Abstract: The present disclosure provides a system and method for responding to an unintended increase in pressure within a high pressure processing system. The system and method of the present disclosure provides a pressure relief system that releases pressure reliably even if the material under pressure is of mixed phase. In addition, the system and method for releasing pressure avoids the need for complex subsystems to contain and process materials that escape the system during the pressure release process.

Abstract: Systems and methods for hydroprocessing a heavy oil feedstock, the system employs a plurality of contacting zones and separation zones and an interstage solvent deasphalting unit. 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 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. At least a portion of the non-volatile fractions recovered from at least one of the separation zones is sent to the interstage solvent deasphalting unit, for separating unconverted heavy oil feedstock into deasphalted oil and asphaltenes. The deasphalted oil stream is sent to one of the contacting zones for further upgrade.

Abstract: The present disclosure provides a system and method for responding to an unintended increase in pressure within a high pressure processing system. The system and method of the present disclosure provides a pressure relief system that releases pressure reliably even if the material under pressure is of mixed phase. In addition, the system and method for releasing pressure avoids the need for complex subsystems to contain and process materials that escape the system during the pressure release process.

Abstract: An integrated process for producing liquid fuel and lubricating base oil from Fischer-Tropsch derived products which comprises (a) recovering separately from a Fischer-Tropsch synthesis reactor a Fischer-Tropsch wax and condensate; (b) hydroprocessing the wax and recovering a waxy intermediate and a hydrogen-rich normally, liquid fraction; (c) mixing the condensate and at least part of the hydrogen-rich normally liquid fraction to form a Fischer-Tropsch condensate mixture; (d) hydrotreating the condensate mixture and recovering a Fischer-Tropsch condensate product; (e) recovering from the condensate product a liquid fuel; (f) separately dewaxing the waxy intermediate and recovering a base oil; (g) hydrofinishing the base oil; (h) recovering from the hydrofinishing zone a stabilized base oil and a hydrogen-rich gas; and (i) recycling the hydrogen-rich gas to the wax hydroprocessing zone wherein the total pressure in the hydrofinishing zone is at least as high as the total pressure in the wax hydroprocessing zo

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

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 present invention is directed to a method for hydroprocessing Fischer-Tropsch products. The invention in particular relates to an integrated method for producing liquid fuels from a hydrocarbon stream provided by Fischer-Tropsch synthesis. The method involves separating the Fischer-Tropsch products into a light fraction (FT condensate) and a heavy fraction. The heavy fraction is subjected to hydrocracking conditions, preferably through multiple catalyst beds, to reduce the chain length. The products of the hydrocracking reaction following the last catalyst bed are subjected to a separation step. The lighter material is combined with the Fischer-Tropsch condensate and hydrotreated. The hydrotreatment conditions hydrogenate double bonds, reduce oxygenates to paraffins, and desulfurize and denitrify the products. The heavier material from the separation step is sent to the lube plant for hydroisomerization, or is subjected to subsequent fraction steps to produce fuels and middle distillates.

Abstract: 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.

Abstract: 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.

Abstract: Systems and methods for hydroprocessing a heavy oil feedstock, the system employs a plurality of contacting zones and separation zones and an interstage solvent deasphalting unit. 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 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. At least a portion of the non-volatile fractions recovered from at least one of the separation zones is sent to the interstage solvent deasphalting unit, for separating unconverted heavy oil feedstock into deasphalted oil and asphaltenes. The deasphalted oil stream is sent to one of the contacting zones for further upgrade.

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: 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.

Abstract: 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.

Abstract: A new residuum full hydroconversion slurry reactor system has been developed that allows the catalyst, unconverted oil, products and hydrogen 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. In the next reactor, a portion of the unconverted oil is converted to lower boiling point hydrocarbons, once again creating a mixture of unconverted oil, products, hydrogen 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. The slurry reactor system is, in this invention, preceded by an in-line pretreating step, such as hydrotreating or deasphalting.

Abstract: The present invention relates to the field of hydroprocessing, and more particularly relates to a process directed to fuels hydrocracking and distillate feed hydrofining. This process has at least two stages. A relatively unconverted hydrofined product may be removed prior to the second stage, providing flexibility. In another embodiment, fresh feed may be added prior to the second stage. In both embodiments, fuels production is maintained at a constant level.

Abstract: Applicants have developed 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 gas, while permitting the unconverted oil and the slurry catalyst to continue on into the next sequential reactor. A portion of the unconverted oil is then converted to lower boiling point hydrocarbons, once again creating a mixture of unconverted oil, products, hydrogen, and slurry catalyst. Further hydroprocessing may occur in additional reactors, fully converting the oil. Additional oil may be added at the interstage feed inlet, possibly in combination with slurry. The oil may alternately be partially converted, leaving a highly concentrated catalyst in unconverted oil which can be recycled directly to the first reactor.

Abstract: 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.