Abstract: This invention makes possible substantially continuous flow of uniformly distributed hydrogen and hydrocarbon liquid across a densely packed catalyst bed to fill substantially the entire volume of a reactor vessel by introducing the fluids as alternate annular rings of gas and liquid (i.e. a mixture of liquid hydrocarbon and a hydrogen-containing gas) at a rate insufficient to levitate or ebullate the catalyst bed. Catalyst are selected by density, shape and size at a design feed rate of liquids and gas to prevent ebullation of the packed bed at the design feed rates. Catalysts are selected by measuring bed expansion, such as in a large pilot plant run, with hydrocarbon, hydrogen, and catalyst at the design pressures and flow velocities. The liquid and gas components of the feed flow into the bed in alternate annular rings across the full area of the bed.

Abstract: This invention makes possible substantially continuous flow of uniformly distributed hydrogen and hydrocarbon liquid across a densely packed catalyst bed to fill substantially the entire volume of a reactor vessel by introducing the fluids as alternate annular rings of gas and liquid (i.e. a mixture of liquid hydrocarbon and a hydrogen-containing gas) at a rate insufficient to levitate or ebullate the catalyst bed. Catalyst are selected by density, shape and size at a design feed rate of liquids and gas to prevent ebullation of the packed bed at the design feed rates. Catalysts are selected by measuring bed expansion, such as in a large pilot plant run, with hydrocarbon, hydrogen, and catalyst at the design pressures and flow velocities. The liquid and gas components of the feed flow into the bed in alternate annular rings across the full area of the bed.

Abstract: Sulfuric acids or salts thereof are used to remove metals, particularly organically-bound calcium, from hydrocarbonaceous feedstocks. An aqueous solution of the acid or its salts is used to extract the metals from the feedstock prior to processing.

Abstract: This invention makes possible substantially continuous flow of uniformly distributed hydrogen and hydrocarbon liquid across a densely packed catalyst bed to fill substantially the entire volume of a reactor vessel by introducing the fluids as alternate annular rings of gas and liquid (i.e. a mixture of liquid hydrocarbon and a hydrogen-containing gas) at a rate insufficient to levitate or ebullate the catalyst bed. Catalyst are selected by density, shape and size at a design feed rate of liquids and gas to prevent ebullation of the packed bed at the design feed rates. Catalysts are selected by measuring bed expansion, such as in a large pilot plant run, with hydrocarbon, hydrogen, and catalyst at the design pressures and flow velocities. The liquid and gas components of the feed flow into the bed in alternate annular rings across the full area of the bed.

Abstract: This invention makes possible substantially continuous flow of uniformly distributed hydrogen and hydrocarbon liquid across a densely packed catalyst bed to fill substantially the entire volume of a reactor vessel by introducing the fluids as alternate annular rings of gas and liquid at a rate insufficient to levitate the catalyst bed. Catalyst are selected by density, shape and size at a design feed rate of liquids and gas to prevent ebullation of the packed bed at the design feed rates. Catalysts are selected by measuring bed expansion with hydrocarbon, hydrogen, and catalyst at the design pressures and flow velocities. The liquid and gas components of the feed flow into the bed in alternate annular rings across the full area of the bed. At the desired flow rate, such catalyst continually flows in a plug-like manner downwardly through the reactor vessel by introducing fresh catalyst at the top of the catalyst bed by laminarly flowing such catalyst in a liquid stream on a periodic or semicontinuous basis.

Abstract: On-stream catalyst replacement hydroprocessing method wherein an upstream mixture of hydrogen and hydrocarbon liquid counter flows through a downwardly moving bed of hydroprocessing catalyst in a reactor vessel. The mixed feed stream of hydrogen and liquid hydrocarbon components enters a surge zone between the lower end of the reactor and a plenum zone to form a common pool under a conical support for the lower end of the downflowing catalyst bed. The mixed feed enters the plenum chamber through a plurality of passageways extending downwardly from the plenum zone to the same depth adjacent the lower end of the surge zone so that the liquid component normally prevents hydrogen from establishing independent paths before entering the plenum zone. Separation of the hydrogen and hydrocarbon liquid components from the mixed feed is thus assured to occur in the plenum zone directly below the pervious conical support to form a plurality of stepped concentric local reservoir rings under the conical support.

