A method of making a heat generating catalyst for hydrocarbon cracking. The method includes providing at least one mordenite framework-inverted (MFI) zeolite having a Si/Al molar ratio of 15 or greater and providing at least one metal oxide precursor. Further, the at least one metal oxide precursor is dispersed within a microstructure of the MFI zeolite catalyst. The method additionally includes calcining the heat generating material with the at least one metal oxide precursor dispersed within the microstructure of the MFI zeolite catalyst to form at least one metal oxide in situ. The heat generating catalyst includes at least one MFI zeolite and at least one metal oxide in a ratio between 50:50 and 95:5. Additionally, an associated method of using the heat generating catalyst in a hydrocarbon cracking process is provided.

A method of producing olefins by catalytic cracking of hydrocarbons is disclosed. The method may include catalytic cracking hydrocarbons in a feed stream that includes the hydrocarbons and the dry gas diluent. The catalytic cracking may be carried out in a process using a train of fixed bed reactors while one or more other trains of fixed bed reactors are being regenerated or are on standby after being regenerated. When the train of fixed bed reactors being used needs regenerating, it is taken out of service and the one or more other trains of fixed bed reactors put in service to carry out the catalytic cracking process. Dry gas instead of steam may be used to reduce the partial pressure of hydrocarbons.

A method of producing olefins by catalytic cracking of hydrocarbons is disclosed. The method may include catalytic cracking hydrocarbons in a feed stream that includes the hydrocarbons and the dry gas diluent. The catalytic cracking may be carried out in a process using a train of fixed bed reactors while one or more other trains of fixed bed reactors are being regenerated or are on standby after being regenerated. When the train of fixed bed reactors being used needs regenerating, it is taken out of service and the one or more other trains of fixed bed reactors put in service to carry out the catalytic cracking process. Dry gas instead of steam may be used to reduce the partial pressure of hydrocarbons.

In an embodiment, a process for converting a hydrocarbon feed includes introducing a hydrocarbon feed comprising a C.sub.2-C.sub.50 acyclic alkane and a C.sub.3-C.sub.50 cyclic alkane to a catalyst composition in a reactor. The process further includes converting the hydrocarbon feed in the reactor under reactor conditions to a product mixture comprising at least one of a C.sub.6-C.sub.9 aromatic product or a C.sub.12+ distillate product.

In an embodiment, a process for converting a hydrocarbon feed includes introducing a hydrocarbon feed comprising a C.sub.2-C.sub.50 acyclic alkane and a C.sub.3-C.sub.50 cyclic alkane to a catalyst composition in a reactor. The process further includes converting the hydrocarbon feed in the reactor under reactor conditions to a product mixture comprising at least one of a C.sub.6-C.sub.9 aromatic product or a C.sub.12+ distillate product.

An integrated process for conversion of a hydrocarbon stream comprising light naphtha to enhanced value products. The process includes passing the hydrocarbon stream through a first reactor, the first reactor being a catalytic bed reactor with a dual-function catalyst to simultaneously reform light naphtha to BTEX and crack light naphtha to ethane, propane, and butanes. Further, the process includes passing an effluent of the first reactor to a gas-liquid separating unit to generate a liquid stream and a gas stream, and passing the gas stream to a gas separator unit to remove hydrogen gas and methane and generate an enhanced gas stream. The process further includes passing the enhanced gas stream through a second reactor, the second reactor being a pyrolysis unit operated at steam cracking conditions to convert ethane, propane, and butanes in the enhanced gas stream to light. An associated system for performing the process is also provided wherein the integrated process does not include passage of a process stream to a separate and independent hydrocracking unit to crack light alkanes in the hydrocarbon stream to smaller alkanes.

An integrated process for conversion of a hydrocarbon stream comprising light naphtha to enhanced value products. The process includes passing the hydrocarbon stream through a first reactor, the first reactor being a catalytic bed reactor with a dual-function catalyst to simultaneously reform light naphtha to BTEX and crack light naphtha to ethane, propane, and butanes. Further, the process includes passing an effluent of the first reactor to a gas-liquid separating unit to generate a liquid stream and a gas stream, and passing the gas stream to a gas separator unit to remove hydrogen gas and methane and generate an enhanced gas stream. The process further includes passing the enhanced gas stream through a second reactor, the second reactor being a pyrolysis unit operated at steam cracking conditions to convert ethane, propane, and butanes in the enhanced gas stream to light. An associated system for performing the process is also provided wherein the integrated process does not include passage of a process stream to a separate and independent hydrocracking unit to crack light alkanes in the hydrocarbon stream to smaller alkanes.

Apparatuses and methods of use are provided for a lobular catalyst for use in processes featuring water at high pressures and high temperatures, including in supercritical or near supercritical water conditions. The lobular catalyst structure features a shaped, plate-like structure extending along the reactor length with a high surface area. The lobular catalyst structure is fixed in place and mounted within a high temperature and high pressure reactor. The catalyst includes a catalytically active component, which can be a transition metal. The catalyst can be used in high pressure and high temperature processes, including in supercritical or near supercritical water processes, to improve heavy oil upgrading and hydrocarbon conversion in chemical processes.

Apparatuses and methods of use are provided for a lobular catalyst for use in processes featuring water at high pressures and high temperatures, including in supercritical or near supercritical water conditions. The lobular catalyst structure features a shaped, plate-like structure extending along the reactor length with a high surface area. The lobular catalyst structure is fixed in place and mounted within a high temperature and high pressure reactor. The catalyst includes a catalytically active component, which can be a transition metal. The catalyst can be used in high pressure and high temperature processes, including in supercritical or near supercritical water processes, to improve heavy oil upgrading and hydrocarbon conversion in chemical processes.

An integrated process for conversion of a hydrocarbon stream comprising light naphtha to enhanced value products. The process includes passing the hydrocarbon stream through a first reactor, the first reactor being a catalytic bed reactor with a dual-function catalyst to simultaneously reform light naphtha to BTEX and crack light naphtha to ethane, propane, and butanes. Further, the process includes passing an effluent of the first reactor to a gas-liquid separating unit to generate a liquid stream and a gas stream, and passing the gas stream to a gas separator unit to remove hydrogen gas and methane and generate an enhanced gas stream. The process further includes passing the enhanced gas stream through a second reactor, the second reactor being a pyrolysis unit operated at steam cracking conditions to convert ethane, propane, and butanes in the enhanced gas stream to light. An associated system for performing the process is also provided wherein the integrated process does not include passage of a process stream to a separate and independent hydrocracking unit to crack light alkanes in the hydrocarbon stream to smaller alkanes.