Abstract: The instant invention is directed to a process for upgrading heavy oils using a slurry composition. The slurry composition is prepared in a series of steps, involving mixing a Group VIB metal oxide with 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 compound. 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 invention relates to a crude oil desulfurization process which comprises hydrodesulfurizing a crude oil feed in a crude desulfurization unit. The desulfurized crude oil is then separated into a light gas oil fraction, a vacuum gas oil fraction and a vacuum residuum fraction. The vacuum gas oil is hydrocracked to form at least one low sulfur fuel product. The light gas oil fraction is hydrotreated. The vacuum gas oil may be hydrocracked in one or more stages. Hydrocracking in the second stage, if present, will convert of at least 20% of the first zone effluent, to create a low sulfur light gas oil fraction. The light gas oil fraction may then be hydrotreated.

Abstract: A reactor system and process for hydrotreating a heavy feedstock contaminated with metals sulfur and carbon residue using an upflow fixed bed reactor with at least two catalyst layers having different hydrogenation activity.

Abstract: This invention relates to a crude oil desulfurization process which comprises hydrodesulfurizing a crude oil feed in a crude desulfurization unit. The desulfurized crude oil is then separated into a light gas oil fraction, a vacuum gas oil fraction and a vacuum residuum fraction. The vacuum gas oil is hydrocracked to form at least one low sulfur fuel product. The light gas oil fraction is hydrotreated. The vacuum gas oil may be hydrocracked in one or more stages. Hydrocracking in the second stage, if present, will convert of at least 20% of the first zone effluent, to create a low sulfur light gas oil fraction. The light gas oil fraction may then be hydrotreated.

Abstract: Catalyst particles are presulfided in a treatment zone separate from a hydroconversion reaction zone. The presulfided catalyst is then added to a substantially packed bed of catalyst in the hydroconversion reaction zone at reaction pressure, so that the reactor is not shut down to replace catalyst. The presulfiding process is particularly beneficial for use in moving bed reactors for heavy oil conversion.

Abstract: A distributor assembly for hydroprocessing a hydrocarbon mixture of hydrogen-containing gas and liquid hydrocarbon is presented. The distributor assembly has a circular plate with a plurality of hollow risers bound thereto for distributing hydrogen-containing gas and liquid hydrocarbon through openings in the circular plate member. Each of the hollow risers has a tubular opening In its associated side. The distributor assembly is connected to an internal wall of a reactor. A method is also presented for hydroprocessing a hydrocarbon feed stream comprising flowing a mixture of hydrogen-containing gas and liquid hydrocarbon into a reactor zone to produce evolved hydrogen-containing gas; and flowing the mixture of hydrogen-containing gas and liquid hydrocarbon through a plurality of tubular zones while admixing simultaneously therewith the evolved hydrogen-containing gas.

Abstract: A distributor assembly for hydroprocessing a hydrocarbon mixture of hydrogen-containing gas and liquid hydrocarbon is presented. The distributor assembly has a circular plate with a plurality of hollow risers bound thereto for distributing hydrogen-containing gas and liquid hydrocarbon through openings in the circular plate member. Each of the hollow risers has a tubular opening in its associated side. The distributor assembly is connected to an internal wall of a reactor. A method is also presented for hydroprocessing a hydrocarbon feed stream comprising flowing a mixture of hydrogen-containing gas and liquid hydrocarbon into a reactor zone to produce evolved hydrogen-containing gas; and flowing the mixture of hydrogen-containing gas and liquid hydrocarbon through a plurality of tubular zones while admixing simultaneously therewith the evolved hydrogen-containing gas.

Abstract: This invention makes possible substantially continuous flow of uniformly distributed hydrogen and hydrocarbon liquid across a densely packed catalyst bed which substantially fills the entire volume of a reactor vessel. Catalyst are selected to be essentially the same density, shape and size at a design feed rate of liquids and gas to prevent ebullation of the packed catalyst bed at the design feed rates. The liquid and gas components of the hydrocarbon feed stream flow into the bed of catalyst and a quenching medium, which is preferably a liquid, is injected into the bed of catalyst. Injection of a liquid quench reduces the gas component of the hydrocarbon feed stream while simultaneously increasing the residence time and reducing the liquid velocity of the liquid component of the hydrocarbon feed stream within the substantially packed bed of catalyst.

Abstract: An apparatus for quenching in hydroprocessing of a hydrocarbon feed stream, which provides a substantially continuous flow of uniformly distributed hydrogen and hydrocarbon liquid across a densely packed catalyst bed which substantially fills the entire volume of a reactor vessel. Catalyst are selected to be essentially the same density, shape and size at a design feed rate of liquids and gas to prevent ebullation of the packed catalyst bed at the design feed rates. The liquid and gas components of the hydrocarbon feed stream flow into the bed of catalyst and a quenching medium, which is preferably a liquid, is injected into the bed of catalyst. Injection of a liquid quench reduces the gas component of the hydrocarbon feed stream while simultaneously increasing the residence time and reducing the liquid velocity of the liquid component of the hydrocarbon feed stream within the substantially packed bed of catalyst.

