Abstract: A system and method for preparing and conditioning a heavy oil feedstock for hydroprocessing in a hydroprocessing system includes forming metal sulfide catalyst particles in situ within the heavy oil feedstock. The metal sulfide catalyst particles are formed in situ by (1) premixing a catalyst precursor with a hydrocarbon diluent to form a diluted precursor mixture, (2) mixing the diluted precursor mixture with the heavy oil feedstock to form a conditioned feedstock, and (3) heating the conditioned feedstock to decompose the catalyst precursor and cause or allow metal from the precursor to react with sulfur in the heavy oil feedstock to form metal sulfide catalyst particles in situ in the heavy oil feedstock. The in situ formed metal sulfide catalyst particles catalyze beneficial upgrading reactions between the heavy oil feedstock and hydrogen and eliminates or reduces formation of coke precursors and sediment.

Abstract: A hydrocracking system is upgraded by modifying an existing ebullated bed initially utilizing a supported ebullated bed catalyst to thereafter utilize a dual catalyst system that includes metal sulfide catalyst particles and supported ebullated bed catalyst. The upgraded hydrocracking system achieves at least one of: (1) hydroprocess lower quality heavy oil; (2) increase conversion of higher boiling hydrocarbons that boil at 524° C. (975° F.) or higher; (3) reduce the concentration of supported ebullated bed catalyst required to operate an ebullated bed reactor at a given conversion level; and/or (4) proportionally convert the asphaltene fraction in heavy oil at the same conversion level as the heavy oil as a whole. The metal sulfide catalyst may include colloidal or molecular catalyst particles less than 1 micron in size and formed in situ within the heavy oil using a catalyst precursor well-mixed within the heavy oil and decomposed to form catalyst particles.

Abstract: A hydroprocessing system involves introducing heavy oil and in situ formed metal sulfide catalyst particles, or a catalyst precursor capable of forming metal sulfide catalyst particles in situ within the heavy oil, into a hydroprocessing reactor. The metal sulfide catalyst particles are formed in situ by 1) premixing a catalyst precursor with a hydrocarbon diluent to form a precursor mixture, 2) mixing the precursor mixture with heavy oil to form a conditioned feedstock, and 3) heating the conditioned feedstock to decompose the catalyst precursor and cause or allow metal from the precursor to react with sulfur in the heavy oil to form the metal sulfide catalyst particles in situ in the heavy oil. The in situ formed metal sulfide catalyst particles catalyze beneficial upgrading reactions between the heavy oil and hydrogen and eliminates or reduces formation of coke precursors and sediment.

Abstract: A system and method for preparing and conditioning a heavy oil feedstock for hydroprocessing in a hydroprocessing system includes forming metal sulfide catalyst particles in situ within the heavy oil feedstock. The metal sulfide catalyst particles are formed in situ by (1) premixing a catalyst precursor with a hydrocarbon diluent to form a diluted precursor mixture, (2) mixing the diluted precursor mixture with the heavy oil feedstock to form a conditioned feedstock, and (3) heating the conditioned feedstock to decompose the catalyst precursor and cause or allow metal from the precursor to react with sulfur in the heavy oil feedstock to form metal sulfide catalyst particles in situ in the heavy oil feedstock. The in situ formed metal sulfide catalyst particles catalyze beneficial upgrading reactions between the heavy oil feedstock and hydrogen and eliminates or reduces formation of coke precursors and sediment.

Abstract: A hydroprocessing system involves introducing heavy oil and in situ formed metal sulfide catalyst particles, or a catalyst precursor capable of forming metal sulfide catalyst particles in situ within the heavy oil, into a hydroprocessing reactor. The metal sulfide catalyst particles are formed in situ by 1) premixing a catalyst precursor with a hydrocarbon diluent to form a precursor mixture, 2) mixing the precursor mixture with heavy oil to form a conditioned feedstock, and 3) heating the conditioned feedstock to decompose the catalyst precursor and cause or allow metal from the precursor to react with sulfur in the heavy oil to form the metal sulfide catalyst particles in situ in the heavy oil. The in situ formed metal sulfide catalyst particles catalyze beneficial upgrading reactions between the heavy oil and hydrogen and eliminates or reduces formation of coke precursors and sediment.

