A highly active hydroprocessing catalyst that comprises a doped support impregnated with at lease one hydrogenation metal component and filled with an organic additive blend. The catalyst is made by providing a doped support particle followed by impregnating the doped support particle with a metal impregnation solution to provide a metal-impregnated doped support particle. The metal-impregnated doped support particle is dried but not calcined and impregnated with an organic additive blend component.

A catalyst system has been designed that disrupts the sedimentation process. The catalyst system achieves this by saturating key feed components before the feed components are stripped into their incompatible aromatic cores. The efficacy of this disruptive catalyst system is particularly evident in a hydrocracker configuration that runs in two-stage-recycle operation. The catalyst is a self-supported multi-metallic catalyst prepared from a precursor in the hydroxide form, and the catalyst must be toward the top level of the second stage of the two-stage system.

Processes and systems for fluid catalytic cracking (FCC) of hydrocarbon feeds using a multiple riser FCC reactor are described. The conditions in each riser can be tailored for handling a different feed. For example, one riser may be configured to crack heavy hydrocarbons, such as vacuum gas oil (VGO) to yield medium and light products. Other risers may be configured to crack low and/or medium hydrocarbons to yield light olefins. Embodiments of the disclosed processes and systems may be used to provide a product spectrum that has greater amounts of light olefins.

A hydrocarbon conversion catalyst composition which comprises ZSM-48 and/or EU-2 zeolite particles and refractory oxide binder essentially free of alumina in which the average aluminium concentration of the ZSM-48 and/or EU-2 zeolite particles is at least 1.3 times the aluminium concentration at the surface of the particles, processes for preparing such catalyst compositions and processes for converting hydrocarbon feedstock with the help of such compositions.

A supercritical water separation process and system is disclosed for the removal of metals, minerals, particulate, asphaltenes, and resins from a contaminated organic material. The present invention takes advantage of the physical and chemical properties of supercritical water to effect the desired separation of contaminants from organic materials and permit scale-up. At a temperature and pressure above the critical point of water (374 C., 22.1 MPa), nonpolar organic compounds become miscible in supercritical water (SCW) and polar compounds and asphaltenes become immiscible. The process and system disclosed continuously separates immiscible contaminants and solids from the supercritical water and clean oil product solution. The present invention creates a density gradient that enables over 95% recovery of clean oil and over 99% reduction of contaminants such as asphaltenes and particulate matter depending on the properties of the contaminated organic material.

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.

For the shipping industry, these fuels provide solutions to long outstanding technical problems that heretofore hindered supply of low sulfur marine fuels in quantities needed to meet worldwide sulfur reduction goals. Marine shipping use of high sulfur bunker oils is reported as largest source of worldwide transportation SOx emissions. When ships on the open seas burn cheap low grade heavy bunker oils high in sulfur, nitrogen and metals, the SOx, NOx, and metal oxides go to the environment. This invention converts essentially all of each barrel of crude feed to a single ultraclean fuel versus conventional refining where crude feed is cut into many pieces, and each piece is sent down a separate market path meeting various different product specifications. When in port, ships can use these fuels to generate and sell electricity to land based electrical grids to offset fuel cost in an environment-friendly manner.

A system for upgrading a hydrocarbon feed includes a thermal hydrodealkylation unit and a hydrocracking unit. A method for reducing formation of heavy polynuclear aromatic compounds during hydrocracking includes contacting a hydrocarbon feed comprising polynuclear aromatic compounds with hydrogen at reaction conditions sufficient to hydrodealkylate at least a portion of the polynuclear aromatic compounds in the hydrocarbon feed to produce a hydrodealkylated effluent. The method can also include contacting at least a portion of the hydrodealkylated effluent with hydrogen in the presence of a hydrocracking catalyst, where the contacting causes at least a portion of hydrocarbons in the hydrodealkylated effluent to undergo hydrocracking to produce a hydrocracked effluent. The systems and methods may reduce or prevent formation of heavy polynuclear aromatic compounds in the hydrocracking unit by hydrodealkylating heavy polynuclear aromatic precursors in the hydrocarbon feed.

A system that includes a fuel treatment system. The fuel treatment system includes a hydrodynamic cavitation reactor that receives a fluid that includes fuel from a fuel supply and water from a water supply. The hydrodynamic cavitation reactor cavitates the fluid. Cavitation of the fluid cracks the fuel and forms radicals that combine with one or more substances in the fuel. A separator receives the fluid and separates the fluid into water, fuel, and one or more substances.

A method for heavy oil lightening and synthesis gas production and a device thereof are provided, where the method uses a cracking/gasification coupled reactor, which internally has a cracking section and a gasification section that communicate with each other, and includes the following steps: feeding a heavy oil material into the cracking section to implement a cracking reaction, to produce a light oil gas and a coke; the coke being carried by the coke powders and descending into the gasification section to implement a gasification reaction, to produce a synthesis gas; at least performing a first stage gas-solid separation, collecting coke powder particles and dividing them into two parts; performing an oil and gas fractionation on a purified oil and gas product output by the gas-solid separation system, and collecting a light oil product and a synthesis gas product.