With Subsequent Hydrocracking Patents (Class 208/68)
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Patent number: 11788020Abstract: Processes herein may be used to thermally crack various hydrocarbon feeds, and may eliminate the refinery altogether while making the crude to chemicals process very flexible in terms of crude. In embodiments herein, crude is progressively separated into at least light and heavy fractions. Depending on the quality of the light and heavy fractions, these are routed to one of three upgrading operations, including a fixed bed hydroconversion unit, a fluidized catalytic conversion unit, or a residue hydrocracking unit that may utilize an ebullated bed reactor. Products from the upgrading operations may be used as feed to a steam cracker.Type: GrantFiled: July 15, 2022Date of Patent: October 17, 2023Assignees: LUMMUS TECHNOLOGY LLC, Saudi Arabian Technology Company, Chevron Lummus Global LLCInventors: Kareemuddin Shaik, Ujjal Mukherjee, Essam Abdullah Al-Sayed, Pedro Santos, Theodorus Maesen, Mazin Tamimi, Julie Chabot, Ibrahim Abba, Kandasamy Sundaram, Sami Barnawi, Ronald M. Venner
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Patent number: 11773037Abstract: A process for producing light alkanes and creating a flexible distribution system for those alkanes and related systems are disclosed. The process can include supplying a butane feed stream to a butane conversion unit to produce a light alkane output stream including at least methane, ethane, propane, and hydrogen, separating at least part of the light alkane output stream into separate streams of methane, ethane, and propane and distributing the separated streams as desired. The distribution of the separated streams can include sending the separated ethane and propane streams to downstream processing units which use them as feedstock. The butane containing feed and/or unreacted butane feed can include isobutane, which can be converted to n-butane and then further processed.Type: GrantFiled: February 27, 2020Date of Patent: October 3, 2023Assignee: SABIC GLOBAL TECHNOLOGIES B.V.Inventors: Dustin Fickel, Ramakumar Allada, Kaushik Gandhi, Uwaidh Al-Harethi, Robert Broekhuis
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Patent number: 11760947Abstract: Processes herein may be used to thermally crack various hydrocarbon feeds, and may eliminate the refinery altogether while making the crude to chemicals process very flexible in terms of crude. In embodiments herein, crude is progressively separated into at least light and heavy fractions. Depending on the quality of the light and heavy fractions, these are routed to one of three upgrading operations, including a fixed bed hydroconversion unit, a fluidized catalytic conversion unit, or a residue hydrocracking unit that may utilize an ebullated bed reactor. Products from the upgrading operations may be used as feed to a steam cracker.Type: GrantFiled: July 15, 2022Date of Patent: September 19, 2023Assignees: LUMMUS TECHNOLOGY LLC, Saudi Aramco Technologies Company, Chevron Lummus Global LLCInventors: Kareemuddin Shaik, Ujjal Mukherjee, Essam Abdullah Al-Sayed, Pedro Santos, Theodorus Maesen, Mazin Tamimi, Julie Chabot, Ibrahim Abba, Kandasamy Sundaram, Sami Barnawi, Ronald M. Venner
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Patent number: 11674095Abstract: A process of reforming a diesel feedstock to convert diesel to a gasoline blending component may include desulfurizing and denitrogenizing the diesel feedstock to reduce the sulfur and nitrogen content; and then hydrocracking the diesel feedstock over a metal containing zeolitic catalyst to produce an isomerate fraction. The diesel feedstock may have boiling points ranging from 200 to 360° C.Type: GrantFiled: March 7, 2022Date of Patent: June 13, 2023Assignee: SAUDI ARABIAN OIL COMPANYInventors: Omer Refa Koseoglu, Ashok Kumar Punetha
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Patent number: 11624033Abstract: A process for the catalytic cracking of hydrocarbon oils includes the step of contacting a hydrocarbon oil feedstock with a catalytic cracking catalyst in a reactor having one or more fast fluidized reaction zones for reaction. At least one of the fast fluidized reaction zones of the reactor is a full dense-phase reaction zone, and the axial solid fraction ? of the catalyst is controlled within a range of about 0.1 to about 0.2 throughout the full dense-phase reaction zone. When used for catalytic cracking of hydrocarbon oils, particularly heavy feedstock oils, the process, reactor and system show a high contact efficiency between oil and catalyst, a selectivity of the catalytic reaction, an effectively reduced yield of dry gas and coke, and an improved yield of high value-added products such as ethylene and propylene.Type: GrantFiled: July 15, 2019Date of Patent: April 11, 2023Assignees: CHINA PETROLEUM & CHEMICAL CORPORATION, RESEARCH INSTITUTE OF PETROLEUM PROCESSING, SINOPECInventors: Jianhong Gong, Zhigang Zhang, Xiaoli Wei
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Patent number: 11597883Abstract: Favorable isomerization conditions for producing normal paraffins can produce olefins. The process for separating normal paraffins from non-normal paraffins by adsorption has a limit on olefin concentration, so the olefins must be removed. We propose to remove olefins from the isomerization effluent stream that is recycled to the adsorption separation process.Type: GrantFiled: June 7, 2021Date of Patent: March 7, 2023Assignee: UOP LLCInventors: Mark Lapinski, Ram Ganesh Rokkam, Gregory Funk
