Patents by Inventor Bruce Reynolds
Bruce Reynolds has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 7938954Abstract: Systems and methods for hydroprocessing a heavy oil feedstock with reduced heavy oil deposits, the system employs a plurality of contacting zones and separation zones zone under hydrocracking conditions to convert at least a portion of the heavy oil feedstock to lower boiling hydrocarbons, forming upgraded products. The contacting zones operate under hydrocracking conditions, employing a slurry catalyst for upgrading the heavy oil feedstock, forming upgraded products of lower boiling hydrocarbons. In the separation zones, upgraded products are removed overhead and optionally, further treated in an in-line hydrotreater. At least a portion of the non-volatile fractions recovered from at least one of the separation zones is recycled back to the first contacting zone in the system, in an amount ranging between 3 to 50 wt. % of the heavy oil feedstock.Type: GrantFiled: September 18, 2008Date of Patent: May 10, 2011Assignee: Chevron U.S.A. Inc.Inventors: Julie Chabot, Bo Kou, Vivion Andrew Brennan, Erin Maris, Shuwu Yang, Bruce Reynolds
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Patent number: 7931796Abstract: Systems and methods for hydroprocessing a heavy oil feedstock, the system employs a plurality of contacting zones and separation zones with at least some of the fresh slurry catalyst being supplied to at least a contacting zone other than the first contacting zone. The contacting zones operate under hydrocracking conditions, employing the slurry catalyst for upgrading the heavy oil feedstock, forming upgraded products of lower boiling hydrocarbons. In the separation zones, upgraded products are removed overhead and optionally, further treated in an in-line hydrotreater. A least a portion of the non-volatile fractions recovered from the separation zones is recycled back to the first contacting zone in the system.Type: GrantFiled: September 18, 2008Date of Patent: April 26, 2011Assignee: Chevron U.S.A. Inc.Inventors: Julie Chabot, Kaidong Chen, Bruce Reynolds
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Patent number: 7931797Abstract: A process for hydroprocessing heavy oil feedstock is disclosed. The process operates in once-through mode, employing a plurality of contacting zones and at least a separation zone to convert at least a portion of the heavy oil feedstock to lower boiling hydrocarbons, forming upgraded products. In the once-through upgrade system, little if any of the unconverted material and slurry catalyst mixture is recycled back to the system for further upgrading. The contacting zones operate under hydrocracking conditions, employing a slurry catalyst for upgrading the heavy oil feedstock. The slurry catalyst feed comprises an active metal catalyst having an average particle size of at least 1 micron in a hydrocarbon oil diluent, at a concentration of greater than 500 wppm of active metal catalyst to heavy oil feedstock.Type: GrantFiled: July 21, 2009Date of Patent: April 26, 2011Assignee: Chevron U.S.A. Inc.Inventors: Julie Chabot, Shuwu Yang, Bruce Reynolds
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Patent number: 7901569Abstract: Applicants have developed a new residuum full hydroconversion slurry reactor system that allows the catalyst, unconverted oil, hydrogen, and converted oil to circulate in a continuous mixture throughout an entire reactor with no confinement of the mixture. The mixture is separated internally, within one of more of the reactors, to separate only the converted oil and hydrogen into a vapor product while permitting the unconverted oil and the slurry catalyst to continue on into the next sequential reactor as a liquid product. A portion of the unconverted oil is then converted to lower boiling point hydrocarbons in the next reactor, once again creating a mixture of unconverted oil, hydrogen, converted oil, and slurry catalyst. Further hydroprocessing may occur in additional reactors, fully converting the oil. The oil may alternately be partially converted, leaving a concentrated catalyst in unconverted oil which can be recycled directly to the first reactor.Type: GrantFiled: September 17, 2008Date of Patent: March 8, 2011Assignee: Chevron U.S.A. Inc.Inventors: Darush Farshid, James Murphy, Bruce Reynolds
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Publication number: 20110017637Abstract: A process for hydroprocessing heavy oil feedstock is disclosed. The process operates in once-through mode, employing a plurality of contacting zones and separation zones in sequential mode, parallel mode, or combinations thereof to convert at least a portion of the heavy oil feedstock to lower boiling hydrocarbons, forming upgraded products. The contacting zones operate under hydrocracking conditions, employing a slurry catalyst for upgrading the heavy oil feedstock. In one embodiment, the effluent stream from the contacting zone is sent to a separation zone in series operating at a pressure drop of at most 100 psi from the contacting zone. In another embodiment, the effluent from a contacting zone to the next contacting zone in series for further upgrade, with the next contacting zone having a pressure drop of at most 100 psi, with the pressure drop is not due to a pressure reducing device as in the prior art.Type: ApplicationFiled: July 21, 2009Publication date: January 27, 2011Inventors: Bruce Reynolds, Julie Chabot
