SYSTEMS AND METHODS FOR PRODUCING A CRUDE PRODUCT

摘要

Systems and methods for hydroprocessing heavy oil feedstocks are disclosed. The process employs a plurality of contacting zones operating under hydrocracking conditions and at least one separation zone to convert at least a portion of the heavy oil feedstock to lower boiling hydrocarbons, forming upgraded products. The first contacting zone consists of one or more ebullated bed reactors. Most of the metals in the heavy oil feed are converted and adsorbed on the ebullated bed catalyst and can be removed during catalyst replacement. The second contacting zone consists of one or more slurry phase reactors. The slurry phase reactor can be operated at higher temperature to achieve higher conversion.

主权项

1. A process for upgrading a heavy oil feedstock, the process comprising:
(a) contacting a heavy oil feedstock and a hydrogen-containing gas with at least one supported catalyst under hydrocracking conditions in a first contacting zone consisting of one or more ebullated bed reactors to convert at least a portion of the heavy oil feedstock to upgraded products comprising lower boiling hydrocarbons and form a first effluent comprising the upgraded products, the hydrogen-containing gas, and an unconverted portion of the heavy oil feedstock; (b) sending the first effluent to a first separation zone, whereby the upgraded products are separated with the hydrogen-containing gas as an overhead stream, and the unconverted portion of the heavy oil feedstock is separated as a first non-volatile stream; (c) contacting at least a portion of the first non-volatile stream with a slurry catalyst and an additional hydrogen-containing gas feed under hydrocracking conditions in a second contacting zone consisting of one or more slurry phase reactors to convert at least a portion of the unconverted portion of the heavy oil feedstock to lower boiling hydrocarbons to additional upgraded products comprising lower boiling hydrocarbons and form a second effluent comprising additional upgraded products, additional hydrogen-containing gas, the slurry catalyst and an unconverted portion of the heavy oil feedstock; and (d) sending the second effluent to a second separation zone, whereby the additional upgraded products are removed with the additional hydrogen-containing gas as an overhead stream, and the slurry catalyst and the unconverted heavy oil feedstock are removed as a second non-volatile stream.