The present invention relates to a process for production of high yield of hydrogen by carrying out the dry reforming of the dry gas generated from the process itself by utilizing the same catalyst for cracking and producing high yield of light olefins such as ethylene, propylene and butylenes from residue feedstocks.

The invention provides a process of alkaline catalytic cracking of inferior heavy oil with double reaction tubes in milliseconds and gaseous coupling, the process comprising: a high-efficiency atomizing nozzle sprays the preheated heavy oil into an upper portion of a downflow reaction tube, the produced oil mist mixes with a high temperature regenerated alkaline catalyst flowing downward from a dual-regulation return feeder, so as to heat, vaporize and crack the oil mist, the obtained stream containing a cracked oil and gas and an alkali catalyst to be generated flows rapidly and downward to the bottom of the downflow reaction tube to carry out a gas-solid separation; then the cracked oil and gas obtained from the gas-solid separation enters a fractionation column to be separated, the oil slurry obtained by separating the cracked oil and gas returns to mix with the heavy oil for recyclable use, while the other products separated from the cracked oil and gas are output as intermediate products; the alkali catalyst to be generated obtained from the gas-solid separation is subject to steam stripping and enters into a lower portion of a riser gasification reactor and carries out a catalytic gasification reaction with an oxidant and water vapor at a reaction temperature of 750 C. to 1,000 C., the subsequently generated material stream containing synthesis gas and regenerated alkaline catalyst flows rapidly and upward to a top of the riser gasification reactor to carry out a gas-solid separation; the high-temperature regenerated alkaline catalyst obtained from the gas-solid separation flows into the dual-regulation return feeder, wherein a portion of the high-temperature regenerated alkaline catalyst flows into the downflow reaction tube to continue to crack the heavy oil, the remaining portion of the high-temperature regenerated alkaline catalyst returns to the riser gasification reactor so as to continue the regeneration gasification; the synthesis gas obtained from the gas-solid separation is subject to a heat exchange and then output as a product.

An industrial high temperature reformer and the reforming method in which a temperature of the reforming furnace is maintained at 1000 C. or higher by burning the coke, and a temperature of at least an upper half of the reforming furnace is maintained at 1200 C. or higher by burning the syngas, thereby producing syngas at a capacity of 500 m.sup.3/hour or more by reforming all carbonaceous feedstock which is supplied to the reforming furnace.

The present invention relates to a method and system for recovering and processing a hydrocarbon mixture from a subterranean formation. The method comprises: (i) mobilizing said hydrocarbon mixture; (ii) recovering said mobilized hydrocarbon mixture; (iii) coking said recovered hydrocarbon mixture to produce decoked hydrocarbon and coke; (iv) combusting said coke to generate steam and/or energy and CO.sub.2; (v) upgrading said decoked hydrocarbon by hydrogen addition to produce upgraded hydrocarbon; and (v) adding a diluent to the decoked hydrocarbon prior to upgrading and/or adding a diluent to the upgraded hydrocarbon; wherein said method is at least partially self-sufficient in terms of steam and/or energy and diluent.

Systems and methods are provided for producing high quality synthesis gas from a fluidized coking system that includes an integrated gasifier. Additionally or alternately, systems and methods are provided for integrating a fluidized coking process, a coke gasification process, and processes for production of compounds from the synthesis gas generated during the coke gasification. The integrated process can also allow for reduced or minimized production of inorganic nitrogen compounds by using oxygen from an air separation unit as the oxygen source for gasification. Although the amount of nitrogen introduced as a diluent into the gasification will be reduced, minimized, or eliminated, the integrated process can also allow for gasification of coke while reducing, minimizing, or eliminating production of slag or other glass-like substances in the gasifier. Examples of compounds that can be produced from the synthesis gas include, but are not limited to, methanol, ammonia, and urea.

Systems and methods are provided for integrating a fluidized coking process, optionally a coke gasification process, and processes for production of additional liquid products from the coking and/or gasification process. In some aspects, the integrated processes can allow for conversion of olefins generated during a fluidized coking process to form additional liquid products. Additionally or alternately, in some aspects the integrated processes can allow for separation of syngas from the flue gas/fuel gas generated by a gasifier integrated with a fluidized coking process. This syngas can then be used to form methanol, which can then be converted in a methanol conversion process to form heavier products. In such aspects, olefins generated during the fluidized coking process can be added to the methanol conversion process to improve the yield. Additionally, in various aspects, the off-gas from the integrated conversion process can be used as an additional paraffin feed that can be recycled to one of the heat integration conduits in the fluidized coker for additional generation of olefins. This can provide a further increase in liquid yields using a carbon source (C.sub.4 paraffins) that is conventionally viewed as a low value product from coking.

A system for gasification of a carbonaceous material and recycling char or solids from a gasifier is disclosed. The recycling system may include a standpipe that receives a solids stream from a separator, the standpipe generating a pressure differential across a bed of accumulated char, thereby producing a bottoms stream having a greater pressure than the inlet solids stream. The recycling system may also include a holding vessel that receives the bottoms stream and a fluidized-bed distribution vessel that receives char from the holding vessel and is configured to provide a continuous and precise flow of recycled char to the gasification reactor.

The present invention relates to a process and system for complete conversion of crude oils by integrating delayed coking process, high severity catalytic cracking process and naphtha cracking processes along with olefin recovery section, aromatic recovery section and gasifier section to maximize the crude oil conversion to valuable products like light olefins, aromatics and chemicals.

The disclosure relates generally to methods and systems for manufacturing ammonia, ammonium sulfate, nitric acid, ammonium nitrate, or combinations thereof, and particularly to clean and efficient methods and system configurations for manufacturing ammonia, ammonium sulfate, nitric acid, ammonium nitrate, or combinations thereof using coal, petcoke, asphaltenes and/or hydrocarbon waste products.

An industrial high temperature reformer and the reforming method in which a temperature of the reforming furnace is maintained at 1000 C. or higher by burning the coke, and a temperature of at least an upper half of the reforming furnace is maintained at 1200 C. or higher by burning the syngas, thereby producing syngas at a capacity of 500 m.sup.3/hour or more by reforming all carbonaceous feedstock which is supplied to the reforming furnace.