Abstract: System and method for mixing a catalyst precursor into heavy oil include parallel mixing lines configured to receive and mix a diluted precursor mixture (catalyst precursor premixed with a hydrocarbon diluent) with heavy oil to form a conditioned feedstock. One of the mixing lines can be periodically taken offline (e.g., for maintenance) while one or more remaining mixing lines continue to form conditioned feedstock. A bypass line maintains substantially continuous flow volume of heavy oil when one of the mixing lines is taken offline. Valves and flow meters can be used to regulate flow through the mixing lines and bypass line. The system permits virtually unlimited scaleup of the mixing process while permitting periodic maintenance of the system without taking it completely offline. Mixing a catalyst precursor into heavy oil forms colloidal-sized catalyst particles in situ having high catalytic activity that promote beneficial upgrading reactions when hydroprocessing heavy oil.

Abstract: An ebullated bed hydroprocessing system is upgraded using a dual catalyst system that includes a heterogeneous catalyst and dispersed metal sulfide particles, which permits recycling of vacuum bottoms without recycle buildup of asphaltenes. The dual catalyst system more effectively converts asphaltenes in the ebullated bed reactor and increases asphaltene conversion by an amount that at least offsets higher asphaltene concentration resulting from recycling of vacuum bottoms. In this way, there is no recycle buildup of asphaltenes in upgraded ebullated bed reactor notwithstanding recycling of vacuum bottoms. In addition, residual dispersed metal sulfide catalyst particles in the vacuum bottoms can maintain or increase the concentration of the dispersed metal sulfide catalyst in the ebullated bed reactor.

Abstract: An ebullated bed hydroprocessing system is upgraded using a dual catalyst system that includes a heterogeneous catalyst and dispersed metal sulfide particles, which permits recycling of vacuum bottoms without recycle buildup of asphaltenes. The dual catalyst system more effectively converts asphaltenes in the ebullated bed reactor and increases asphaltene conversion by an amount that at least offsets higher asphaltene concentration resulting from recycling of vacuum bottoms. In this way, there is no recycle buildup of asphaltenes in upgraded ebullated bed reactor notwithstanding recycling of vacuum bottoms. In addition, residual dispersed metal sulfide catalyst particles in the vacuum bottoms can maintain or increase the concentration of the dispersed metal sulfide catalyst in the ebullated bed reactor.

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 pre-coking hydrocracking reactor, a separator, and a coking reactor. The colloidal or molecular catalyst promotes upgrading reactions that reduce the quantity of asphaltenes or other coke forming precursors in the feedstock, increase hydrogen to carbon ratio in the upgraded material, and decrease boiling points of hydrocarbons in the upgraded material. The methods and systems can be used to upgrade vacuum tower bottoms and other low grade heavy oil feedstocks.

Abstract: Methods and systems for hydroprocessing heavy oil feedstocks to form upgraded material use a colloidal or molecular catalyst dispersed within heavy oil feedstock, pre-coking hydrocracking reactor, separator, and coking reactor. The colloidal or molecular catalyst promotes upgrading reactions that reduce the quantity of asphaltenes or other coke forming precursors in the feedstock, increase hydrogen to carbon ratio in the upgraded material, and decrease boiling points of hydrocarbons in the upgraded material. The methods and systems can be used to upgrade vacuum tower bottoms and other low grade heavy oil feedstocks.

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 pre-coking hydrocracking reactor, a separator, and a coking reactor. The colloidal or molecular catalyst promotes upgrading reactions that reduce the quantity of asphaltenes or other coke forming precursors in the feedstock, increase hydrogen to carbon ratio in the upgraded material, and decrease boiling points of hydrocarbons in the upgraded material. The methods and systems can be used to upgrade vacuum tower bottoms and other low grade heavy oil feedstocks.

Abstract: Methods and systems for hydroprocessing heavy oil feedstocks to form upgraded material use a colloidal or molecular catalyst dispersed within heavy oil feedstock, pre-coking hydrocracking reactor, separator, and coking reactor. The colloidal or molecular catalyst promotes upgrading reactions that reduce the quantity of asphaltenes or other coke forming precursors in the feedstock, increase hydrogen to carbon ratio in the upgraded material, and decrease boiling points of hydrocarbons in the upgraded material. The methods and systems can be used to upgrade vacuum tower bottoms and other low grade heavy oil feedstocks.