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Patent number: 11421167Abstract: Integrated pyrolysis and hydrocracking systems and processes for efficiently cracking of hydrocarbon mixtures, such as mixtures including compounds having a normal boiling temperature of greater than 450° C., 500° C., or even greater than 550° C., such as whole crudes for example, are disclosed.Type: GrantFiled: September 30, 2020Date of Patent: August 23, 2022Assignee: LUMMUS TECHNOLOGY LLCInventors: Ujjal K. Mukherjee, Kandasamy Meenakshi Sundaram, Ronald M. Venner, Stephen J. Stanley
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Patent number: 11390817Abstract: Processes herein may be used to thermally crack various hydrocarbon feeds, and may eliminate the refinery altogether while making the crude to chemicals process very flexible in terms of crude. In embodiments herein, crude is progressively separated into at least light and heavy fractions. Depending on the quality of the light and heavy fractions, these are routed to one of three upgrading operations, including a fixed bed hydroconversion unit, a fluidized catalytic conversion unit, or a residue hydrocracking unit that may utilize an ebullated bed reactor. Products from the upgrading operations may be used as feed to a steam cracker.Type: GrantFiled: March 16, 2020Date of Patent: July 19, 2022Assignees: LUMMUS TECHNOLOGY LLC, Saudi Aramco Technologies Company, Chevron Lummus Global LLCInventors: Kareemuddin Shaik, Ujjal Mukherjee, Essam Abdullah Al-Sayed, Pedro Santos, Theodorus Maesen, Mazin Tamimi, Julie Chabot, Ibrahim Abba, Kandasamy Sundaram, Sami Barnawi, Ronald Venner
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Patent number: 10808188Abstract: A catalytic cracking process includes the following steps: i) subjecting a heavy feedstock oil to flail catalytic cracking; ii) separating the catalytic cracking reaction product obtained from step i) to obtain a catalytic cracking gasoline and a catalytic cracking light cycle oil; iii) splitting the catalytic cracking gasoline to obtain a light gasoline fraction, a medium gasoline fraction and a heavy gasoline fraction; iv) subjecting the catalytic cracking light cycle oil to hydrogenation to obtain a hydrogenated light cycle oil); v) mixing a portion of the light gasoline fraction with at least a portion of the hydrogenated light cycle oil to obtain a mixed fraction; vi) subjecting the mixed fraction to catalytic cracking; and vii) subjecting a portion of the medium gasoline fraction to flail catalytic cracking. The process is capable of producing more catalytic cracking gasoline, reducing the olefin content of the catalytic cracking gasoline, and increasing its octane number.Type: GrantFiled: September 25, 2018Date of Patent: October 20, 2020Assignees: CHINA PETROLEUM & CHEMICAL CORPORATION, RESEARCH INSTITUTE OF PETROLEUM PROCESSING, SINOPECInventors: Jianhong Gong, Zekun Li, Jinlian Tang, Anguo Mao, Jiushun Zhang, Yuying Zhang, Jun Long
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Patent number: 9523668Abstract: A fuel property determination method includes a reaction mechanism analysis process (S1) of analyzing elementary reactions that compose chemical reactions between a plurality of types of initial materials including the materials that compose the fuel and obtaining the elementary reactions as fuel elementary reactions, and an octane number determination process (S2) of calculating the combustion characteristics of the fuel by performing a simulation based on the fuel elementary reactions and determining the octane number based on the combustion characteristics of the fuel.Type: GrantFiled: May 18, 2010Date of Patent: December 20, 2016Assignees: TOHOKU UNIVERSITY, IHI CORPORATIONInventors: Kaoru Maruta, Hisashi Nakamura, Soichiro Kato
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Patent number: 9157037Abstract: A process and apparatus for improving flow properties of crude may include processing a first crude stream, which may in turn include cracking the first crude stream with catalyst to form a cracked stream and spent catalyst, hydrotreating a portion of the cracked stream and then mixing the hydrotreated stream with an unprocessed second crude stream.Type: GrantFiled: December 18, 2008Date of Patent: October 13, 2015Assignee: UOP LLCInventors: Brian W. Hedrick, Daniel B. Gillis
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Patent number: 8888991Abstract: Heavy gas oil components, coking process recycle, and heavier hydrocarbons in the delayed coking process are cracked in the coking vessel by injecting a catalytic additive into the vapors above the gas/liquid-solid interface in the coke drum during the coking cycle. The additive comprises cracking catalyst(s) and quenching agent(s), alone or in combination with seeding agent(s), excess reactant(s), carrier fluid(s), or any combination thereof to modify reaction kinetics to preferentially crack these components. The quenching effect of the additive can be effectively used to condense the highest boiling point compounds of the traditional recycle onto the catalyst(s), thereby focusing the catalyst exposure to these target reactants. Exemplary embodiments of the present invention can also provide methods to (1) reduce coke production, (2) reduce fuel gas production, and (3) increase liquids production.Type: GrantFiled: February 12, 2013Date of Patent: November 18, 2014Inventor: Roger G. Etter