Abstract: A hydroprocessing method and system involves introducing heavy oil and well-dispersed metal sulfide catalyst particles, or a catalyst precursor capable of forming the well-dispersed metal sulfide catalyst particles in situ within the heavy oil, into a hydroprocessing reactor. The well-dispersed or in situ metal sulfide catalyst particles are formed by 1) premixing a catalyst precursor with a hydrocarbon diluent to form a precursor mixture, 2) mixing the precursor mixture with heavy oil to form a conditioned feedstock, and 3) heating the conditioned feedstock to decompose the catalyst precursor and cause or allow metal from the precursor to react with sulfur in the heavy oil to form the well-dispersed or in situ metal sulfide catalyst particles. The well-dispersed or in situ metal sulfide catalyst particles catalyze beneficial upgrading reactions between the heavy oil and hydrogen and eliminates or reduces formation of coke precursors and sediment.

Abstract: A hydrocracking system is upgraded by modifying an existing ebullated bed initially utilizing a supported ebullated bed catalyst to thereafter utilize a dual catalyst system that includes metal sulfide catalyst particles and supported ebullated bed catalyst. The upgraded hydrocracking system achieves at least one of: (1) hydroprocess lower quality heavy oil; (2) increase conversion of higher boiling hydrocarbons that boil at 524° C. (975° F.) or higher; (3) reduce the concentration of supported ebullated bed catalyst required to operate an ebullated bed reactor at a given conversion level; and/or (4) proportionally convert the asphaltene fraction in heavy oil at the same conversion level as the heavy oil as a whole. The metal sulfide catalyst may include colloidal or molecular catalyst particles less than 1 micron in size and formed in situ within the heavy oil using a catalyst precursor well-mixed within the heavy oil and decomposed to form catalyst particles.

Abstract: A hydroprocessing method and system involves introducing heavy oil and well-dispersed metal sulfide catalyst particles, or a catalyst precursor capable of forming the well-dispersed metal sulfide catalyst particles in situ within the heavy oil, into a hydroprocessing reactor. The well-dispersed or in situ metal sulfide catalyst particles are formed by 1) premixing a catalyst precursor with a hydrocarbon diluent to form a precursor mixture, 2) mixing the precursor mixture with heavy oil to form a conditioned feedstock, and 3) heating the conditioned feedstock to decompose the catalyst precursor and cause or allow metal from the precursor to react with sulfur in the heavy oil to form the well-dispersed or in situ metal sulfide catalyst particles. The well-dispersed or in situ metal sulfide catalyst particles catalyze beneficial upgrading reactions between the heavy oil and hydrogen and eliminates or reduces formation of coke precursors and sediment.

Abstract: A hydrocracking system involves introducing a heavy oil feedstock and a colloidal or molecular catalyst, or a catalyst precursor capable of forming the colloidal or molecular catalyst, into a hydrocracking reactor. The colloidal or molecular catalyst is formed in situ within the heavy oil feedstock by 1) premixing the catalyst precursor with a hydrocarbon diluents to form a catalyst precursor mixture, 2) mixing the catalyst precursor mixture with the heavy oil feedstock, and 3) raising the temperature of the feedstock to above the decomposition temperature of the catalyst precursor to form the colloidal or molecular catalyst. The colloidal or molecular catalyst catalyzes upgrading reactions between the heavy oil feedstock and hydrogen and eliminates or reduces formation of coke precursors and sediment.

Abstract: A hydrocracking system involves introducing a heavy oil feedstock and a colloidal or molecular catalyst, or a precursor composition capable of forming the colloidal or molecular catalyst, into a hydrocracking reactor. The colloidal or molecular catalyst is formed in situ within the heavy oil feedstock by intimately mixing a catalyst precursor composition into a heavy oil feedstock and raising the temperature of the feedstock to above the decomposition temperature of the precursor composition to form the colloidal or molecular catalyst. The colloidal or molecular catalyst catalyzes upgrading reactions between the heavy oil feedstock and hydrogen and eliminates or reduces formation of coke precursors and sediment. At least a portion of a resid fraction containing residual colloidal or molecular catalyst is recycled back into the hydrocracking reactor to further upgrade the recycled resid fraction portion and provide recycled colloidal or molecular catalyst within the hydrocracking reactor.

