An ebullated bed hydroprocessing system is upgraded using a dual catalyst system that includes a heterogeneous catalyst and dispersed metal sulfide particles to improve the quality of vacuum residue. The improved quality of vacuum residue can be provided by one or more of reduced viscosity, reduced density (increased API gravity), reduced asphaltene content, reduced carbon residue content, reduced sulfur content, and reduced sediment. Vacuum residue of improved quality can be produced while operating the upgraded ebullated bed reactor at the same or higher severity, temperature, throughput and/or conversion. Similarly, vacuum residue of same or higher quality can be produced while operating the upgraded ebullated bed reactor at higher severity, temperature, throughput and/or conversion.

A new catalyst hydroisomerizes C18 paraffins from fatty acids to a high degree to produce a composition with acceptable freeze point which retains 18 carbon atoms in the hydrocarbon molecule for jet fuel. We have discovered a fuel composition comprising at least 14 wt % hydrocarbon molecules having at least 18 carbon atoms and a freeze point not higher than −40° C. The composition also may exhibit a exhibiting a final boiling point of no more than 300° C. The hydroisomerization process can be once through or a portion of the product diesel stream may be selectively hydrocracked or recycled to hydroisomerization to obtain a fuel composition that meets jet fuel specifications.

A process for producing a base oil composition from a deasphalted oil (DAO) feed, where the DAO feed undergoes hydrotreating, hydrocracking, catalytically dewaxing, hydrofinishing, and fractionating to generate the base oil composition. The base oil composition includes a hazy-free at 0° C. heavy base oil comprising (a) a kinetic viscosity ranging from 15 to 21 cSt at 100° C., (b) a 5 viscosity index of at least 95, (c) a pour point of less than −12° C., (d) a cloud point of less than −18° C., and (e) a total aromatics content of 2 wt % or less, where the hazy-free at 0° C. heavy base oil maintains a hazy-free appearance when stored undisturbed at 0° C. during a test period.

A method for producing a catalyst or catalyst precursor is described including: applying a slurry of a particulate catalyst compound in a carrier fluid to an additive layer manufactured support structure to form a slurry-impregnated support, and drying and optionally calcining the slurry-impregnated support to form a catalyst or catalyst precursor. The mean particle size (D50) of the particulate catalyst compound in the slurry is in the range 1-50 μm and the support structure has a porosity ≧0.02 ml/g.

This disclosure relates to red mud compositions. This disclosure also relates to methods of making red mud compositions. This disclosure additionally relates to methods of using red mud compositions.

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.

A process is disclosed for producing distillate range hydrocarbons using MTW and/or SSZ-41x catalysts.

A method of making a hydrodesulfurization catalyst having nickel and molybdenum sulfides deposited on a support material containing mesoporous silica that is optionally modified with zirconium. The method of making the hydrodesulfurization catalyst involves a single-step calcination and reduction procedure. The utilization of the hydrodesulfurization catalyst in treating a hydrocarbon feedstock containing sulfur compounds (e.g. dibenzothiophene, 4,6-dimethyldibenzothiophene) to produce a desulfurized hydrocarbon stream is also provided.

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.

Improved alkylation catalysts, alkylation methods, and methods of making alkylation catalysts are described. The alkylation method comprises reaction over a solid acid, zeolite-based catalyst and can be conducted for relatively long periods at steady state conditions. The alkylation catalyst comprises a crystalline zeolite structure, a Si/Al molar ratio of 20 or less, less than 0.5 weight percent alkali metals, and further having a characteristic catalyst life property. Some catalysts may contain rare earth elements in the range of 10 to 35 wt %. One method of making a catalyst includes a calcination step following exchange of the rare earth element(s) conducted at a temperature of at least 575° C. to stabilize the resulting structure followed by an deammoniation treatment. An improved method of deammoniation uses low temperature oxidation.