Abstract: This invention makes possible substantially continuous flow of uniformly distributed hydrogen and hydrocarbon liquid across a densely packed catalyst bed which substantially fills the entire volume of a reactor vessel. Catalyst are selected to be essentially the same density, shape and size at a design feed rate of liquids and gas to prevent ebullation of the packed catalyst bed at the design feed rates. The liquid and gas components of the hydrocarbon feed stream flow into the bed of catalyst and a quenching medium, which is preferably a liquid, is injected into the bed of catalyst. Injection of a liquid quench reduces the gas component of the hydrocarbon feed stream while simultaneously increasing the residence time and reducing the liquid velocity of the liquid component of the hydrocarbon feed stream within the substantially packed bed of catalyst.

Abstract: A process for removing calcium from a hydrocarbon feed having at least 1 ppm oil-soluble calcium. The process employs a catalyst system, comprising catalyst particles, wherein a high volume percent of the catalyst particles are in the form of mesopores (less than 1000 Angstrom in diameter), low surface area, low hydrogenation activity, and th inclusion of Group VIII metals, in particular nickel, on a silica catalyst base.

Abstract: We disclose a process for removing calcium from a hydrocarbon feed having at least 1 ppm oil-soluble calcium. It comprises employing a catalyst layer characterized as a fixed bed of catalyst particles, a high volume percent of their pore volume in the form of macropores above 1000 Angstrom in diameter, or an average mesopore diameter of 100-800 .ANG., low surface area, and low hydrogenation activity, and the inclusion of Group I metals, in particular potassium, on the catalyst base.

Abstract: A catalyst system is disclosed which is capable of removing calcium from a hydrocarbon feed having at least 1 ppm oil-soluble calcium. The catalyst system comprises catalyst particles, wherein such catalyst particles are in the form of mesopores (less than 1000 Angstrom in diameter), low surface area, and low hydrogenation activity, and the inclusion of Group VIII metals, in particular nickel, on a silica catalyst base.

Abstract: A catalyst system is disclosed which is capable of removing calcium from a hydrocarbon feed having at least 1 ppm oil-soluble calcium. It comprises a catalyst layer characterized as a fixed bed of catalyst particles, such fixed bed of catalyst particles may be graded, a high volume percent of their pore volume in the form of macropores above 1000 Angstrom in diameter, or an average meso pore diameter of 100-800 .ANG., low surface area, and low hydrogenation activity, and the inclusion of Group I metals, in particular potassium, on the catalyst base.

Abstract: A hydroconversion effluent separation process is provided.The effluent from the hydroconversion zone is passed to a hot high pressure separation zone. The gas phase from that zone is then passed to a cold high pressure separation zone while the liquid hydrocarbon bottoms is passed to a hot low pressure separation zone. The gas phase is partially condensed in the cold high pressure separation zone to obtain a hydrogen-rich gas and a liquid hydrocarbon bottoms. A portion of the hydrogen-rich gas is recycled to the hydroconversion zone. A second portion is sent to a hydrogen purification step, most preferably by membrane separation, and the purified gas is recycled to the hydroconversion zone. The overhead from the hot low pressure separation is fed to a cold low pressure separation zone. The gas phase from the cold low pressure separation zone is recycled to the hydroconversion zone. Preferably, two cold low pressure separation zones are utilized in the process.

Abstract: We provide a graded catalyst system which is used for removing calcium and sodium from hydrocarbon feed having at least 1 ppm calcium and 1 ppm sodium. It comprises two catalyst zones characterized as having decreasing porosity, increasing activity, and increasing surface to volume ratio in the direction of feed flow through the system. We also disclose a process for using it and a method for selecting catalyst for use therein.

Abstract: We disclose a catalyst system which is capable of removing sodium from a hydrocarbon feed having at least 1 ppm oil-soluble sodium. It comprises a catalyst layer characterized as a fixed bed of catalyst particles having a low volume percent of their pore volume percent in the form of macropores above 1000 .ANG. in diameter, high surface area, and high hydrogenation activity. We also disclose a process of using the system.

Abstract: We disclose a catalyst system which is capable of removing calcium from a hydrocarbon feed having at least 1 ppm oil-soluble calcium. It comprises a catalyst layer characterized as a fixed bed of catalyst particles, a high volume percent of their pore volume in the form of macropores above 1000 .ANG. in diameter, low surface area, and low hydrogenation activity. We also disclose a process of using the system.