Abstract: An ebullated bed hydroprocessing system, and also a method for upgrading an existing ebullated bed hydroprocessing system, involves introducing a colloidal or molecular catalyst, or a catalyst precursor capable of forming the colloidal or molecular catalyst, into an ebullated bed reactor. The colloidal or molecular catalyst is formed by intimately mixing a catalyst precursor into a heavy oil feedstock and raising the temperature of the feedstock to above the decomposition temperature of the catalyst precursor to form the colloidal or molecular catalyst in situ. The improved ebullated bed hydroprocessing system includes at least one ebullated bed reactor that employs both a porous supported catalyst and the colloidal or molecular catalyst to catalyze hydroprocessing reactions involving the feedstock and hydrogen. The colloidal or molecular catalyst provides catalyst in what would otherwise constitute catalyst free zones within the ebullated bed hydroprocessing system.

Abstract: An ebullated bed hydroprocessing system, and also a method for upgrading an existing ebullated bed hydroprocessing system, involves introducing a colloidal or molecular catalyst, or a catalyst precursor capable of forming the colloidal or molecular catalyst, into an ebullated bed reactor. The colloidal or molecular catalyst is formed by intimately mixing a catalyst precursor into a heavy oil feedstock and raising the temperature of the feedstock to above the decomposition temperature of the catalyst precursor to form the colloidal or molecular catalyst in situ. The improved ebullated bed hydroprocessing system includes at least one ebullated bed reactor that employs both a porous supported catalyst and the colloidal or molecular catalyst to catalyze hydroprocessing reactions involving the feedstock and hydrogen. The colloidal or molecular catalyst provides catalyst in what would otherwise constitute catalyst free zones within the ebullated bed hydroprocessing system.

Abstract: A hydrocracking system involves introducing a heavy oil feedstock and a colloidal or molecular catalyst, or a catalyst precursor capable of forming the colloidal or molecular catalyst, into a hydrocracking reactor. The colloidal or molecular catalyst is formed in situ within the heavy oil feedstock by 1) premixing the catalyst precursor with a hydrocarbon diluents to form a catalyst precursor mixture, 2) mixing the catalyst precursor mixture with the heavy oil feedstock, and 3) raising the temperature of the feedstock to above the decomposition temperature of the catalyst precursor to form the colloidal or molecular catalyst. The colloidal or molecular catalyst catalyzes upgrading reactions between the heavy oil feedstock and hydrogen and eliminates or reduces formation of coke precursors and sediment.

Abstract: A hydrocracking system involves introducing a heavy oil feedstock and a colloidal or molecular catalyst, or a precursor composition capable of forming the colloidal or molecular catalyst, into a hydrocracking reactor. The colloidal or molecular catalyst is formed in situ within the heavy oil feedstock by intimately mixing a catalyst precursor composition into a heavy oil feedstock and raising the temperature of the feedstock to above the decomposition temperature of the precursor composition to form the colloidal or molecular catalyst. The colloidal or molecular catalyst catalyzes upgrading reactions between the heavy oil feedstock and hydrogen and eliminates or reduces formation of coke precursors and sediment. At least a portion of a resid fraction containing residual colloidal or molecular catalyst is recycled back into the hydrocracking reactor to further upgrade the recycled resid fraction portion and provide recycled colloidal or molecular catalyst within the hydrocracking reactor.

Abstract: An ebullated bed hydroprocessing system, and also a method for upgrading a pre-existing ebullated bed hydroprocessing system, involves introducing a colloidal or molecular catalyst, or a precursor composition capable of forming the colloidal or molecular catalyst, into an ebullated bed reactor. The colloidal or molecular catalyst is formed by intimately mixing a catalyst precursor composition into a heavy oil feedstock and raising the temperature of the feedstock to above the decomposition temperature of the precursor composition to form the colloidal or molecular catalyst in situ. The improved ebullated bed hydroprocessing system includes at least one ebullated bed reactor that employs both a porous supported catalyst and the colloidal or molecular catalyst to catalyze hydroprocessing reactions involving the feedstock and hydrogen. The colloidal or molecular catalyst provides catalyst in what would otherwise constitute catalyst free zones within the ebullated bed hydroprocessing system.

