A catalyst structure includes a porous support structure, where the support structure includes an aluminosilicate material. Any two or more metals are loaded in the porous support structure, the two or more metals selected from the group consisting of Ga, Ag, Mo, Zn, Co and Ce, where each metal loaded in the porous support structure is present in an amount from about 0.1 wt % to about 20 wt %. In example embodiments, the catalyst structure includes three or more of the metals loaded in the porous support structure. The catalyst structure is used in a hydrocarbon upgrading process that is conducted in the presence of methane, nitrogen or hydrogen.

A method or catalytic compressed air conversion of hydrocarbonaceous substances to oil has the steps of: providing a hydrocarbonaceous substance and a catalyst oil in a mixing turbine, mixing the catalyst oil with the hydrocarbonaceous substance to give a mixture, where the step of mixing comprises producing heat for a catalytic oxidation in the mixing turbine, providing the distillation device downstream of the mixing turbine, removing liquid constituents of the mixture into the distillation device, distilling the liquid constituents, and collecting oil and water, and is characterized in that the step of mixing comprises introducing oxygen into the mixing turbine. An apparatus with which this method can be employed has a mixing turbine comprising a first feed for a catalyst oil and a hydrocarbonaceous substance and an outlet for liquid constituents after a catalytic oxidation. In addition, such an apparatus comprises a distillation device for distilling the liquid constituents led out of the mixing turbine and a collecting device for collecting oil and water separated out from the distillation device, wherein the mixing turbine has a second feed for oxygen.

A method or catalytic compressed air conversion of hydrocarbonaceous substances to oil has the steps of: providing a hydrocarbonaceous substance and a catalyst oil in a mixing turbine, mixing the catalyst oil with the hydrocarbonaceous substance to give a mixture, where the step of mixing comprises producing heat for a catalytic oxidation in the mixing turbine, providing the distillation device downstream of the mixing turbine, removing liquid constituents of the mixture into the distillation device, distilling the liquid constituents, and collecting oil and water, and is characterized in that the step of mixing comprises introducing oxygen into the mixing turbine. An apparatus with which this method can be employed has a mixing turbine comprising a first feed for a catalyst oil and a hydrocarbonaceous substance and an outlet for liquid constituents after a catalytic oxidation. In addition, such an apparatus comprises a distillation device for distilling the liquid constituents led out of the mixing turbine and a collecting device for collecting oil and water separated out from the distillation device, wherein the mixing turbine has a second feed for oxygen.

Catalyst systems are provided for reforming of hydrocarbons, along with methods for using such catalyst systems. The catalyst systems can be deposited or otherwise coated on a surface or structure, such as a monolith, to achieve improved activity and/or structural stability. The metal oxide support layer can correspond to a thermally stable metal oxide support layer, such as a metal oxide support layer that is thermally phase stable at temperatures of 800 C. to 1600 C. The catalyst systems can be beneficial for use in cyclical reaction environments, such as reverse flow reactors or other types of reactors that are operated using flows in opposing directions and different times within a reaction cycle.

Catalyst systems are provided for reforming of hydrocarbons, along with methods for using such catalyst systems. The catalyst systems can be deposited or otherwise coated on a surface or structure, such as a monolith, to achieve improved activity and/or structural stability. The metal oxide support layer can correspond to a thermally stable metal oxide support layer, such as a metal oxide support layer that is thermally phase stable at temperatures of 800 C. to 1600 C. The catalyst systems can be beneficial for use in cyclical reaction environments, such as reverse flow reactors or other types of reactors that are operated using flows in opposing directions and different times within a reaction cycle.

A system and process for producing synthetic gas from solid fuel comprising waste material, municipal solid waste or biomass, and for upgrading the synthetic gas produced. The system and process utilizes a first thermal chamber having a gasification zone in which a fuel stream is gasified by thermal oxidation to produce a first synthetic gas stream and heat; a pyrolysis reactor housed within the first thermal chamber where fuel undergoes pyrolysis to produce a second synthetic gas stream; and a thermal catalytic reactor comprising a second thermal chamber having a catalyst chamber within with a selected catalyst. The first synthetic gas stream is completely thermally oxidized to produce high temperature flue gas that imparts heat to the catalyst chamber in which the second synthetic gas stream is thermally cracked and directed over the catalyst to yield a finished gas or liquid product having a desired chemical composition as determined by the selected catalyst.

A system and process for producing synthetic gas from solid fuel comprising waste material, municipal solid waste or biomass, and for upgrading the synthetic gas produced. The system and process utilizes a first thermal chamber having a gasification zone in which a fuel stream is gasified by thermal oxidation to produce a first synthetic gas stream and heat; a pyrolysis reactor housed within the first thermal chamber where fuel undergoes pyrolysis to produce a second synthetic gas stream; and a thermal catalytic reactor comprising a second thermal chamber having a catalyst chamber within with a selected catalyst. The first synthetic gas stream is completely thermally oxidized to produce high temperature flue gas that imparts heat to the catalyst chamber in which the second synthetic gas stream is thermally cracked and directed over the catalyst to yield a finished gas or liquid product having a desired chemical composition as determined by the selected catalyst.

A process for combusting coke from catalyst in partial burn mode is disclosed. The partial burn regenerator runs deprived of oxygen such that the flue gas will contain a fair amount of carbon monoxide. The oxygen present in the flue gas can burn in the bed before reaching the dilute phase. The catalyst distributor is positioned in the upper chamber of the regeneration vessel for discharging the catalyst.

A process for combusting coke from catalyst in partial burn mode is disclosed. The partial burn regenerator runs deprived of oxygen such that the flue gas will contain a fair amount of carbon monoxide. The oxygen present in the flue gas can burn in the bed before reaching the dilute phase. The catalyst distributor is positioned in the upper chamber of the regeneration vessel for discharging the catalyst.

A process for combusting coke from catalyst in partial burn mode is disclosed. The partial burn regenerator runs deprived of oxygen such that the flue gas will contain a fair amount of carbon monoxide. The oxygen present in the flue gas can burn in the bed before reaching the dilute phase. The catalyst distributor is positioned in the upper chamber of the regeneration vessel for discharging the catalyst.