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Patent number: 8709233Abstract: In the invention, tar is upgraded by deasphalting and then hydrocracking to produce valuable products such as low sulfur diesel fuel and mogas. The invention is also directed to a system integrating a pyrolysis furnace operation with refinery operations.Type: GrantFiled: July 25, 2007Date of Patent: April 29, 2014Assignee: ExxonMobil Chemical Patents Inc.Inventors: James N. McCoy, Paul F. Keusenkothen
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Patent number: 8691076Abstract: Disclosed is a method of manufacturing high-quality naphthenic base oil by subjecting, as a feedstock, light cycle oil (LCO) and slurry oil (SLO) obtained through fluidized catalytic cracking (FCC) to hydrotreating and dewaxing.Type: GrantFiled: November 21, 2007Date of Patent: April 8, 2014Assignee: SK Lubricants Co., Ltd.Inventors: Chang Kuk Kim, Jee Sun Shin, Ju Hyun Lee, Sam Ryong Park, Gyung Rok Kim, Yoon Mang Hwang
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Patent number: 8674153Abstract: A method for converting lignocellulosic biomass to a useful fuel is disclosed in a process sequence resulting in low levels of depositable tars in an output gas stream. One disclosed embodiment comprises performing a sequence of steps at elevated pressure and elevated hydrogen partial pressure, including fast (or flash) hydropyrolysis of a lignocellulosic biomass feed followed sequentially with catalytically enhanced reactions for the formation of methane operating at moderate temperatures of from about 400° C. to about 650° C. under moderately elevated pressure (about 5 atm to about 50 atm). A temperature rise in the catalyst above pyrolysis temperature is achieved without the addition of air or oxygen. Gas residence time at elevated temperature downstream of methane formation zones extends beyond the time required for methane formation. This sequence results in low tar deposit levels. The catalyst promotes preferential formation of methane and non-deposit forming hydrocarbons, and coke re-gasification.Type: GrantFiled: January 25, 2013Date of Patent: March 18, 2014Assignee: G4 Insights Inc.Inventors: Brian G. Sellars, Matthew L. Babicki, Bowie G. Keefer, Edson Ng
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Publication number: 20130292298Abstract: Disclosed are a catalytic cracking method and an apparatus for implementing the method.Type: ApplicationFiled: November 2, 2011Publication date: November 7, 2013Inventor: Baozhen Shi
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Publication number: 20130261340Abstract: Biomass (e.g., plant biomass, animal biomass, and municipal waste biomass) is processed to produce useful products, such as fuels. For example, systems can use feedstock materials, such as cellulosic and/or lignocellulosic materials and/or starchy materials, to produce ethanol and/or butanol, e.g., by fermentation.Type: ApplicationFiled: March 13, 2013Publication date: October 3, 2013Inventor: Marshall Medoff
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Publication number: 20130233764Abstract: The invention relates to upgraded pyrolysis products, processes for upgrading products obtained from hydrocarbon pyrolysis, equipment useful for such processes, and the use of upgraded pyrolysis products.Type: ApplicationFiled: August 31, 2012Publication date: September 12, 2013Inventors: Stephen H. Brown, S. Mark Davis, Teng Xu, Keith G. Reed, Ananthakrishnan Bhasker
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Publication number: 20130087483Abstract: A process for maximizing p-xylene production includes producing a naphtha fraction and a light cycle oil fraction from a fluid catalytic cracking zone. These fractions are combined and hydrotreated. Fractionation of the hydrotreated product makes a hydrocracker feed that is sent to a hydrocracking zone to make a naphtha cut and a hydrocracker product. The hydrocracker product is recycled back to the fractionation zone, and the naphtha cut is dehydrogenated in a dehydrogenation zone to make aromatics. Reforming catalyst from a catalyst regenerator moves downward through the dehydrogenation zone. Straight run naphtha and raffinate from the aromatics unit are introduced to an additional series of reforming zones. The reforming catalyst moves in parallel through the first reforming zone and the dehydrogenation zones, then is combined for entry to the second and subsequent reforming zones prior to regeneration.Type: ApplicationFiled: October 7, 2011Publication date: April 11, 2013Applicant: UOP LLCInventors: Robert Haizmann, Laura E. Leonard
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Patent number: 8383871Abstract: Embodiments of a thermochemical method to convert lignocellulosic biomass to a useful fuel are disclosed in a process sequence resulting in low levels of depositable tars in the output gas stream. One disclosed embodiment comprises performing a sequence of steps at elevated pressure and elevated hydrogen partial pressure, including fast (or flash) hydropyrolysis of a lignocellulosic biomass feed followed sequentially with catalytically enhanced reactions for the formation of methane operating at moderate temperatures of from about 400° C. to about 650° C. and under moderately elevated pressure (about 5 atm to about 50 atm). A temperature rise in the catalyst above pyrolysis temperature is achieved without the addition of air or oxygen. Gas residence time at elevated temperature downstream of methane formation zones is extended well beyond the time required for methane formation. This sequence results in low depositable tars in the output gas stream.Type: GrantFiled: September 1, 2011Date of Patent: February 26, 2013Inventors: Brian G. Sellars, Matthew L. Babicki, Bowie G. Keefer, Edson Ng
