The present invention relates to a catalyst system comprising: i. a first layer of a hydrocarbon conversion catalyst, the hydrocarbon conversion catalyst comprising: a first composition comprising a platinum group metal on a solid support; and a second composition comprising a transition metal on an inorganic support; ii. a second layer comprising a cracking catalyst; and to a process for conversion of a hydrocarbon feed utilizing this catalyst system.

A process for commencing a continuous reaction in a reactor system includes introducing a catalyst to a catalyst processing portion of the reactor system, the catalyst initially having a first temperature of 500 C or less, and contacting the catalyst at the first temperature with a commencement fuel gas stream, which includes at least 80 mol % commencement fuel gas, in the catalyst processing portion. Contacting of the catalyst with the commencement fuel gas stream causes combustion of the commencement fuel gas. The process includes maintaining the contacting of the catalyst with the commencement fuel gas stream until the temperature of the catalyst increases from the first temperature to a second temperature at which combustion of a regenerator fuel source maintains an operating temperature range in the catalyst processing portion.

The present disclosure relates to an FCC catalyst additive for cracking of petroleum feedstock and a process for its preparation. The FCC catalyst additive of the present disclosure comprises at least one zeolite, at least one clay, at least one binder, phosphorous in the form of P.sub.2O.sub.5, and at least one Group IVB metal compound. The FCC catalyst additive of the present disclosure is hydrothermally stable and has improved matrix surface area even after various hydrothermal treatments. The FCC catalyst additive of the present disclosure can be used in combination with the conventional FCC catalyst for catalytic cracking to selectively enhance the propylene and LPG yields.

A process for converting C2-5 alkanes to higher value C5-24 hydrocarbon fuels and blendstocks. The C2-5 alkanes are converted to olefins by thermal olefination, without the use of a dehydrogenation catalyst and without the use of steam. The product olefins are fed to an oligomerization reactor containing a zeolite catalyst to crack, oligomerize and cyclize the olefins to the fuel products which are then recovered. Optionally, hydrogen and methane are removed from the product olefin stream prior to oligomerization. Further optionally, C2-5 alkanes are removed from the product olefin stream prior to oligomerization.

Described herein is a method for producing a zeolite catalyst useful for aromatization of a lower alkane, a zeolite catalyst useful for aromatization of a lower alkane obtainable by said method and a process for aromatization of a lower alkane using the zeolite catalyst.

Systems and methods for production of externally-pore-blocked, internally-pore-opened modified zeolite crystals, the method including mixing zeolite crystals with an organic pore blocking agent; heating the zeolite crystals mixed with the organic pore blocking agent to block internal pores of the zeolite crystals and produce internally-pore-blocked zeolite crystals; mixing the internally-pore-blocked zeolite crystals with an external pore blocking agent; and calcining the internally-pore-blocked zeolite crystals mixed with the external pore blocking agent, to re-open internal pores via decomposition of the organic pore blocking agent and to block external pores via formation of a silica layer over external pores of the zeolite crystals, forming the externally-pore-blocked, internally-pore-opened modified zeolite crystals.

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 gas oil steam 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 aromatics extraction zone within the battery limits. Feeds to the gas oil steam cracker include hydrotreated gas oil range intermediates from vacuum gas oil hydrotreating.

The present disclosure relates generally processes and systems for converting a C2-C7 light alkanes feed to liquid transportation fuels or value-added chemicals. The feed is contacted with an aromatization catalyst at a temperature and pressure that selectively converts C4 and larger alkanes to an intermediate product comprising monocyclic aromatics and olefins. Following separation of the aromatics and C5+ hydrocarbons from the intermediate product, unconverted C2-C3 alkanes are thermally-cracked to produce olefins that are subsequently oligomerized to produce a liquid transportation fuel blend stock or value-added chemicals.

Processes for increasing an octane value of a gasoline component by dehydrogenating a stream comprising C.sub.7 hydrocarbons and methylcyclohexane in a first dehydrogenation zone to form an intermediate dehydrogenation effluent, and then dehydrogenating the intermediate dehydrogenation effluent in a second dehydrogenation zone to form a C.sub.7 dehydrogenation effluent. The C.sub.7 dehydrogenation effluent has an increased olefins content compared to an olefins content of the intermediate dehydrogenation effluent. The first dehydrogenation zone is operated under conditions to convert methylcyclohexane to toluene and minimize cracking reactions. The intermediate dehydrogenation effluent may be heated before being passed to the second dehydrogenation zone.

Provided are systems and methods for obtaining ethylene and propylene products from, for example, shale gas and shale gas condensate feedstocks. These systems and method operate by utilizing a hydrocracker train to crack C4 and C5 hydrocarbons to a product stream of propane and ethane or using a hydrogenolysis train to process C4 and C5 hydrocarbons to a product stream of propane and ethane that is provided to a cracker for an efficient conversion to ethylene and propylene. The disclosed systems are configured to reduce the amount of offsite hydrogen needed and also provide product streams that include a well-defined set of products as compared to existing approaches.