Abstract: A method to upgrade heavy oil feedstock using an ebullated bed reactor and a novel catalyst system is provided. The ebullated bed reactor system includes two different catalyst with different characteristics: an expanded catalyst zone containing particulate catalyst having a particle size of greater than 0.65 mm; and a slurry catalyst having an average particle size ranging from 1 to 300 ?m. The slurry catalyst is provided to the ebullated bed system containing the heavy oil feedstock, and entrained in the upflowing hydrocarbon liquid passing through the ebullated bed reaction zone. The slurry catalyst reduces the formation of sediment and coke precursors in the ebullating bed reactor system. The slurry catalyst is prepared from rework materials, which form a slurry catalyst in-situ upon mixing with the heavy oil feedstock.

Abstract: A method to upgrade heavy oil feedstock using an ebullated bed reactor and a novel catalyst system is provided. The ebullated bed reactor system includes two different catalyst with different characteristics: an expanded catalyst zone containing particulate catalyst having a particle size of greater than 0.65 mm; and a slurry catalyst having an average particle size ranging from 1 to 300 ?m. The slurry catalyst is introduced to the ebullated bed system with the heavy oil feedstock, and entrained in the upflowing hydrocarbon liquid passing through the ebullated bed reaction zone. The slurry catalyst reduces the formation of sediment and coke precursors in the ebullating bed reactor system. The slurry catalyst is prepared from at least a water-soluble metal precursor and pre-sulfided prior to being introduced with the heavy oil feedstock to the reactor system, or sulfided in-situ in the ebullated bed reactor in another embodiment.

Abstract: A method of recovering unsupported fine catalyst from heavy oil comprises combining a slurry comprising unsupported fine catalyst in heavy oil with solvent to form a combined slurry-solvent stream. The combined slurry-solvent stream is filtered in a deoiling zone. A stream comprising unsupported fine catalyst and solvent is recovered from the deoiling zone. Unsupported fine catalyst is separated from the stream comprising unsupported fine catalyst and solvent. Filtering in the deoiling zone can comprise filtering the slurry and solvent through a cross-flow microfiltration unit, recovering a retentate stream of the cross-flow microfiltration unit, combining the retentate stream of the cross-flow microfiltration unit with solvent to form a combined retentate-solvent stream, and filtering the combined retentate-solvent stream through a cross-flow microfiltration unit.

Abstract: A method to upgrade heavy oil feedstock using an ebullated bed reactor and a novel catalyst system is provided. The ebullated bed reactor system includes two different catalyst with different characteristics: an expanded catalyst zone containing particulate catalyst having a particle size of greater than 0.65 mm; and a slurry catalyst having an average particle size ranging from 1 to 300 ?m. The slurry catalyst is introduced to the ebullated bed system with the heavy oil feedstock, and entrained in the upflowing hydrocarbon liquid passing through the ebullated bed reaction zone. The slurry catalyst reduces the formation of sediment and coke precursors in the ebullating bed reactor system. The slurry catalyst is prepared from at least a water-soluble metal precursor and pre-sulfided prior to being introduced with the heavy oil feedstock to the reactor system, or sulfided in-situ in the ebullated bed reactor in another embodiment.

Abstract: A method to upgrade heavy oil feedstock using an ebullated bed reactor and a novel catalyst system is provided. The ebullated bed reactor system includes two different catalyst with different characteristics: an expanded catalyst zone containing particulate catalyst having a particle size of greater than 0.65 mm; and a slurry catalyst having an average particle size ranging from 1 to 300 ?m. The slurry catalyst is provided to the ebullated bed system containing the heavy oil feedstock, and entrained in the upflowing hydrocarbon liquid passing through the ebullated bed reaction zone. The slurry catalyst reduces the formation of sediment and coke precursors in the ebullating bed reactor system. The slurry catalyst is prepared from rework materials, which form a slurry catalyst in-situ upon mixing with the heavy oil feedstock.

Abstract: An integrated process for extracting and refining bitumen comprises hydroconverting bitumen in a reactor to provide valuable products and light oil by-product; separating the light oil by-product from the valuable products; transporting the light oil to oil sands reserves; producing steam in steam generators at the oil sands reserves using a portion of the light oil transported to the oil sands reserves; extracting bitumen from the oil sands reserves using steam produced in the steam generators; blending bitumen extracted from the oil sands reserves and a portion of the light oil transported to the oil sands reserves to form a transport blend; and transporting the transport blend to the reactor.

Abstract: A process for slurry hydroprocessing, which involves preconditioning a slurry catalyst for activity improvement in vacuum residuum hydroprocessing units Preconditioning the slurry catalyst raises its temperature, thereby reducing shock on the catalyst slurry as it enters the hydroprocessing reactor.

Abstract: A process for recovering catalytic metals from fine catalyst slurried in heavy oil comprises pyrolizing fine catalyst slurried in heavy oil to provide one or more lighter oil products and a coke-like material and recovering catalytic metals from the coke-like material.

