Processes for cracking an alkane reactant to form a lower aliphatic hydrocarbon product and for converting an alkane reactant into a higher aliphatic hydrocarbon product are disclosed, and these processes include a step of contacting the alkane reactant with a supported chromium (II) catalyst. In addition to the formation of various aliphatic hydrocarbons, such as linear alkanes, branched alkanes, 1-alkenes, and internal alkenes, aromatic hydrocarbons and hydrogen also can be produced.

According to embodiments, a process for aromatizing hydrocarbons may include contacting the hydrocarbons with a zinc- or gallium-doped ZSM-5 catalyst having a mesopore volume of greater than 0.09 cm.sup.3/g. Contacting the hydrocarbons with the catalyst causes a least a portion of the hydrocarbons to undergo chemical reactions to form aromatic hydrocarbons.

According to embodiments, a process for aromatizing hydrocarbons may include contacting the hydrocarbons with a zinc- or gallium-doped ZSM-5 catalyst having a mesopore volume of greater than 0.09 cm.sup.3/g. Contacting the hydrocarbons with the catalyst causes a least a portion of the hydrocarbons to undergo chemical reactions to form aromatic hydrocarbons.

Systems and methods include an aromatics complex (ARC), the ARC in fluid communication with a naphtha reforming unit (NREF) and operable to receive a reformate stream produced by the NREF, and the ARC further operable to separate the reformate stream into a gasoline pool stream, an aromatics stream, and an aromatic bottoms stream; and a hydrodearylation unit operable to receive heavy, non-condensed, alkyl-bridged, multi-aromatic compounds from the aromatic bottoms stream, the hydrodearylation unit further operable to hydrogenate and hydrocrack the heavy, non-condensed, alkyl-bridged, multi-aromatic compounds to produce a stream suitable for recycle to the NREF or the reformate stream, where the hydrodearylation unit is further operable to receive hydrogen produced in the NREF.

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.

Improved catalytic reforming processes and systems employ reforming reactors in a more efficient manner and can avoid problems associated with yield loss. A portion of the naphtha feed is pre-reformed for conversion of paraffinic naphtha-range compounds into naphthenes and/or aromatics prior to passing to a reforming unit.

A catalyst structure includes a porous support structure, where the support structure includes an aluminosilicate material and any two or more metals loaded in the porous support structure selected from Ga, Ag, Mo, Zn, Co and Ce. The catalyst structure is used in a hydrocarbon upgrading process that is conducted in the presence of methane, nitrogen or hydrogen.

According to embodiments, a process for aromatizing hydrocarbons may include contacting the hydrocarbons with a zinc- or gallium-doped ZSM-5 catalyst having a mesopore volume of greater than 0.09 cm.sup.3/g. Contacting the hydrocarbons with the catalyst causes a least a portion of the hydrocarbons to undergo chemical reactions to form aromatic hydrocarbons.

A method of making a multifunctional catalyst for upgrading pyrolysis oil includes contacting a zeolite support with a solution including at least a first metal catalyst precursor and a second metal catalyst precursor, the first metal catalyst precursor, the second metal catalyst precursor, or both, including a heteropolyacid. Contacting the zeolite support with the solution deposits or adsorbs the first metal catalyst precursor and the second catalyst precursor onto outer surfaces and pore surfaces of the zeolite support to produce a multifunctional catalyst precursor. The method further includes removing excess solution from the multifunctional catalyst precursor and calcining the multifunctional catalyst precursor to produce the multifunctional catalyst comprising at least a first metal catalyst and a second metal catalyst deposited on the outer surfaces and pore surfaces of the zeolite support.

A method of producing a hierarchical zeolite composite catalyst. The method including dissolving, in an alkaline solution and in the presence of a surfactant, a catalyst precursor comprising mesoporous zeolite to yield a dissolved zeolite solution, where the mesoporous zeolite comprises large pore mordenite and medium pore ZSM-5. The method also including condensing the dissolved zeolite solution to yield a solid zeolite composite from the dissolved zeolite solution and heating the solid zeolite composite to remove the surfactant. The method further including impregnating the solid zeolite composite with one or more active metals selected from the group consisting of molybdenum, platinum, rhenium, nickel, and combinations thereof to yield impregnated solid zeolite composite and calcining the impregnated solid zeolite composite to produce the hierarchical zeolite composite catalyst. The hierarchical zeolite composite catalyst has a mesostructure comprising at least one disordered mesophase and at least one ordered mesophase.