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Patent number: 8372265Abstract: Undesirable gas oil components are selectively cracked or coked in a coking vessel by injecting an additive into the vapors of traditional coking processes in the coking vessel prior to fractionation. The additive contains catalyst(s), seeding agent(s), excess reactant(s), quenching agent(s), carrier(s), or any combination thereof to modify reaction kinetics to preferentially crack or coke these undesirable components that typically have a high propensity to coke. Exemplary embodiments of the present invention also provide methods to control the (1) coke crystalline structure and (2) the quantity and quality of volatile combustible materials (VCMs) in the resulting coke. That is, by varying the quantity and quality of the catalyst, seeding agent, and/or excess reactant the process may affect the quality and quantity of the coke produced, particularly with respect to the crystalline structure (or morphology) of the coke and the quantity & quality of the VCMs in the coke.Type: GrantFiled: November 19, 2007Date of Patent: February 12, 2013Inventor: Roger G. Etter
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Publication number: 20130026065Abstract: An integrated process and system for conversion of a heavy crude oil to produce transportation fuels is provided. The process includes separating the hydrocarbon feed into an aromatic-lean fraction and an aromatic-rich fraction. The aromatic-rich fraction is hydrocracked under relatively high pressure to convert at least a portion of refractory aromatic organosulfur and organonitrogen compounds and to produce a hydrocracked product stream. Unconverted bottoms effluent is recycled to the aromatic separation step. The aromatic-lean fraction is cracked in a fluidized catalytic cracking reaction zone to produce a cracked product stream, a light cycle oil stream and a heavy cycle oil stream. In certain embodiments the aromatic-lean fraction can be hydrotreated prior to fluidized catalytic cracking.Type: ApplicationFiled: July 25, 2012Publication date: January 31, 2013Inventor: Omer Refa Koseoglu
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Publication number: 20130001129Abstract: A catalytic conversion process for increasing the cetane number barrel of diesel, in which contacting the feedstock oil with a catalytic cracking catalyst having a relatively homogeneous activity containing mainly the large pore zeolites in a catalytic conversion reactor, wherein the reaction temperature, residence time of oil vapors and weight ratio of the catalyst/feedstock oil are sufficient to obtain a reaction product containing from about 12 to about 60% by weight of a fluid catalytic cracking gas oil relative to the weight of the feedstock oil and containing a diesel; the reaction temperature ranges from about 420° C. to about 550° C.; the residence time of oil vapors ranges from about 0.1 to about 5 seconds; the weight ratio of the catalytic cracking catalyst/feedstock oil is about 1-about 10. The fluid catalytic cracking gas oil is fed into other unit for further treatment or is fed back to the initial catalytic conversion reactor.Type: ApplicationFiled: October 20, 2010Publication date: January 3, 2013Applicants: Research Institute of Petroleum Processing, Sinopec, CHINA PETROLEUM & CHEMICAL CORPORATIONInventors: Youhao Xu, Jianhong Gong, Congli Cheng, Shouye Cui, Zhihai Hu, Yun Chen
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Publication number: 20120222991Abstract: Novel catalytic compositions for cracking of crude oil fractions are disclosed. The catalytic compositions comprise a basic material. When used in a cracking process, preferably a FCC process, the resulting LCO and HCO fractions have desirably low aromatics levels. Further disclosed is a one-stage FCC process using the catalytic composition of the invention. Also disclosed is a two-stage FCC process for maximizing the LCO yield.Type: ApplicationFiled: April 2, 2012Publication date: September 6, 2012Applicant: ALBEMARLE NETHERLANDS B.V.Inventors: PAUL O'CONNOR, KING YEN YUNG, AVELINO CORMA CANOS, ELBERT ARJAN DE GRAAF, ERJA PÄIVI HELENA RAUTIAINEN
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Patent number: 8206574Abstract: A reactor process added to a coking process to modify the quantity or yield of a coking process product and/or modify certain characteristics or properties of coking process products.Type: GrantFiled: February 11, 2009Date of Patent: June 26, 2012Inventor: Roger G. Etter