Abstract: On-stream catalyst replacement apparatus for countercurrent upstream flow of a gas and hydrocarbon liquid through a downward moving catalyst bed in a reactor vessel. A mixed feed stream of gas and liquid hydrocarbon components enters a reservoir formed between the lower end of the reactor and a conical screen supporting the lower end of a catalyst bed. A wall across the vessel divides the reservoir into a lower surge chamber for receiving the mixed feed and an upper plenum chamber for separating the components into alternate feed rings of gas and hydrocarbon liquid under the conical screen. The mixed feed enters the plenum chamber through a plurality of tubes extending downwardly from the wall to the same depth in the surge chamber that prevents establishing preferential paths for gas to independently enter the plenum chamber.

Abstract: An improved catalytic slurry hydroprocess comprising a hydrogenation zone having a hydrogen partial pressure of at least about 100 psia characterized by active catalyst recycle accompanied by minimal catalyst deactivation from coking or asphaltene agglomeration in which the improvement comprises the steps of:1) separating at least a portion of active catalyst from the liquid hydrogenation product eluted from the hydrogenation zone of said hydroprocess, and2) recycling at least a portion of said separated active catalyst to said hydrogenation zone;wherein said steps are carried out while maintaining said active catalyst under conditions substantially the same as those encountered in said hydrogenation zone.

Abstract: An improved catalytic slurry hydroprocess comprising a hydrogenation zone having a hydrogen partial pressure of at least about 100 psia characterized by active catalyst recycle accompanied by minimal catalyst deactivation from coking or asphaltene agglomeration in which the improvement comprises the steps of:(1) separating at least a portion of active catalyst from the liquid hydrogenation product eluted from the hydrogenation zone of said hydroprocess, and(2) recycling at least a portion of said separated active catalyst to said hydrogenation zone;wherein said steps are carried out while maintaining said active catalyst under conditions substantially the same as those encountered in said hydrogenation zone.

Abstract: This invention makes possible substantially continuous flow of uniformly distributed hydrogen and hydrocarbon liquid across a densely packed catalyst bed to fill substantially the entire volume of a reactor vessel by introducing the fluids as alternate annular rings of gas and liquid at a rate insufficient to levitate the bed and with catalyst selected by a density, shape and size at a design feed rate of liquids and gas to prevent ebulation of the packed bed at the design feed rates. Catalysts are selected by measuring bed expansion in a large pilot plant run with hydrocarbon, hydrogen, and catalyst at the design pressures and flow velocities. The liquid and gas components of the feed flow into the bed in alternate annular rings across the full area of the bed.

Abstract: Monobasic carboxylic acids or salts thereof are used to remove metals, particularly calcium and iron, from hydrocarbonaceous feedstocks. An aqueous solution of the acid is used to extract the metals from the feedstock prior to processing. Acetic acid is the preferred carboxylic acid.

Abstract: A packed bed reactor for hydrocarbon processing and method of use is provided. The reactor comprises:(a) a first packed bed of particles in fluid communication with a feed inlet to said reactor, said first packed bed extending more than 3 to 18 inches in the direction of flow and comprising predominantly particles at least about 3/8 inch in diameter;(b) a second packed bed of particles in fluid communication with said first packed bed and downstream of said first packed bed, said second packed bed extending at least 12 to 48 inches in the direction of flow and comprising predominantly particles having diameters within the range of 3/16 to 5/16 inch and smaller than the average diameter of particles in said first bed; and(c) a third packed bed of particles in fluid communication with said second packed bed and downstream of said second packed bed, said third packed bed comprising predominantly particles having diameters below 1/8 inch.