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Publication number: 20110017635Abstract: A process for hydroprocessing heavy oil feedstock is disclosed. The process operates in once-through mode, employing a plurality of contacting zones and at least a separation zone to convert at least a portion of the heavy oil feedstock to lower boiling hydrocarbons, forming upgraded products. In the once-through upgrade system, little if any of the unconverted material and slurry catalyst mixture is recycled back to the system for further upgrading. The contacting zones operate under hydrocracking conditions, employing a slurry catalyst for upgrading the heavy oil feedstock. The slurry catalyst feed comprises an active metal catalyst having an average particle size of at least 1 micron in a hydrocarbon oil diluent, at a concentration of greater than 500 wppm of active metal catalyst to heavy oil feedstock.Type: ApplicationFiled: July 21, 2009Publication date: January 27, 2011Inventors: Julie Chabot, Shuwu Yang, Bruce Reynolds
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Publication number: 20110017638Abstract: A flexible once-through process for hydroprocessing heavy oil feedstock is disclosed. The process employs a plurality of contacting zones and at least a separation zone to convert at least a portion of the heavy oil feedstock to lower boiling hydrocarbons, forming upgraded products. The contacting zones operate under hydrocracking conditions, employing a slurry catalyst for upgrading the heavy oil feedstock.Type: ApplicationFiled: July 21, 2009Publication date: January 27, 2011Inventors: Darush Farshid, Bruce Reynolds
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Publication number: 20100234212Abstract: A hydroprocessing bulk catalyst is provided. A process to prepare hydroprocessing bulk catalysts is also provided. The hydroprocessing catalyst has the formula (Mt)a(Lu)b(Sv)d(Cw)e(Hx)f(Oy)g(Nz)h,, wherein M is at least one group VIII metal; promoter metal L is optional and if present, L is at least one Group VIII non-noble metal; t, u, v, w, x, y, z representing the total charge for each of the components (M, L, S, C, H, O and N, respectively); ta+ub+vd+we+xf+yg+zh=0; 0=<b; and 0=<b/a=<5, (a+0.5b)<=d<=(5a+2b), 0<=e<=11(a+b), 0<=f<=7(a+b), 0<=g<=5(a+b), 0<=h<=0.5(a+b). The catalyst has an X-ray powder diffraction pattern with at least one broad diffraction peak at any of Bragg angles: 8 to 18°, 32 to 40°, and 55 to 65° (from 0 to 70° 2-? scale).Type: ApplicationFiled: May 26, 2010Publication date: September 16, 2010Inventors: Axel Brait, Alexander E. Kuperman, Jaime Lopez, Oleg Mironov, Bruce Reynolds, Kaidong Chen
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Patent number: 7737073Abstract: A hydroprocessing bulk catalyst is provided. A process to prepare hydroprocessing bulk catalysts is also provided. The hydroprocessing catalyst has the formula (Mt)a(Lu)b(Sv)d(Cw)e(Hx)f(Oy)g(Nz)h, wherein M is at least one group VIB metal; promoter metal L is optional and if present, L is at least one Group VIII non-noble metal; t, u, v, w, x, y, z representing the total charge for each of the components (M, L, S, C, H, O and N, respectively); ta+ub+vd+we+xf+yg+zh=0; 0=<b; and 0=<b/a=<5, (a+0.5b)<=d<=(5a+2b), 0<=e<=11(a+b), 0<=f<=7(a+b), 0<=g<=5(a+b), 0<=h<=0.5(a+b). The catalyst has an X-ray powder diffraction pattern with at least one broad diffraction peak at any of Bragg angles: 8 to 18°, 32 to 40°, and 55 to 65° (from 0 to 70° 2-? scale).Type: GrantFiled: October 29, 2008Date of Patent: June 15, 2010Assignee: Chevron U.S.A. Inc.Inventors: Oleg Mironov, Alexander E. Kuperman, Jaime Lopez, Axel Brait, Bruce Reynolds, Kaidong Chen
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Patent number: 7737072Abstract: A hydroprocessing catalyst is provided. The hydroprocessing catalyst has the formula (Mt)a(Xu)b(Sv)d(Cw)e(Hx)f(Oy)g(Nz)h, wherein M is at least one group VIB metal; X is at least one Group VIII non-noble metal; t, u, v, w, x, y, z representing the total charge for each of the components (M, X, S, C, H, O and N, respectively); ta+ub+vd+we+xf+yg+zh=0; and 0=<b/a=<5, (a+0.5b)<=d<=(5a+2b), 0<=e<=11(a+b), 0<=f<=7(a+b), 0<=g<=5(a+b), 0<=h<=0.5(a+b). The catalyst has an X-ray powder diffraction pattern with at least one broad diffraction peak at any of Bragg angles: 8 to 18°, 32 to 40°, and 55 to 65° (from 0 to 70° 2-? scale). In one embodiment, the at least one diffraction peak is greater than 2 degrees wide at ½ height.Type: GrantFiled: October 31, 2007Date of Patent: June 15, 2010Assignee: Chevron USA Inc.Inventors: Oleg Mironov, Alexander E. Kuperman, Jaime Lopez, Axel Brait, Bruce Reynolds, Kaidong Chen