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Publication number: 20110180456Abstract: This invention relates to a process for cracking hydrocarbon feedstock containing resid comprising: (a) heating a hydrocarbon feedstock containing resid; (b) adding molecular hydrogen to said heated feedstock to form a mixture stream; (c) adding a catalyst containing metal-sulfide particles to said heated feedstock and/or said mixture stream; (d) reacting said mixture in a catalytic hydrovisbreaking reactor under conditions of temperature, pressure and residence time sufficient to catalytically hydrovisbreak at least a portion of said resid into hydrovisbroken hydrocarbon components; (e) passing said reacted mixture stream into a high pressure separator and separating hydrogen from said reacted mixture; (f) passing said reacted mixture through a knockout drum to remove catalyst and unreacted or uncracked resid as a bottoms stream; and (g) passing said catalytically hydrovisbroken hydrocarbon components into a steam cracking furnace and thermally cracking said hydrocarbon components to form light olefins, aType: ApplicationFiled: January 22, 2010Publication date: July 28, 2011Inventors: Stephen Mark Davis, Paul F. Keusenkothen, Jonathan Martin Mcconnachie, Larry L. Iaccino, Richard C. Stell
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Publication number: 20110174682Abstract: The present invention is directed to a process for hydroprocessing of a liquid hydrocarbon feedstock, comprising: (a) mixing liquid, partially vaporized and/or vaporized hydrocarbon feedstock with molecular hydrogen; (b) feeding said mixture into a compression reactor; (c) compressing said mixture to a pressure, a temperature and for a residence time sufficient to: i) thermally crack at least a portion of hydrocarbon molecules in said hydrocarbon feedstock, and ii) react hydrogen in the presence of a hydrogenation catalyst with unstable portions of the cracked molecules, forming a hydroprocessed product; and (d) expanding said mixture to reduce the pressure and temperature thereby reducing subsequent undesirable reactions.Type: ApplicationFiled: January 18, 2010Publication date: July 21, 2011Inventor: Larry L. Iaccino
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Publication number: 20110073523Abstract: The present invention relates to a catalytic conversion process for producing more diesel and propylene, comprising contacting the feedstock oil with a catalyst having a relatively homogeneous activity in a reactor, wherein the reaction temperature, weight hourly space velocity and weight ratio of the catalyst/feedstock oil are sufficient to obtain a reaction product containing from 12 to 60% by weight of a fluid catalytic cracking gas oil relative to the weight of the feedstock oil; the fluid catalytic cracking gas oil is fed into the fluid catalytic cracking gas oil treatment device for further processing. Catalytic cracking, hydrogenation, solvent extraction, hydrocracking and process for producing more diesel are organically combined together, and hydrocarbons such as alkanes, alkyl side chains in the feedstocks for catalysis are selectively cracked and isomerized.Type: ApplicationFiled: September 23, 2010Publication date: March 31, 2011Applicants: CHINA PETROLEUM & CHEMICAL CORPORATION, Research Institute of Petroleum Processing, SinopecInventors: Shouye CUI, Youhao XU, Zhihai HU, Jianhong GONG, Chaogang XIE, Yun CHEN, Zhigang ZHANG, Jianwei DONG
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Patent number: 7815791Abstract: A process and apparatus are provided for steam cracking heavy feeds, including steam cracked tars. The invention heats a steam cracked tar feed to provide a depolymerized steam cracked tar containing lower boiling molecules than the steam cracked tar feed, hydrogenates the depolymerized steam cracked tar using a hydrogenating catalyst, e.g., a downward flow fixed bed hydrotreater, to provide a hydrogenated steam cracked tar. At least a portion of the hydrogenated steam cracked tar is steam cracked in a steam cracking furnace comprising a convection zone and a radiant zone.Type: GrantFiled: April 30, 2008Date of Patent: October 19, 2010Assignee: ExxonMobil Chemical Patents Inc.Inventor: Paul F. Keusenkothen
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Patent number: 7815789Abstract: A process to prepare a base oil having a viscosity index of above 80 and a saturates content of above 90 wt % from a crude derived feedstock by (a) contacting a crude derived feedstock in the presence of hydrogen with a catalyst having at least one Group VIB metal component and at least one non-noble Group VIII metal component supported on a refractory oxide carrier; (b) adding to the effluent of step (a) or part of the effluent of step (a) a Fischer-Tropsch derived fraction boiling at least partly in the base oil range in an amount effective to achieve the target viscosity index of the final base oil; and (c) dewaxing the mixture as obtained in step (b).Type: GrantFiled: June 21, 2004Date of Patent: October 19, 2010Assignee: Shell Oil CompanyInventors: Peter James Wardle, William Leonard Alexander King
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Patent number: 7803265Abstract: A process is disclosed for converting distillate to gasoline-range hydrocarbons using a two-stage catalyst system including a first catalyst containing platinum, palladium, or platinum and palladium, and an acidic support, and a second catalyst containing iridium and an inorganic oxide support, and optionally nickel.Type: GrantFiled: February 4, 2009Date of Patent: September 28, 2010Assignee: ConocoPhillips CompanyInventors: Tushar V. Choudhary, Paul F. Meier, Edward L. Sughrue, II, Walter E. Alvarez
