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 making a multifunctional catalyst for upgrading pyrolysis oil includes contacting a hierarchical mesoporous zeolite support with a solution including at least a first metal catalyst precursor and a second metal catalyst precursor, each or both of which may include a heteropolyacid. The hierarchical mesoporous zeolite support may have an average pore size of from 2 nm to 40 nm. Contacting the hierarchical mesoporous 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 hierarchical mesoporous zeolite support to produce a multifunctional catalyst precursor. The method further includes removing excess solution 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 hierarchical mesoporous zeolite support.

A method of making a multifunctional catalyst for upgrading pyrolysis oil includes contacting a hierarchical mesoporous zeolite support with a solution including at least a first metal catalyst precursor and a second metal catalyst precursor, each or both of which may include a heteropolyacid. The hierarchical mesoporous zeolite support may have an average pore size of from 2 nm to 40 nm. Contacting the hierarchical mesoporous 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 hierarchical mesoporous zeolite support to produce a multifunctional catalyst precursor. The method further includes removing excess solution 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 hierarchical mesoporous zeolite support.

A process for producing benzene comprising the steps of: (a) separating a source feedstream comprising C5-C12 hydrocarbons including benzene and alkylbenzenes into a first feedstream comprising a higher proportion of benzene than the source feedstream and a second feedstream comprising a lower proportion of benzene than the source feedstream and subsequently,
(b) contacting the first feedstream in the presence of hydrogen with a first hydrocracking catalyst, and
(c) contacting the second feedstream with hydrogen under second process conditions to produce a second product stream comprising benzene, wherein
i) the second process conditions are suitable for hydrocracking and step (c) involves contacting the second feedstream in the presence of hydrogen with a second hydrocracking catalyst,
ii) the second process conditions are suitable for toluene disproportionation and involve contacting the second feedstream with a toluene disproportionation catalyst or
iii) the second process conditions are suitable for hydrodealkylation.

A process for producing benzene comprising the steps of: (a) separating a source feedstream comprising C5-C12 hydrocarbons including benzene and alkylbenzenes into a first feedstream comprising a higher proportion of benzene than the source feedstream and a second feedstream comprising a lower proportion of benzene than the source feedstream and subsequently,
(b) contacting the first feedstream in the presence of hydrogen with a first hydrocracking catalyst, and
(c) contacting the second feedstream with hydrogen under second process conditions to produce a second product stream comprising benzene, wherein
i) the second process conditions are suitable for hydrocracking and step (c) involves contacting the second feedstream in the presence of hydrogen with a second hydrocracking catalyst,
ii) the second process conditions are suitable for toluene disproportionation and involve contacting the second feedstream with a toluene disproportionation catalyst or
iii) the second process conditions are suitable for hydrodealkylation.

Recycle of slurry hydrocracked product to a subsequent slurry hydrocracking reactor downstream of a lead slurry hydrocracking reactor produces reduced mesophase and provides better reactor stability as opposed to recycle to the lead slurry hydrocracking reactor. The recycle stream may be a vacuum bottoms stream and/or a slop wax stream from a fractionation column.

Recycle of slurry hydrocracked product to a subsequent slurry hydrocracking reactor downstream of a lead slurry hydrocracking reactor produces reduced mesophase and provides better reactor stability as opposed to recycle to the lead slurry hydrocracking reactor. The recycle stream may be a vacuum bottoms stream and/or a slop wax stream from a fractionation column.

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 making a multifunctional catalyst for upgrading pyrolysis oil includes contacting a hierarchical mesoporous zeolite support with a solution including at least a first metal catalyst precursor and a second metal catalyst precursor, each or both of which may include a heteropolyacid. The hierarchical mesoporous zeolite support may have an average pore size of from 2 nm to 40 nm. Contacting the hierarchical mesoporous 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 hierarchical mesoporous zeolite support to produce a multifunctional catalyst precursor. The method further includes removing excess solution 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 hierarchical mesoporous zeolite support.

Process scheme configurations are disclosed that enable conversion of crude oil feeds with several processing units in an integrated manner into petrochemicals. The designs utilize minimum capital expenditures to prepare suitable feedstocks for the steam cracker complex. The integrated process for converting crude oil to petrochemical products including olefins and aromatics, and fuel products, includes mixed feed steam cracking and fluid catalytic cracking. Feeds to the mixed feed steam cracker include light products and naphtha from hydroprocessing zones within the battery limits, recycle streams from the C3 and C4 olefins recovery steps, and raffinate from a pyrolysis gasoline and FCC naphtha aromatics extraction zone within the battery limits.