Abstract: A SHC apparatus and process comprise a catalyst precursor reactor for providing a catalyst precursor stream in downstream communication with a source of molybdenum, a SHC feed line for providing a heavy hydrocarbon feed stream in downstream communication with a heater, and a SHC reactor in downstream communication with the SHC feed line and with the catalyst precursor reactor. A process for SHC, the process comprising preparing a catalyst precursor stream comprising molybdenum in a catalyst precursor reactor, mixing the catalyst precursor stream with a heavy hydrocarbon stream to provide a catalyst precursor concentrate stream, heating a hydrocracking hydrocarbon feed stream in a heater to provide a heated hydrocracking feed stream, mixing the catalyst precursor concentrate stream with the heated hydrocarbon stream to provide a SHC feed stream, and reacting the SHC feed stream in a SHC reactor.

Abstract: A SHC apparatus and process comprise a catalyst precursor reactor for providing a catalyst precursor stream in downstream communication with a source of molybdenum, a SHC feed line for providing a heavy hydrocarbon feed stream in downstream communication with a heater, and a SHC reactor in downstream communication with the SHC feed line and with the catalyst precursor reactor. A process for SHC, the process comprising preparing a catalyst precursor stream comprising molybdenum in a catalyst precursor reactor, mixing the catalyst precursor stream with a heavy hydrocarbon stream to provide a catalyst precursor concentrate stream, heating a hydrocracking hydrocarbon feed stream in a heater to provide a heated hydrocracking feed stream, mixing the catalyst precursor concentrate stream with the heated hydrocarbon stream to provide a SHC feed stream, and reacting the SHC feed stream in a SHC reactor.

Abstract: A process using a dealkylated aromatic liquid improves a heavy hydrocarbon liquid used for supporting molybdenum carbonized catalyst. Dealkylated aromatic liquid can be derived from heavy hydrocarbon materials that have been subjected to cracking, such as fluid catalytic cracking or slurry hydrocracking. The heavy hydrocarbon liquid can comprise a portion of resid SHC feed and a portion of a gas oil stream from SHC effluent.

Abstract: Recycle of slurry hydrocracked product to a subsequent slurry hydrocracking reactor downstream of a lead slurry hydrocracking reactor produces reduced mesophase and provides better reactor stability as opposed to recycle to the lead slurry hydrocracking reactor. The recycle stream may be a vacuum bottoms stream and/or a slop wax stream from a fractionation column.

Abstract: A method of reducing catalyst agglomeration in a slurry hydrocracking zone containing at least two reactors is described. A hydrocarbon feed and a slurry hydrocracking catalyst are contacted in a first reactor to form a first effluent containing slurry hydrocracking reaction products, unreacted hydrocarbon feed, and the slurry hydrocracking catalyst, wherein the slurry hydrocracking catalyst agglomerates. The first effluent and an unsupported hydrogenation catalyst are contacted in a second reactor to form a second effluent containing the slurry hydrocracking reaction products, unreacted hydrocarbon feed, the slurry hydrocracking catalyst, and asphaltene reaction products.

Abstract: Settling unconverted pitch from a SHC reactor effluent before fractionation improves efficiency of fractionation of slurry hydrocracked products. The recycle of soft pitch to the SHC reactor results in improved reactor operation by avoiding the recycle of lighter products which vaporize in the reactor to occupy reactor space and the recycle of hard pitch which will not convert. The settling step facilitated by mixing with a solvent can achieve a separation between soft pitch and hard pitch not achievable in a fractionation column.

Abstract: A process using a dealkylated aromatic liquid improves a heavy hydrocarbon liquid used for supporting molybdenum carbonized catalyst. Dealkylated aromatic liquid can be derived from heavy hydrocarbon materials that have been subjected to cracking, such as fluid catalytic cracking or slurry hydrocracking. The heavy hydrocarbon liquid can comprise a portion of resid SHC feed and a portion of a gas oil stream from SHC effluent.

Abstract: Utilization of at least three strippers is proposed for a slurry hydrocracking unit to reduce heater duty for a product fractionation column. A stripping column for stripping a hydrocracked stream from a wash oil stripper is proposed in addition to a cold stripper for a cold hydrocracked stream and a warm stripper for a warm hydrocracked stream. The arrangement enables omission of heating a hot hydrocracked stream from a hot separator in a fired heater before product fractionation.

Abstract: Processes for hydrotreating an effluent from a slurry hydrocracking process are described. Different streams are formed from the SHC effluent, and different hydroprocessing conditions are applied to the streams, e.g., more severe conditions are applied to streams which need additional hydroprocessing, while less severe conditions are applied to streams which do not need as much hydroprocessing. Common equipment is shared between different hydroprocessing steps.