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Publication number: 20100155295Abstract: A process and apparatus for improving flow properties of crude may include processing a first crude stream, which may in turn include cracking the first crude stream with catalyst to form a cracked stream and spent catalyst, hydrotreating a portion of the cracked stream and then mixing the hydrotreated stream with an unprocessed second crude stream.Type: ApplicationFiled: December 18, 2008Publication date: June 24, 2010Inventors: Brian W. Hedrick, Daniel B. Gillis
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Publication number: 20090288987Abstract: Contact of a crude feed with one or more catalysts comprising one or more metals from Column 6 of the Periodic Table produces a total product that includes a crude product. The crude feed contains oxygen and sulfur. The crude product is a liquid mixture at 25° C. and 0.101 MPa and contains at most 90% of the oxygen content of the crude feed and from 70% to 130% of the sulfur content of the crude feed.Type: ApplicationFiled: July 30, 2009Publication date: November 26, 2009Inventors: Opinder Kishan BHAN, Scott Lee Wellington
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Patent number: 7563357Abstract: A process for steam cracking liquid hydrocarbon feedstocks containing synthetic crude oil comprises i) hydroprocessing a wide boiling range aliquot containing a) normally liquid hydrocarbon portion substantially free of resids and b) thermally cracked hydrocarbon liquid, boiling in a range from about 600° to about 1050° F., to provide a synthetic crude oil substantially free of resids; ii) adding to the synthetic crude oil a normally liquid hydrocarbon component boiling in a range from about 100° to about 1050° F.; and iii) cracking the mixture resulting from ii) in a cracker furnace comprising a radiant coil outlet to provide a cracked effluent, wherein the cracking is carried out under conditions sufficient to effect a radiant coil outlet temperature which is greater than the optimum radiant coil outlet temperature for cracking the synthetic crude oil separately. A method for upgrading synthetic crude for use in cracking is also provided, as well as a feedstock for cracking.Type: GrantFiled: January 26, 2007Date of Patent: July 21, 2009Assignee: ExxonMobil Chemical Patents Inc.Inventors: Paul F Keusenkothen, James N McCoy, James Earl Graham, Chad David Reimann
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Publication number: 20090050523Abstract: A method for thermally cracking a feed composed of whole crude oil and/or natural gas condensate using a vaporizer to vaporize the feed before cracking same, recovering pyrolysis gas oil from the cracked feed, subjecting the recovered pyrolysis gas oil to hydrocracking to form a paraffinic hydrocracked product, and passing at least part of the hydrocracked product to the vaporizer as additional thermal cracking feed.Type: ApplicationFiled: August 20, 2007Publication date: February 26, 2009Inventor: Richard B. Halsey
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Patent number: 7431823Abstract: The instant invention is directed to a new residuum full hydroconversion slurry reactor system that allows the catalyst, unconverted oil and converted oil to circulate in a continuous mixture throughout an entire reactor with no confinement of the mixture. The mixture is partially separated in between the reactors to remove only the products and hydrogen, while permitting the unconverted oil and the slurry catalyst to continue on into the next sequential reactor where a portion of the unconverted oil is converted to lower boiling point hydrocarbons, once again creating a mixture of unconverted oil, converted oil, and slurry catalyst. Further hydroprocessing may occur in additional reactors, fully converting the oil. The oil may alternately be partially converted, leaving a highly concentrated catalyst in unconverted oil which can be recycled directly to the first reactor.Type: GrantFiled: December 16, 2005Date of Patent: October 7, 2008Assignee: Chevron U.S.A. Inc.Inventors: Darush Farshid, Bruce Reynolds
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Patent number: 7431822Abstract: Applicants have developed a new residuum full hydroconversion slurry reactor system that allows the catalyst, unconverted oil, hydrogen, and converted oil to circulate in a continuous mixture throughout an entire reactor with no confinement of the mixture. The mixture is separated internally, within one of more of the reactors, to separate only the converted oil and hydrogen into a vapor product while permitting the unconverted oil and the slurry catalyst to continue on into the next sequential reactor as a liquid product. A portion of the unconverted oil is then converted to lower boiling point hydrocarbons in the next reactor, once again creating a mixture of unconverted oil, hydrogen, converted oil, and slurry catalyst. Further hydroprocessing may occur in additional reactors, fully converting the oil. The oil may alternately be partially converted, leaving a concentrated catalyst in unconverted oil which can be recycled directly to the first reactor.Type: GrantFiled: December 16, 2005Date of Patent: October 7, 2008Assignee: Chevron U.S.A. Inc.Inventors: Darush Farshid, James Murphy, Bruce Reynolds