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Patent number: 7708877Abstract: A new residuum full hydroconversion slurry reactor system has been developed that allows the catalyst, unconverted oil and converted oil to circulate in a continuous mixture throughout an entire reactor with no confinement of the mixture. The mixture is partially separated in between the reactors to remove only the converted oil while permitting the unconverted oil and the slurry catalyst to continue on into the next sequential reactor where a portion of the unconverted oil is converted to lower boiling point hydrocarbons, once again creating a mixture of unconverted oil, converted oil, and slurry catalyst. Further hydroprocessing may occur in additional reactors, fully converting the oil. The oil may alternately be partially converted, leaving a highly concentrated catalyst in unconverted oil which can be recycled directly to the first reactor. Fully converted oil is subsequently hydrofinished for the nearly complete removal of hetoroatoms such as sulfur and nitrogen.Type: GrantFiled: April 24, 2006Date of Patent: May 4, 2010Assignee: Chevron USA Inc.Inventors: Darush Farshid, Bruce Reynolds
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Publication number: 20100065471Abstract: Systems and methods for hydroprocessing a heavy oil feedstock, the system employs a plurality of contacting zones and separation zones with at least some of the fresh slurry catalyst being supplied to at least a contacting zone other than the first contacting zone. The contacting zones operate under hydrocracking conditions, employing the slurry catalyst for upgrading the heavy oil feedstock, forming upgraded products of lower boiling boiling hydrocarbons. In the separation zones, upgraded products are removed overhead and optionally, further treated in an in-line hydrotreater. A least a portion of the non-volatile fractions recovered from the separation zones is recycled back to the first contacting zone in the system.Type: ApplicationFiled: September 18, 2008Publication date: March 18, 2010Inventors: Julie Chabot, Kaidong Chen, Bruce Reynolds
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Publication number: 20090200204Abstract: A hydroprocessing catalyst is provided. The hydroprocessing catalyst has the formula (Mt)a(Xu)b(Sv)d(Cw)e(Hx)f(Oy)g(Nz)h, wherein M is at least one group VIB metal; X is at least one Group VIII non-noble metal; t, u, v, w, x, y, z representing the total charge for each of the components (M, X, S, C, H, O and N, respectively); ta+ub+vd+we+xf+yg+zh=0; and 0=<b/a=<5, (a+0.5b)<=d<=(5a+2b), 0<=e<=11(a+b), 0<=f<=7(a+b), 0<=g<=5(a+b), 0<=h<=0.5(a+b). The catalyst has an X-ray powder diffraction pattern with at least one broad diffraction peak at any of Bragg angles: 8 to 18°, 32 to 40°, and 55 to 65° (from 0 to 70° 2-? scale). In one embodiment, the at least one diffraction peak is greater than 2 degrees wide at ½ height.Type: ApplicationFiled: October 31, 2007Publication date: August 13, 2009Inventors: Oleg Mironov, Alexander E. Kuperman, Jaime Lopez, Axel Brait, Bruce Reynolds, Kaidong Chen
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Publication number: 20090163350Abstract: A process to upgrade heavy oil and convert the heavy oil into lower boiling hydrocarbon products is provided. The process employs a catalyst slurry comprising catalyst particles with an average particle size ranging from 1 to 20 microns. In the upgrade process, spent slurry catalyst in heavy oil is generated as an effluent stream, which is subsequently recovered/separated from the heavy oil via membrane filtration. In one embodiment, dynamic filtration is used for the separation of the heavy oil from the catalyst particles. Valuable metals can be recovered from catalyst particles for subsequent re-use in a catalyst synthesis unit, generating a fresh slurry catalyst.Type: ApplicationFiled: December 30, 2008Publication date: June 25, 2009Inventors: Andre R. Da Costa, Bruce Reynolds, Christopher A. Powers
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Publication number: 20090159505Abstract: A process to upgrade heavy oil and convert the heavy oil into lower boiling hydrocarbon products is provided. The process employs a catalyst slurry comprising catalyst particles with an average particle size ranging from 1 to 20 microns. In the upgrade process, spent slurry catalyst in heavy oil is generated as an effluent stream, which is subsequently recovered/separated from the heavy oil via a filtration assembly. The filtration assembly has a least a filtration unit employing at least a membrane for separating heavy oil from the catalyst particles. Valuable metals can be recovered from catalyst particles for subsequent re-use in a catalyst synthesis unit, generating a fresh slurry catalyst.Type: ApplicationFiled: December 30, 2008Publication date: June 25, 2009Inventors: Andre R. Da Costa, Bruce Reynolds, Christopher A. Powers, Seyi A. Odueyungbo