Abstract: Settling unconverted pitch from a SHC reactor effluent before fractionation improves efficiency of fractionation of slurry hydrocracked products. The recycle of soft pitch to the SHC reactor results in improved reactor operation by avoiding the recycle of lighter products which vaporize in the reactor to occupy reactor space and the recycle of hard pitch which will not convert. The settling step facilitated by mixing with a solvent can achieve a separation between soft pitch and hard pitch not achievable in a fractionation column.

Abstract: Utilization of at least three strippers is proposed for a slurry hydrocracking unit to reduce heater duty for a product fractionation column. A stripping column for stripping a hydrocracked stream from a wash oil stripper is proposed in addition to a cold stripper for a cold hydrocracked stream and a warm stripper for a warm hydrocracked stream. The arrangement enables omission of heating a hot hydrocracked stream from a hot separator in a fired heater before product fractionation.

Abstract: Recycle of slurry hydrocracked product to a subsequent slurry hydrocracking reactor downstream of a lead slurry hydrocracking reactor produces reduced mesophase and provides better reactor stability as opposed to recycle to the lead slurry hydrocracking reactor. The recycle stream may be a vacuum bottoms stream and/or a slop wax stream from a fractionation column.

Abstract: The subject process enhances catalytic activity for demetallization and desulfurization of a residue feed stream by injecting water into the feed and hydrotreating in two stages with interstage separation. Water injection improves the demetallation activity of the HDM catalyst and separating vapor comprising hydrogen sulfide from the demetallized effluent improves the activity of the HDS catalyst. We have discovered that the water injection and hydrogen sulfide removal together provide a profound synergetic effect.

Abstract: The subject process enhances catalytic activity for demetallization and desulfurization of a residue feed stream by injecting water into the feed and hydrotreating in two stages with interstage separation. Water injection improves the demetallation activity of the HDM catalyst and separating vapor comprising hydrogen sulfide from the demetallized effluent improves the activity of the HDS catalyst. We have discovered that the water injection and hydrogen sulfide removal together provide a profound synergetic effect.

Abstract: A method of reducing catalyst agglomeration in a slurry hydrocracking zone containing at least two reactors is described. A hydrocarbon feed and a slurry hydrocracking catalyst are contacted in a first reactor to form a first effluent containing slurry hydrocracking reaction products, unreacted hydrocarbon feed, and the slurry hydrocracking catalyst, wherein the slurry hydrocracking catalyst agglomerates. The first effluent and an unsupported hydrogenation catalyst are contacted in a second reactor to form a second effluent containing the slurry hydrocracking reaction products, unreacted hydrocarbon feed, the slurry hydrocracking catalyst, and asphaltene reaction products.

Abstract: A process for de-ashing pitch. The pitch from a slurry hydrocracking process is mixed with a solvent. The mixture is separated into solvent and soluble materials and insoluble materials. The insoluble materials can be dried to recover solvent which may be recycled. The solvent and soluble materials are separated. The solvent may be recovered and recycled. Hi-Sol 15 may be the solvent. Additionally, CSO may be the solvent and a portion thereof may be used with the de-ashed pitch to make an asphalt binder.

Abstract: Processes for hydrotreating an effluent from a slurry hydrocracking process are described. Different streams are formed from the SHC effluent, and different hydroprocessing conditions are applied to the streams, e.g., more severe conditions are applied to streams which need additional hydroprocessing, while less severe conditions are applied to streams which do not need as much hydroprocessing. Common equipment is shared between different hydroprocessing steps.

Abstract: Methods and apparatus for vacuum separation are described. The method includes heating a feed comprising a mixture of light and heavy hydrocarbons in a first heating zone. The heated feed is flashed in a flash drum to form a liquid stream and a vapor stream. The liquid stream is heated in a second heating zone. The heated liquid stream is introduced into a vacuum distillation column through a first inlet. The vapor stream from the flash drum is introduced into the vacuum distillation column through a second inlet located above the first inlet, the vapor stream of the flash drum being in fluid communication with the vacuum distillation column.

Abstract: An integrated process and apparatus for conversion of gas oil and heavy oil is described. The process includes passing a gas oil feed to a fluid catalytic cracking (FCC) zone to obtain a FCC effluent; separating the FCC effluent in a separation zone into at least two fractions comprising a clarified slurry oil fraction and an overhead fraction; passing the clarified slurry oil fraction to a slurry hydrocracking zone forming at least a naphtha stream; and recycling at least a portion of the slurry hydrocracking naphtha stream to the FCC zone.

Abstract: Methods and apparatus for vacuum separation are described. The method includes heating a feed comprising a mixture of light and heavy hydrocarbons in a first heating zone. The heated feed is flashed in a flash drum to form a liquid stream and a vapor stream. The liquid stream is heated in a second heating zone. The heated liquid stream is introduced into a vacuum distillation column through a first inlet. The vapor stream from the flash drum is introduced into the vacuum distillation column through a second inlet located above the first inlet, the vapor stream of the flash drum being in fluid communication with the vacuum distillation column.