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Patent number: 7431831Abstract: A new residuum full hydroconversion slurry reactor system has been developed that allows the catalyst, unconverted oil, products and hydrogen to circulate in a continuous mixture throughout an entire reactor with no confinement of the mixture. The mixture is partially separated in between the reactors to remove only the products and hydrogen while permitting the unconverted oil and the slurry catalyst to continue on into the next sequential reactor. In the next reactor, a portion of the unconverted oil is converted to lower boiling point hydrocarbons, once again creating a mixture of unconverted oil, products, hydrogen and slurry catalyst. Further hydroprocessing may occur in additional reactors, fully converting the oil. The oil may alternately be partially converted, leaving a highly concentrated catalyst in unconverted oil which can be recycled directly to the first reactor. The slurry reactor system is, in this invention, preceded by an in-line pretreating step, such as hydrotreating or deasphalting.Type: GrantFiled: December 16, 2005Date of Patent: October 7, 2008Assignee: Chevron U.S.A. Inc.Inventors: Darush Farshid, Bruce Reynolds
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Patent number: 7326332Abstract: A multi component catalyst and catalytic cracking process for selectively producing C3 olefins. The catalyst comprises a first molecular sieve having an intermediate pore size, a second molecular sieve and, optionally a third molecular sieve having a large pore size. At least one of the channels of the second molecular sieve has a pore size index that is less than the pore size index of at least one channel of the first molecular sieve. The process is carried out by contacting a feedstock containing hydrocarbons having at least 5 carbon atoms is contacted, under catalytic cracking conditions, with the multi component catalyst. The catalyst finds application in the cracking of naphtha and heavy hydrocarbon feedstocks.Type: GrantFiled: September 25, 2003Date of Patent: February 5, 2008Assignee: ExxonMobil Chemical Patents Inc.Inventors: Tan-Jen Chen, John Scott Buchanan, Brian Erik Henry, Paul F. Keusenkothen, Philip A. Ruziska, David L. Stern
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Patent number: 7318845Abstract: A distillate fuel steam reformer system in which a fuel feed stream is first separated into two process streams: an aliphatics-rich, sulfur-depleted gas stream, and an aromatics- and sulfur-rich liquid residue stream. The aliphatics-rich gas stream is desulfurized, mixed with steam, and converted in a reforming reactor to a hydrogen-rich product stream. The aromatics-rich residue stream is mixed with air and combusted to provide heat necessary for endothermic process operations. Reducing the amounts of sulfur and aromatic hydrocarbons directed to desulfurzation and reforming operations minimizes the size and weight of the overall apparatus. The process of the invention is well suited to the use of microchannel apparatuses for heat exchangers, reactors, and other system components, which may be assembled in slab configuration, further reducing system size and weight.Type: GrantFiled: June 23, 2003Date of Patent: January 15, 2008Assignee: Applied Research Associates, Inc.Inventors: Aly H. Shaaban, Timothy J. Campbell
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Patent number: 6797153Abstract: A catalyst for the hydrocracking of heavy oils contains iron and active carbon having an MCH conversion rate of 40-80%, a specific surface area of 600-1000 m2/g of, a pore volume of 0.5 to 1.4 cm3/g, 2-50 nanometers' mesopore volume of not less than 60% and an average pore diameter of 3-6 nanometers, the iron being carried on the active carbon in an amount of 1 to 20 wt. % to the active carbon. The hydrocracking process using the catalyst includes a first step of conducting hydrocracking at a temperature within the range of 360-450° C. at a hydrogen partial pressure of 2-14 MPaG and a second step of conducting hydrocracking at a temperature within the range of 400-480° C. at a hydrogen partial pressure of 2-18 MPaG, which can suppress the generation of coke and remove, in a high efficiency, heavy metals such as Ni and V, asphaltene, residual carbon, sulfur and nitrogen from the heavy oils.Type: GrantFiled: April 27, 2000Date of Patent: September 28, 2004Assignees: Petroleum Energy Center, Toyo Engineering CorporationInventors: Hidetsugu Fukuyama, Koji Ohtsuka, Satoshi Terai, Shuhei Sawamoto
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Patent number: 6755962Abstract: A slurry phase reactor is designed to treat extra heavy petroleum crude in a combination of thermal-zone and catalytic-zone in a counterflow system where liquid feed is added to the top and hydrogen at the bottom. Feed enters the gas-phase thermal zone, where it passes to a liquid-phase thermal zone. In the liquid-phase thermal zone, the hydrocarbon is thermally cracked and the unreacted liquid is further passed to a catalytic-zone below in communication with the thermal-zone. Catalyst can be added or removed as required in a continuous mode without shutting down the system. The heat generated inside the catalytic cracking zone is distributed to the entire reactor as the gaseous product flows upward. Feed is brought to the reaction conditions by the heat recovered from the gas-phase zone. Reaction temperature could be controlled by feed temperature.Type: GrantFiled: May 9, 2001Date of Patent: June 29, 2004Assignee: ConocoPhillips CompanyInventor: Dwijen K. Banerjee
