Exxon Chemical Patents, Inc.

Exxon Research and Engineering Company

Exxonmobil Technology and Engineering Company

Exxonmobil Research and Engineering Company

Koch-glitsch, Inc.

David C Dankworth

Ramesh Gupta

William B Eckstrom

Jacob I Emert

Keith R Gorda

Joseph V Cusumano

Jon E Stanat

William D Diana

Antonio Gutierrez

Warren A Thaler

Edward Stanley Ellis

Stephen Zushma

Sumathy Raman

Hugo S Caram

Jeffrey William Frederick

James Peter Stokes

James J Schorfheide

Robert M Koros

William B Diana

Dennis D Fleming

Dimitrios M Tsangaris

Mohsen N Harandi

Stuart Leon Soled

Stephen Harold Brown

Michael Siskin

Larry Lee Iaccino

Guang Cao

Jane C Cheng

Lei Zhang

Chuansheng Bai

William Ernest Lewis

Anjaneya Sarma Kovvali

Benjamin S Umansky

Himanshu Gupta

Robert J Falkiner

Richard Charles Dougherty

Juan D Henao

Ramesh R Hemrajani

Salvatore Rea

Thomas Francis Degnan, Jr

Steven Webster Levine

Salvatore Joseph Rossetti

Russell D Sellen

David Lee Vannauker

John T Wyatt

Louis A Curcio

Jeffrey L Kaufman

Harold Wilbur Margo

Todd P Marut

Chris F Meyer

Yiu Wah Wong

August W Bosse

James R Bielenberg

James Philip Bailor

John D Nelson

William H Cross

Cindy J Hughart

Amrit Jalan

Methods are provided for upgrading of pyrolysis carbon in order to allow for conversion of the pyrolysis carbon into higher value products. Instead of attempting to convert methane into a high value carbon product (such as carbon nanotubes) and Hin a single reaction step, pyrolysis conditions can be used to form Hand pyrolysis carbon. The pyrolysis carbon can then be treated in order to convert the pyrolysis carbon (H to C atomic ratio of less than 0.20) into a product with a higher hydrogen content (H to C atomic ratio of 0.25-0.9 or 2.0-7.0 wt % H). The treatment can correspond to exposing the pyrolysis carbon with hydrogen in the presence of a catalyst, exposing the pyrolysis carbon to conditions for alkylation, or a sequential combination thereof. This can convert the pyrolysis carbon into heavy hydrocarbon products that are resin-like solids at room temperature.

Upgrading pyrolysis carbon

Systems and methods are provided for conversion of methane and/or other hydrocarbons to hydrogen by pyrolysis while reducing or minimizing production of carbon oxides. The conversion of hydrocarbons to hydrogen is performed in one or more pyrolysis or conversion reactors that contain a plurality of sequential fluidized beds. The fluidized beds are arranged so that the coke particles forming the fluidized bed move in a counter-current direction relative to the gas phase flow of feed (e.g., methane) and/or product (H) in the fluidized beds. By using a plurality of sequential fluidized beds, the heat transfer and management benefits of fluidized beds can be realized while also at least partially achieving the improved reaction rates that are associated with a plug flow or moving bed reactor.

Methane pyrolysis using stacked fluidized beds

Systems and methods are provided for production of carbon nanotubes and Husing a reaction system configuration that is suitable for large scale production. In the reaction system, a substantial portion of the heat for the reaction can be provided by using a heated gas stream. Optionally, the heated gas stream can correspond to a heated Hgas stream. By using a heated gas stream, when the catalyst precursors for the floating catalyst-chemical vapor deposition (FC-CVD) type catalyst are added to the gas stream, the gas stream can be at a temperature of 1000&#xb0; C. or more. This can reduce or minimize loss of catalyst precursor material and/or deposition of coke on sidewalls of the reactor. Additionally, a downstream portion of the reactor can include a plurality of flow channels of reduced size that are passed through a heat exchanger environment, such as a shell and tube heat exchanger. This can provide cooling of the gas flow after catalyst formation to allow for carbon nanotube formation, while also reducing the Reynolds number of the flow sufficiently to provide laminar flow within the region where carbon nanotubes are formed.

Reactor for carbon nanotube and nanofiber production

Systems and methods for molten media pyrolysis for the conversion of methane into hydrogen and carbon-containing particles are disclosed. The systems and methods include the introduction of seed particles into the molten media to facilitate the growth of larger, more manageable carbon-containing particles. Additionally or alternatively, the systems and methods can include increasing the residence time of carbon-containing particles within the molten media to facilitate the growth of larger carbon-containing particles.

Systems and processes for molten media pyrolysis

Systems and methods are provided for hydroconversion of a heavy oil feed under slurry hydroprocessing conditions and/or solvent assisted hydroprocessing conditions. The systems and methods for slurry hydroconversion can include the use of a configuration that can allow for improved separation of catalyst particles from the slurry hydroprocessing effluent. In addition to allowing for improved catalyst recycle, an amount of fines in the slurry hydroconversion effluent can be reduced or minimized. This can facilitate further processing or handling of any 'pitch' generated during the slurry hydroconversion. The systems and methods for solvent assisted hydroprocessing can include processing of a heavy oil feed in conjunction with a high solvency dispersive power crude.

Processing of heavy hydrocarbon feeds

A method for extending the operating life of a fixed bed reactor for reacting a feedstock in which a feedstock is contacted with a fixed bed of catalytic material contained in the reactor.

Method for extending operating life of a fixed bed reactor

A process for upgrading a liquid petroleum or chemical stream wherein said stream flows countercurrent to the flow of a treat gas, such as a hydrogen-containing gas, in at least one reaction zone. The temperature of at least a portion of the liquid stream in the reactor is used to control the flooding characteristics of the reactor.

