Abstract: Embodiments herein relate to a process flow scheme for the processing of gas oils and especially reactive gas oils produced by thermal cracking of residua using a split flow concept. The split flow concepts disclosed allow optimization of the hydrocracking reactor severities and thereby take advantage of the different reactivities of thermally cracked gas oils versus those of virgin gas oils. This results in a lower cost facility for producing base oils as well as diesel, kerosene and gasoline fuels while achieving high conversions and high catalyst lives.

Abstract: Embodiments herein relate to a process flow scheme for the processing of gas oils and especially reactive gas oils produced by thermal cracking of residua using a split flow concept. The split flow concepts disclosed allow optimization of the hydrocracking reactor severities and thereby take advantage of the different reactivities of thermally cracked gas oils versus those of virgin gas oils. This results in a lower cost facility for producing base oils as well as diesel, kerosene and gasoline fuels while achieving high conversions and high catalyst lives.

Abstract: Embodiments herein relate to a process flow scheme for the processing of gas oils and especially reactive gas oils produced by thermal cracking of residua using a split flow concept. The split flow concepts disclosed allow optimization of the hydrocracking reactor seventies and thereby take advantage of the different reactivities of thermally cracked gas oils versus those of virgin gas oils. This results in a lower cost facility for producing base oils as well as diesel, kerosene and gasoline fuels while achieving high conversions and high catalyst lives.

Abstract: Embodiments herein relate to a process flow scheme for the processing of gas oils and especially reactive gas oils produced by thermal cracking of residua using a split flow concept. The split flow concepts disclosed allow optimization of the hydrocracking reactor seventies and thereby take advantage of the different reactivities of thermally cracked gas oils versus those of virgin gas oils. This results in a lower cost facility for producing base oils as well as diesel, kerosene and gasoline fuels while achieving high conversions and high catalyst lives.

Abstract: In the refining of crude oil, hydroprocessing units such as hydrotreaters and hydrocrackers are used to remove impurities such as sulfur, nitrogen, and metals from the crude oil. They are also used to convert the feed into valuable products such as naphtha, jet fuel, kerosene and diesel. The current invention provides very high to total conversion of heavy oils to products in a single high-pressure loop, using multiple reaction stages. The second stage or subsequent stages may be a combination of co-current and counter-current operation. The benefits of this invention include conversion of feed to useful products at reduced operating pressures using lower catalyst volumes. Lower hydrogen consumption also results. A minimal amount of equipment is employed. Utility consumption is also minimized.

Abstract: High boiling hydrocarbon materials are hydrocracked in a multiple stage process having ebullating or fixed catalyst bed hydrogenation reactor stages in series. Between the hydrogenation reactors is an interstage feed of an aromatic solvent and/or a portion of the high boiling hydrocarbon feedstock.

Abstract: The invention relates to a hydrotreating and hydrocracking process for various oils nominally boiling between 600 and 1500° F. to produce diesel oil and lighter materials. The process includes a first hydrogenation reaction in the presence of multiple hydrogenation catalyst beds which is limited to the hydrogenation level needed for the removal of sulfur and nitrogen and for aromatic saturation and to produce an effluent of both hydrocracked oil and uncracked heavy oil. The effluent is then flashed to produce hydrocracked oil vapors and liquid uncracked heavy oil. The hydrocracked oil fraction is further hydrotreated by catalytic distillation in a post-treatment reactor to give the final product quality while the liquid uncracked heavy oil bypasses the post-treatment reactor. The process significantly reduces hydrogen consumption and reduces the overall reactor and catalyst volumes for a given level of performance.

Abstract: The invention relates to a hydrocracking and hydrotreating process for hydrocracking feedstock oils such as vacuum gas oil to produce diesel and lighter distillate products. A first hydrogenation process is carried out in a main reactor with the feedstock and hydrogen flowing cocurrently down through a top section containing a layered system of hydrotreating and hydrocracking catalyst. The feedstock is substantially desulfurized and denitrified, the aromatics are at least partially saturated and cracked products are formed. The vapor and liquid are separated in a disengaging zone below the top section and the liquid flows down through a bottom section also containing a layered catalyst system countercurrent to make-up hydrogen flowing up. The vapor removed from the disengaging zone and the liquid bottoms are then further processed in a post treatment catalytic distillation reactor having an upper catalytic distillation section and a lower stripping section which may also contain a catalyst.

Abstract: High boiling hydrocarbon materials are hydrocracked in a multiple stage process having ebullating catalyst bed hydrogenation reactor stages in series. Between the hydrogenation reactors is an interstage separator/stripper to separate a vapor phase and to strip the liquid phase with hydrogen to produce a heavier, more concentrated liquid phase as the feed to the next ebullating bed reactor stage in the series. The feed to the second stage may be blended with an aromatic solvent and/or a portion of the high boiling hydrocarbon feedstock.