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Publication number: 20030150775Abstract: The invention relates to a process for converting cycle oils produced in catalytic cracking reactions into olefin and naphtha. More particularly, the invention relates to a process for hydroprocessing a catalytically cracked light cycle oil, and then re-cracking it in an upstream zone of the primary FCC riser reactor.Type: ApplicationFiled: October 2, 2002Publication date: August 14, 2003Inventors: Gordon F. Stuntz, George A. Swan, William E. Winter, Michel Daage, Michele S. Touvelle, Darryl P. Klein
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Publication number: 20030132137Abstract: The invention relates to a process for converting cycle oils produced in catalytic cracking reactions into light olefin and naphtha. More particularly, the invention relates to a process for hydroprocessing a catalytically cracked light cycle oil in order to form a hydroprocessed cycle oil containing a significant amount of tetralins. The hydroprocessed cycle oil is then re-cracked in an upstream zone of the primary FCC riser reactor.Type: ApplicationFiled: October 2, 2002Publication date: July 17, 2003Inventors: Gordon F. Stuntz, George A. Swan, William E. Winter, Michel Daage, Michele S. Touvelle, Darryl P. Klein
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Publication number: 20030100807Abstract: The invention includes a process for converting biomass into C7-C10 alkylbenzenes useful as blending components for petroleum or petroleum derived fuels. The process includes a base catalyzed depolymerization of lignin within the biomass, followed by hydroprocessing of the depolymerized lignin to C7-C10 alkylbenzenes. The C7-C10 alkylbenzenes are useful for enhancing the octane level of petroleum or petroleum-derived fuels, such as gasoline. In addition, the C7-C10 alkylbenzenes are useful as intermediates in the production of numerous organic chemicals.Type: ApplicationFiled: October 5, 2001Publication date: May 29, 2003Inventors: Joseph S. Shabtai, Wlodzimierz W. Zmierczak, Esteban Chornet, David Johnson
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Publication number: 20020166797Abstract: A slurry phase reactor is designed to treat extra heavy petroleum crude in a combination of thermal-zone and catalytic-zone in a counterflow system where liquid feed is added to the top and hydrogen at the bottom. Feed enters the gas-phase thermal zone, where it passes to a liquid-phase thermal zone. In the liquid-phase thermal zone, the hydrocarbon is thermally cracked and the unreacted liquid is further passed to a catalytic-zone below in communication with the thermal-zone. Catalyst can be added or removed as required in a continuous mode without shutting down the system. The heat generated inside the catalytic cracking zone is distributed to the entire reactor as the gaseous product flows upward. Feed is brought to the reaction conditions by the heat recovered from the gas-phase zone. Reaction temperature could be controlled by feed temperature.Type: ApplicationFiled: May 9, 2001Publication date: November 14, 2002Inventor: Dwijen K. Banerjee
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Publication number: 20010042701Abstract: The invention relates to a process for converting cycle oils produced in catalytic cracking reactions into light olefin and naphtha. More particularly, the invention relates to a process for hydroprocessing a catalytically cracked light cycle oil in order to form a hydroprocessed cycle oil containing a significant amount of tetralins. The hydroprocessed cycle oil is then re-cracked in an upstream zone of the primary FCC riser reactor.Type: ApplicationFiled: March 16, 2001Publication date: November 22, 2001Inventors: Gordon F. Stuntz, George A. Swan, William E. Winter, Michel Daage, Michele S. Touvelle, Darryl P. Klein
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Publication number: 20010042700Abstract: The invention relates to a process for converting naphtha and cycle oils produced in catalytic cracking reactions into light olefins. More particularly, the invention relates to a process for hydroprocessing a catalytically cracked light cycle oil, and then re-cracking it along with naphtha in an upstream zone of the primary FCC riser reactor.Type: ApplicationFiled: March 16, 2001Publication date: November 22, 2001Inventors: George A. Swan,, William E. Winter
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Publication number: 20010042702Abstract: The invention relates to a process for converting cycle oils produced in catalytic cracking reactions into olefin and naphtha. More particularly, the invention relates to a process for hydroprocessing a catalytically cracked light cycle oil, and then re-cracking it in an upstream zone of the primary FCC riser reactor.Type: ApplicationFiled: March 16, 2001Publication date: November 22, 2001Inventors: Gordon F. Stuntz, George A. Swan, William E. Winter, Michel Daage, Michele S. Touvelle, Darryl P. Klein
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Patent number: 6315890Abstract: The invention is related to a two step process wherein the first step comprises cracking an olefinic naphtha resulting in a cracked product having a diminished total concentration of olefinic species. The second step comprises hydroprocessing at least a portion of the cracked product, especially a naphtha fraction, to provide a hydroprocessed cracked product having a reduced concentration of contaminant species but without a substantial octane reduction.Type: GrantFiled: November 10, 1999Date of Patent: November 13, 2001Assignee: ExxonMobil Chemical Patents Inc.Inventors: Paul K. Ladwig, Gordon F. Stuntz, Garland B. Brignac, Thomas R. Halbert