Abstract: The instant invention is directed to the preparation of a slurry catalyst composition. The slurry catalyst composition is prepared in a series of steps, involving mixing a Group VIB metal oxide and aqueous ammonia to form an aqueous mixture and sulfiding the mixture to form a slurry. The slurry is then promoted with a Group VIII metal. Subsequent steps involve mixing the slurry with a hydrocarbon oil, and combining the resulting mixture with hydrogen gas (under conditions which maintain the water in a liquid phase) to produce the active slurry catalyst.

Abstract: This application discloses a process for decomposition of ammonium sulfates found in a stream comprising ammonium sulfate and slurry catalyst in oil. The ammonium sulfate is broken down into ammonia and hydrogen sulfide gas. These gases have many uses throughout the refinery, including the preparation of slurry hydroprocessing catalyst.

Abstract: An integrated process for extracting and refining bitumen comprises hydroconverting bitumen in a reactor to provide valuable products and light oil by-product; separating the light oil by-product from the valuable products; transporting the light oil to oil sands reserves; producing steam in steam generators at the oil sands reserves using a portion of the light oil transported to the oil sands reserves; extracting bitumen from the oil sands reserves using steam produced in the steam generators; blending bitumen extracted from the oil sands reserves and a portion of the light oil transported to the oil sands reserves to form a transport blend; and transporting the transport blend to the reactor.

Abstract: A process for recovering catalytic metals from fine catalyst slurried in heavy oil comprises pyrolizing fine catalyst slurried in heavy oil to provide one or more lighter oil products and a coke-like material and recovering catalytic metals from the coke-like material.

Abstract: A method of recovering unsupported fine catalyst from heavy oil comprises combining a slurry comprising unsupported fine catalyst in heavy oil with solvent to form a combined slurry-solvent stream. The combined slurry-solvent stream is filtered in a deoiling zone. A stream comprising unsupported fine catalyst and solvent is recovered from the deoiling zone. Unsupported fine catalyst is separated from the stream comprising unsupported fine catalyst and solvent. Filtering in the deoiling zone can comprise filtering the slurry and solvent through a cross-flow microfiltration unit, recovering a retentate stream of the cross-flow microfiltration unit, combining the retentate stream of the cross-flow microfiltration unit with solvent to form a combined retentate-solvent stream, and filtering the combined retentate-solvent stream through a cross-flow microfiltration unit.

Abstract: The instant invention is directed to the preparation of a slurry catalyst composition. The slurry catalyst composition is prepared in a series of steps, involving mixing a Group VIB metal oxide and aqueous ammonia to form an aqueous mixture and sulfiding the mixture to form a slurry. The slurry is then promoted with a Group VIII metal. Subsequent steps involve mixing the slurry with a hydrocarbon oil, and combining the resulting mixture with hydrogen gas (under conditions which maintain the water in a liquid phase) to produce the active slurry catalyst.

Abstract: The instant invention is directed to the preparation of a catalyst composition suitable for the hydroconversion of heavy oils. The catalyst composition is prepared by a series of steps, involving mixing a Group VIB metal oxide particularly molybdenum oxide and aqueous ammonia to form an aqueous mixture, and sulfiding the mixture to form a slurry. The slurry is then promoted with a Group VIII metal. Subsequent steps involve mixing the slurry with a hydrocarbon oil and combining the resulting mixture with hydrogen gas and a second hydrocarbon oil having a lower viscosity than the first oil. An active catalyst composition is thereby formed.

Abstract: The instant invention is directed to the preparation of a slurry catalyst composition. The slurry catalyst composition is prepared in a series of steps, involving mixing a Group VIB metal oxide, particularly molybdenum and aqueous ammonia to form an aqueous mixture and sulfiding the mixture to form a slurry. The slurry is then promoted with a Group VIII metal. Subsequent steps involve mixing the slurry with a hydrocarbon oil, and combining the resulting mixture with hydrogen gas (under conditions which maintain the water in a liquid phase) to produce the active slurry catalyst.

Abstract: A process for slurry hydroprocessing, which involves preconditioning a slurry catalyst for activity improvement in vacuum residuum hydroprocessing units Preconditioning the slurry catalyst raises its temperature, thereby reducing shock on the catalyst slurry as it enters the hydroprocessing reactor.

Abstract: This application discloses a process for decomposition of ammonium sulfates found in a stream comprising ammonium sulfate and slurry catalyst in oil. The ammonium sulfate is broken down into ammonia and hydrogen sulfide gas. These gases have many uses throughout the refinery, including the preparation of slurry hydroprocessing catalyst.

Abstract: This application discloses a process for concentration and deoiling of a slurry catalyst stream for ease of transport to a hydroprocessing unit. The slurry catalyst may then be diluted with oil for use.

Abstract: The instant invention is directed to a process for upgrading heavy oils using a slurry composition. The slurry composition is prepared by a series of steps, involving mixing a Group VIB metal oxide and aqueous ammonia to form an aqueous mixture, and sulfiding the mixture to form a slurry. The slurry is then promoted with a Group VIII metal. Subsequent steps involve mixing the slurry with a hydrocarbon oil and combining the resulting mixture with hydrogen gas and a second hydrocarbon oil having a lower viscosity than the first oil. An active catalyst composition is thereby formed.