one metal component, other than the catalyst, containing calcium and tin. A composition of matter comprising such catalyst and metal component is also disclosed.

Abstract: By continuously or intermittently adding amounts of magnetically active moieties, e.g. iron compounds, over time so that the moiety deposits on a catalyst or sorbent in a fluid catalytic cracker or similar circulating hydrocarbon conversion unit, older catalyst, being more magnetic, can be readily separated from catalyst which has been in the system a shorter time. Separation is readily accomplished by passing the catalyst and/or sorbent through a magnetic field and discarding the more magnetic 50% by wt. or more preferably 20% by wt., while recycling the remainder back to the hydrocarbon conversion unit.

Abstract: The invention provides a catalyst composition useful in treating hydrocarbons contaminated with vanadium residues, the catalyst comprising a zeolite, a matrix and certain heavier alkaline earth metal oxides.