A system for processing a hydrocarbon feed has a final stage reactor and internal separator with cyclone that forms a substantially gas stream and a substantially non-gas stream. The substantially gas stream is sent directly from the final stage reactor and separator to further downstream processing.

A catalyst has a carrier and a hydrogenation active metal component supported on the carrier. The hydrogenation active metal component contains at least one Group VIB metal component and at least one Group VIII metal component, and the carrier is composed of phosphorus-containing alumina. When the hydrogenation catalyst is measured using a hydrogen temperature programmed reduction method (H.sub.2-TPR), the ratio of the peak height of the low-temperature reduction peak, P.sub.low-temp peak, at a temperature of 300-500° C. to the peak height of the high-temperature reduction peak, P.sub.hi-temp peak, at a temperature of 650-850° C., i.e. S=P.sub.low-temp peak/P.sub.hi-temp peak, is 0.5-2.0; preferably 0.7-1.9, and more preferably 0.8-1.8. The hydrogenation catalyst shows excellent heteroatom removal effect and excellent stability when used in hydrotreatment.

A system for upgrading heavy hydrocarbon feeds, such as crude oil, include a hydrotreating unit, a hydrotreated effluent separation system, a solvent-assisted adsorption system, and a hydrocracking unit. Processes for upgrading heavy hydrocarbon feeds include hydrotreating the hydrocarbon feed to produce a hydrotreated effluent that includes asphaltenes, separating the hydrotreated effluent into a lesser boiling hydrotreated effluent and a greater boiling hydrotreated effluent comprising the asphaltenes, combining the greater boiling hydrotreated effluent with a light paraffin solvent to produce a combined stream, adsorbing the asphaltenes from the combined stream to produce an adsorption effluent, and hydrocracking the lesser boiling hydrotreated effluent and at least a portion of the adsorption effluent to produce a hydrocracked effluent with hydrocarbons boiling less than 180° C. The systems and processes increase the hydrocarbon conversion and yield of hydrocarbons boiling less than 180° C.

Oxidized disulfide oil (ODSO) compounds or ODSO compounds and disulfide oil (DSO) compounds are reacted with a hydrogen addition feed in a hydroprocessing complex. The hydrogen addition process can include naphtha hydrotreatment, middle distillate hydrotreatment, vacuum gas oil hydrocracking, and vacuum gas oil hydrotreatment. The ODSO or ODSO and DSO components are converted to hydrogen sulfide, water and alkanes.

Embodiments of the disclosure provide an aqueous reforming system and a method for upgrading heavy hydrocarbons. A hydrocarbon feed and a surfactant stream are combined to produce a first precursor stream. The first precursor stream and an alkali feed are combined to produce a second precursor stream. The second precursor stream and a transition metal feed are combined to produce a catalytic emulsion stream. The catalytic emulsion stream is heated to produce a catalytic suspension and a decomposition gas, where the decomposition gas is separated by a first separator. The catalytic suspension is combined with a preheated water stream to produce an aqueous reformer feed. The aqueous reformer feed is introduced to an aqueous reformer such that the heavy hydrocarbons undergo conversion reactions to produce an effluent stream. The effluent stream is introduced to a second separator to produce a heavy stream and a light stream. The light stream is introduced to a third separator to produce a gas stream, a distillate stream, and a spent water stream. Optionally, a portion of the distillate stream and the hydrocarbon feed can be combined to produce the first precursor stream such that the first precursor stream is in the absence of a surfactant.

The present invention relates to a sequential thermo-chemical treatment along with adsorption-based pre-treatment process for residual oils having a very high naphthenic acid content. First stage of the process is a thermal pre-treatment step which results into generation of hydrocarbon stream with a reduced naphthenic acid content due to high temperature. In second stage of pre-treatment, generated hydrocarbon stream from stage-1 is subjected to esterification reaction with alcohol, such as methanol, to further reduce the TAN of hydrocarbon stream. After recovery of alcohol from the reaction mixture, depending on TAN reduction required reaction mixture may be subjected to an adsorption stage, third stage pre-treatment, where an adsorbent mixture comprising of FCC spent catalyst is used to adsorb the TAN of feed hydrocarbon stream. The treated hydrocarbon stream is then co-processed with DCU feed stock for producing lighter hydrocarbons.

The present invention relates to a method for producing very low-sulfur fuel oil having high compatibility and high stability, comprising: mixing petroleum residua obtained from at least two different petroleum refining processes, adding a hydrocarbon solvent to the residual petroleum mixture, heating the mixture of the petroleum residua mixture and hydrocarbon solvent to extract and recover a mixture of oil fractions and the hydrocarbon solvent from the mixture of the petroleum residua mixture and hydrocarbon solvent with raffinate having asphaltenes therein being left, and removing the hydrocarbon solvent from the mixture of the oil fractions and the hydrocarbon solvent, thereby obtaining very low-sulfur fuel oil, wherein the very low-sulfur fuel oil has a sulfur content of 0.5 wt % or less bared on the total weight of the very low-sulfur fuel oil, and very low-sulfur fuel oil produced by the production method.

A phosphorus-containing molecular sieve has a phosphorus content of about 0.3-5 wt %, a pore volume of about 0.2-0.95 ml/g, and a ratio of B acid content to L acid content of about 2-10. The molecular sieve has a specific combination of characteristics, including a high ratio of B acid content to L acid content, thereby exhibiting higher hydrocracking activity and ring-opening selectivity when used in the preparation of a hydrocracking catalyst.

In an apparatus for fluid catalytic cracking a riser having a top and a bottom for fluidizing and cracking a hydrocarbon feed stream by contact with catalyst exits an outlet at the top of the riser. A downer in communication with the outlet of the riser receives cracked hydrocarbon product and catalyst. A swirl duct in communication with the downer has a discharge opening below the outlet for discharging said cracked hydrocarbon product and catalyst. A stream of hydrocarbon feed and a catalyst is passed upwardly in a riser. A stream of gaseous hydrocarbon products and catalyst is directedly downwardly and then the stream of gaseous hydrocarbon products and catalyst are directed to flow in an angular direction to separate gaseous hydrocarbon products from the catalyst.

An alumina grain has a single-crystal structure and has an approximate regular octahedral stereoscopic morphology. Eight sides of the alumina grain belong to the {111} family of crystal planes of γ-state alumina, and the grain size is 5-100 μm. The alumina grain is unique in crystal plane exposure and distribution, simple and feasible in preparation, and low in cost, and has higher operability, and thus has good application prospect in the field of catalysis and adsorption.