Systems and methods for upgrading a heavy oil feed to a light product comprising distillate fractions and olefins, the method including combining a heavy oil feed with a naphtha-based cracking additive to produce a mixed heavy oil feed; heating the mixed heavy oil feed with a nano-zeolite catalyst to effect catalytic upgrading of the mixed heavy oil feed to produce lighter distillate fractions and olefins in an upgraded product; and separating the lighter distillate fractions from the olefins.

Methods are provided for refining natural oil feedstocks. The methods comprise reacting the feedstock in the presence of a metathesis catalyst under conditions sufficient to form a metathesized product comprising olefins and esters. In certain embodiments, the methods further comprise separating the olefins from the esters in the metathesized product. In certain embodiments, the methods further comprise hydrogenating the olefins under conditions sufficient to form a fuel composition. In certain embodiments, the methods further comprise transesterifying the esters in the presence of an alcohol to form a transesterified product.

A cascade reactor scheme with acid and hydrocarbon flowing in reverse directions. The systems and processes for alkylation of olefins herein may include providing a first olefin to a first alkylation zone, and a second olefin to a second alkylation zone. Isoparaffin may be provided to the first alkylation zone. The isoparaffin and first olefin may be contacted with a partially spent sulfuric acid in the first alkylation zone to form a spent acid phase and a first hydrocarbon phase including alkylate and unreacted isoparaffin. The first hydrocarbon phase and second olefin may be contacted with a sulfuric acid feed in the second alkylation zone to form a second hydrocarbon phase, also including alkylate and unreacted isoparaffin, and the partially spent sulfuric acid that is fed to the first alkylation zone. Further, the second hydrocarbon phase may be separated, recovering an isoparaffin fraction and an alkylate product fraction.

Processes to selectively crack alkyne compounds from a hydrocarbon stream including olefinic and di-olefinic compounds are described. The process includes contacting the hydrocarbon stream with a supported CuO catalyst under conditions sufficient to crack the alkynes to form a product stream that included cracked compounds and further separating the cracked organic compounds from the hydrocarbon stream.

The disclosure provides a short-process separation system for separating ionic liquid from alkylation reaction effluent, comprising an alkylation reactor, an ionic liquid storage tank, a primary coalescence separator, a secondary coalescence separator, a flash tank, a low-temperature fine coalescence separator and a fractionating tower that are linked in order. The inlet of the ionic liquid storage tank communicates with the bottom flow ports of the primary coalescence separator, the secondary coalescence separator and the low-temperature fine coalescence separator through delivery lines, and the outlet of the ionic liquid storage tank communicates with the return port of the alkylation reactor through a delivery pump. The alkylated oil collected from this system has a high degree of cleanliness, and can be used directly as a component for formulating clean gasoline. The ionic liquid catalyst collected therefrom may be directly returned to the alkylation reactor for cycle use.

A cascade reactor scheme with acid and hydrocarbon flowing in reverse directions. The systems and processes for alkylation of olefins herein may include providing a first olefin to a first alkylation zone, and a second olefin to a second alkylation zone. Isoparaffin may be provided to the first alkylation zone. The isoparaffin and first olefin may be contacted with a partially spent sulfuric acid in the first alkylation zone to form a spent acid phase and a first hydrocarbon phase including alkylate and unreacted isoparaffin. The first hydrocarbon phase and second olefin may be contacted with a sulfuric acid feed in the second alkylation zone to form a second hydrocarbon phase, also including alkylate and unreacted isoparaffin, and the partially spent sulfuric acid that is fed to the first alkylation zone. Further, the second hydrocarbon phase may be separated, recovering an isoparaffin fraction and an alkylate product fraction.

A cracker stream is provided that contains a recycle content pyrolysis oil composition, a predominantly C.sub.5 to C.sub.22 hydrocarbon composition, and steam at a steam-to-hydrocarbon ratio of at least 0.60:1. The method for making olefins includes: (a) combining a predominantly C.sub.5 to C.sub.22 hydrocarbon stream with a recycle content pyrolysis oil composition (r-pyoil) to provide a combined cracker stream; and (b) cracking the combined cracker stream in a cracker furnace to provide an olefin-containing effluent stream, wherein the combined cracker stream contains steam at a steam-to-hydrocarbon ratio greater than 0.60:1. There is also provided a cracker stream including r-pyoil), a predominantly C.sub.2 to C.sub.4 hydrocarbon composition, and steam at a steam-to-hydrocarbon ratio of at least 0.20:1. Olefins can be made from this cracker stream as well.

Olefins are made by passing a cracker stream through a convection section of a cracker furnace; introducing steam and a stream comprising a recycle content pyrolysis oil into the cracker stream to form a combined stream, and the steam, r-pyoil stream, or both are introduced downstream of the inlet to the convection section, such as between the inlet to the coils and the radiant zone, or at the cross-over. Additionally, dilution steam can be added to a stream of r-pyrolysis to form a steam-diluted r-pyoil stream which is then introduced into a cracker furnace at any location, such as downstream of the inlets to the convection box or at a cross-over.

A process to convert paraffinic feedstocks into renewable poly-alpha-olefins (PAO) basestocks. In a preferred embodiment of the invention, renewable feed comprising triglycerides and/or free fatty acids are hydrotreated producing an intermediate paraffin feedstock. This paraffin feedstock is thermally cracked into a mixture of olefins and paraffins comprising linear alpha olefins. The olefins are separated and the un-reacted paraffins are recycled to the thermal cracker. Light olefins preferably are oligomerized with a surface deactivated zeolite producing a mixture of slightly branched oligomers comprising internal olefins. The heavier olefins (C8-C14) are oligomerized, preferably with a BF3 catalyst and co-catalyst to produce PAO products. The oligomerized products can be hydrotreated and distilled together or separate to produce finished products that include naphtha, distillate, solvents, drilling fluid, and PAO lube basestocks.

Systems and a method for manufacturing a base stock from a hydrocarbon stream are provided. An example method includes cracking the hydrocarbon stream to form a raw product stream, separating an ethylene stream from the raw product stream, and oligomerizing the ethylene stream to form a raw oligomer stream. A Light olefinic stream is distilled from the raw oligomer stream and oligomerized the light olefinic stream with the ethylene stream. A heavy olefinic stream is distilled from the raw oligomer stream. The heavy olefinic stream is to form a hydro-processed and distilled to form the base stock.