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Publication number: 20090134064Abstract: The instant invention relates to an upflow for upgrading heavy oil feed stock and a method for upgrading heavy oil feed stock employing an upflow reactor and with a slurry catalyst. In one embodiment, the upflow reactor is a liquid recirculating reactor, which is operated in manner corresponding to a dispersed bubble flow regime, which requires a high liquid to gas ratio. A dispersed bubble flow regime results in more even flow patterns, increasing the amount of liquid, i.e., heavy oil feed stock that can be upgraded in a single reactor.Type: ApplicationFiled: January 16, 2009Publication date: May 28, 2009Inventor: BRUCE REYNOLDS
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Publication number: 20090057195Abstract: Systems and methods for hydroprocessing a heavy oil feedstock, the system employs a plurality of contacting zones and separation zones and a solvent deasphalting (SDA) unit for providing at least a portion of the heavy oil feedstock. The contacting zones operate under hydrocracking conditions, employing a slurry catalyst for upgrading the deasphalted oil, forming upgraded products of lower boiling hydrocarbons. In the separation zones which operates at a temperature within 20° F. and a pressure within 10 psi of the pressure in the contacting zones, upgraded products are removed overhead and optionally, further treated in an in-line hydrotreater.Type: ApplicationFiled: September 18, 2008Publication date: March 5, 2009Inventors: Christopher Alan Powers, Bruce Reynolds
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Publication number: 20090057194Abstract: Applicants have developed a new residuum full hydroconversion slurry reactor system that allows the catalyst, unconverted oil, hydrogen, and converted oil to circulate in a continuous mixture throughout an entire reactor with no confinement of the mixture. The mixture is separated internally, within one of more of the reactors, to separate only the converted oil and hydrogen into a vapor product while permitting the unconverted oil and the slurry catalyst to continue on into the next sequential reactor as a liquid product. A portion of the unconverted oil is then converted to lower boiling point hydrocarbons in the next reactor, once again creating a mixture of unconverted oil, hydrogen, converted oil, and slurry catalyst. Further hydroprocessing may occur in additional reactors, fully converting the oil. The oil may alternately be partially converted, leaving a concentrated catalyst in unconverted oil which can be recycled directly to the first reactor.Type: ApplicationFiled: September 17, 2008Publication date: March 5, 2009Inventors: Darush Farshid, James Murphy, Bruce Reynolds
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Publication number: 20090057193Abstract: The instant invention is directed to a new residuum full hydroconversion slurry reactor system that allows the catalyst, unconverted oil and converted oil to circulate in a continuous mixture throughout an entire reactor with no confinement of the mixture. The mixture is partially separated in between the reactors to remove only the products and hydrogen, while permitting the unconverted oil and the slurry catalyst to continue on into the next sequential reactor where a portion of the unconverted oil is converted to lower boiling point hydrocarbons, once again creating a mixture of unconverted oil, converted oil, and slurry catalyst. Further hydroprocessing may occur in additional reactors, fully converting the oil. The oil may alternately be partially converted, leaving a highly concentrated catalyst in unconverted oil which can be recycled directly to the first reactor.Type: ApplicationFiled: September 17, 2008Publication date: March 5, 2009Inventors: Darush Farshid, Bruce Reynolds
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Publication number: 20090057201Abstract: A hydroprocessing bulk catalyst is provided. A process to prepare hydroprocessing bulk catalysts is also provided. The hydroprocessing catalyst has the formula (Mt)d(Lu)b(Sv)d(Cw)e(Hx)f(Oy)g(Nz)h, wherein M is at least one group VIB metal; promoter metal L is optional and if present, L is at least one Group VIII non-noble metal; t, u, v, w, x, y, z representing the total charge for each of the components (M, L, S, C, H, O and N, respectively); ta+ub+vd+we+xf+yg+zh=0; 0 =<b; and 0=<b/a=<5, (a+0.5b)<=d<=(5a+2b), 0<=e<=11(a+b), 0<=f<=7(a+b), 0<=g<=5(a+b), 0<=h<=0.5(a+b). The catalyst has an X-ray powder diffraction pattern with at least one broad diffraction peak at any of Bragg angles: 8 to 18°, 32 to 40°, and 55 to 65° (from 0 to 70° 2-? scale).Type: ApplicationFiled: October 29, 2008Publication date: March 5, 2009Inventors: Axel Brait, Alexander E. Kuperman, Jaime Lopez, Oleg Mironov, Bruce Reynolds, Kaidong Chen