Control of flooding in a countercurrent flow reactor by use of temperature of liquid product stream

A hydroprocessing process includes two cocurrent flow liquid reaction stages and one vapor stage, in which feed components are catalytically hydroprocessed by reacting with hydrogen. The liquid stages both produce a liquid and a hydrogen-rich vapor effluent, with most of the hydroprocessing accomplished in the first stage. The first stage vapor is also hydroprocessed. The hydroprocessed vapor and second stage vapor are cooled to condense and recover additional product liquid and produce an uncondensed hydrogen-rich vapor. After cleanup to remove contaminants, the hydrogen-rich vapor is recycled back into the first stage as treat gas. Fresh hydrogen is introduced into the second stage. This is useful for hydrotreating heteroatom-containing hydrocarbons.

Three stage cocurrent liquid and vapor hydroprocessing

A continuous process for functionalizing polymers is disclosed, wherein (A) a liquid comprising the polymer and a gas comprising a functionalizing agent are continuously introduced into a dispersing zone operated in laminar flow with high intensity mixing of the liquid and the gas under functionalization conditions, wherein the mixing is conducted for a period of the dispersing zone residence time at a shear rate effective to form a stable gas-liquid dispersion in which the gas is substantially dissolved or dispersed in the liquid for functionalization, and wherein the shear rate is less than about 5 s.sup.-1 for no more than about 30% of the residence time; (B) the gas-liquid dispersion is continuously passed to a blending zone operated in laminar flow with low intensity mixing under functionalization conditions, wherein the mixing is conducted at a shear rate effective to further dissolve the gas into the liquid for further functionalization; and (C) continuously recovering functionalized polymer. The process can be used to carbonylate unsaturated polymers, and is particularly useful in reacting unsaturated polymers with carbon monoxide in the presence of a catalyst and a co-reactant selected from water, H.sub.2 S, alcohols, and thiols to produce functionalized polymer containing carboxylic (thio)acid or carboxylic (thio)ester functional groups.

Process for the continuous production of functionalized polymers

A reaction vessel for processing liquid petroleum or chemical streams wherein the stream flows countercurrent to the flow of a treat gas, such as a hydrogen-containing gas, in at least one interaction zone. The reaction vessel contains vapor, and optionally liquid, passageways to bypass one or more packed beds, preferably catalyst beds. This permits more stable and efficient vessel operation.

Countercurrent reaction vessel

A process for upgrading a liquid petroleum or chemical stream wherein said stream flows countercurrent to the flow of a treat gas, such as a hydrogen-containing gas, in at least one reaction zone. The reaction vessel used in the practice of the present invention contains vapor and optionally liquid passageway means to bypass one or more catalyst beds. This permits more stable and efficient reaction vessel operation.

Hydroprocessing in a countercurrent reaction vessel

A reactor is provided for reacting a liquid with a treat gas in the presence of a catalyst, the reactor comprising a continuous wall enclosing a first reaction zone, wherein the first reaction zone includes a catalyst for causing a desired reaction between the liquid and the treat gas; a liquid inlet above the first reaction zone for allowing a portion of the liquid to enter the reactor; a gas inlet below the first reaction zone for allowing a portion of the treat gas to enter the reactor; a liquid outlet below the first reaction zone for allowing a reacted portion of the liquid to exit the reactor; a gas outlet above the first reaction zone for allowing a portion of the treat gas to exit the reactor; and a gas bypass device in the first reaction zone for allowing a portion of the treat gas to bypass a portion of the first reaction zone, the gas bypass device including a gas bypass regulating device for regulating the amount of treat gas which bypasses the first reaction zone. In a preferred embodiment, a plurality of reaction zones are present, and a liquid distribution tray is disposed above each reaction zone. Preferably, the gas bypass device creates a hydrostatic seal with the liquid accumulating in the distribution tray so that the timing and extent of gas bypass is self-regulating based on predefined flooding conditions.

Countercurrent reactor

A reactor is provided for reacting a liquid with a treat gas in the presence of a catalyst, the reactor comprising a continuous wall enclosing a first reaction zone, wherein the first reaction zone includes a catalyst for causing a desired reaction between the liquid and the treat gas; a liquid inlet above the first reaction zone for allowing an unreacted portion of the liquid to enter the reactor; a gas inlet below the first reaction zone for allowing an unreacted portion of the treat gas to enter the reactor; a liquid outlet below the first reaction zone for allowing a reacted portion of the liquid to exit the reactor; a gas outlet above the first reaction zone for allowing a reacted portion of the treat gas to exit the reactor; and a liquid bypass device in the first reaction zone for allowing a portion of the liquid to bypass a portion of the first reaction zone, the liquid bypass device including a liquid bypass regulating device for regulating the amount of liquid which bypasses the first reaction zone. In a preferred embodiment, a plurality of reaction zones are present, and a liquid distribution tray is disposed above each reaction zone. Preferably, the liquid bypass device creates a hydrostatic seal with the liquid accumulating in the distribution tray so that the timing and extent of liquid bypass is self-regulating based on predefined flooding conditions.

The invention pertains to improved lubricating oil dispersants wherein a fractionating polymer is prepared prior to functionalization (e.g., in the Koch reaction) for making dispersant additives. In one aspect, it was discovered that by fractionating a polymer to remove light hydrocarbon and unreacted monomer from the polymer before the carbonylation step of the Koch reaction, the amount of light ester impurities generated was minimized. Light ester is an undesirable byproduct that adversely affects the recycle of the catalyst from the functionalization step of the Koch reaction. The invention also pertains to improved lubricating oil nitrogen-containing dispersant additives derived from fractionated polymer.

Dispersant additives and process

Growing community of inventors

Whitehouse Station, NJ, United States of America

David C Dankworth