Abstract: An expanded bed hydroprocessing system and related method includes at least one expanded bed reactor that employs a solid catalyst to catalyze hydroprocessing reactions involving hydrogen and a high molecular weight hydrocarbon feedstock (e.g., a Fischer-Tropsch wax) that is contaminated with solid particulates. Hydroprocessing the high molecular weight hydrocarbon feedstock in an expanded bed reactor results in formation of a hydroprocessed material from the hydrocarbon feedstock, while eliminating the risk of plugging of the supported catalyst bed by the solid particulates as compared to a reactor including a stationary catalyst bed.

Abstract: Methods and systems for hydroprocessing heavy oil feedstocks to form an upgraded material involve the use of a colloidal or molecular catalyst dispersed within a heavy oil feedstock, a hydrocracking reactor, and a hot separator. The colloidal or molecular catalyst promotes hydrocracking and other hydroprocessing reactions within the hydrocracking reactor. The catalyst is preferentially associated with asphaltenes within the heavy oil feedstock, which promotes upgrading reactions involving the asphaltenes rather than formation of coke precursors and sediment. The colloidal or molecular catalyst overcomes problems associated with porous supported catalysts in upgrading heavy oil feedstocks, particularly the inability of such catalysts to effectively process asphaltene molecules. The result is one or more of reduced equipment fouling, increased conversion level, and more efficient use of the supported catalyst if used in combination with the colloidal or molecular catalyst.

Abstract: A fixed bed hydroprocessing system, and also a method for upgrading a pre-existing fixed bed hydroprocessing system, involves preliminarily upgrading a heavy oil feedstock in one or more slurry phase reactors using a colloidal or molecular catalyst and then further hydroprocessing the upgraded feedstock within one or more fixed bed reactors using a porous supported catalyst. The colloidal or molecular catalyst is formed by intimately mixing a catalyst precursor composition into a heavy oil feedstock and raising the temperature of the feedstock to above the decomposition temperature of the precursor composition to form the colloidal or molecular catalyst in situ. Asphaltene or other hydrocarbon molecules otherwise too large to diffuse into the pores of the fixed bed catalyst can be upgraded by the colloidal or molecular catalyst.

Abstract: An ebullated bed hydroprocessing system, and also a method for upgrading a pre-existing ebullated bed hydroprocessing system, involves introducing a colloidal or molecular catalyst, or a precursor composition capable of forming the colloidal or molecular catalyst, into an ebullated bed reactor. The colloidal or molecular catalyst is formed by intimately mixing a catalyst precursor composition into a heavy oil feedstock and raising the temperature of the feedstock to above the decomposition temperature of the precursor composition to form the colloidal or molecular catalyst in situ. The improved ebullated bed hydroprocessing system includes at least one ebullated bed reactor that employs both a porous supported catalyst and the colloidal or molecular catalyst to catalyze hydroprocessing reactions involving the feedstock and hydrogen. The colloidal or molecular catalyst provides catalyst in what would otherwise constitute catalyst free zones within the ebullated bed hydroprocessing system.

Abstract: An ebullated bed hydroprocessing system, and also a method for upgrading a pre-existing ebullated bed hydroprocessing system, involves introducing a colloidal or molecular catalyst, or a precursor composition capable of forming the colloidal or molecular catalyst, into an ebullated bed reactor. The colloidal or molecular catalyst is formed by intimately mixing a catalyst precursor composition into a heavy oil feedstock and raising the temperature of the feedstock to above the decomposition temperature of the precursor composition to form the colloidal or molecular catalyst in situ. The improved ebullated bed hydroprocessing system includes at least one ebullated bed reactor that employs both a porous supported catalyst and the colloidal or molecular catalyst to catalyze hydroprocessing reactions involving the feedstock and hydrogen. The colloidal or molecular catalyst provides catalyst in what would otherwise constitute catalyst free zones within the ebullated bed hydroprocessing system.