Patent application number | Description | Published |
20090008291 | Systems and Methods for Producing a Crude Product - Systems and methods for hydroprocessing a heavy oil feedstock with reduced heavy oil deposits, the system employs a plurality of contacting zones and separation zones zone under hydrocracking conditions 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, forming upgraded products of lower boiling hydrocarbons. In the separation 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 recycled back to the first contacting zone in the system, in an amount ranging between 3 to 50 wt. % of the heavy oil feedstock. | 01-08-2009 |
20090011931 | Highly Active Slurry Catalyst Composition - 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. | 01-08-2009 |
20090057193 | Process for upgrading heavy oil using a highly active slurry catalyst composition - 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. | 03-05-2009 |
20090057194 | Process For Upgrading Heavy Oil Using A Reactor WIth A Novel Reactor Separation System. - 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. | 03-05-2009 |
20090057195 | Systems and Methods for Producing a Crude Product - Systems and methods for hydroprocessing a heavy oil feedstock, the system employs a plurality of contacting zones and separation zones and a solvent deasphalting (SDA) unit for providing at least a portion of the heavy oil feedstock. The contacting zones operate under hydrocracking conditions, employing a slurry catalyst for upgrading the deasphalted oil, 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. | 03-05-2009 |
20090057201 | HYDROPROCESSING BULK CATALYST AND USES THEREOF - A hydroprocessing bulk catalyst is provided. A process to prepare hydroprocessing bulk catalysts is also provided. The hydroprocessing catalyst has the formula (M | 03-05-2009 |
20090134064 | REACTOR FOR USE IN UPGRADING HEAVY OIL - The instant invention relates to an upflow for upgrading heavy oil feed stock and a method for upgrading heavy oil feed stock employing an upflow reactor and with a slurry catalyst. In one embodiment, the upflow reactor is a liquid recirculating reactor, which is operated in manner corresponding to a dispersed bubble flow regime, which requires a high liquid to gas ratio. A dispersed bubble flow regime results in more even flow patterns, increasing the amount of liquid, i.e., heavy oil feed stock that can be upgraded in a single reactor. | 05-28-2009 |
20090159505 | HEAVY OIL UPGRADE PROCESS INCLUDING RECOVERY OF SPENT CATALYST - A process to upgrade heavy oil and convert the heavy oil into lower boiling hydrocarbon products is provided. The process employs a catalyst slurry comprising catalyst particles with an average particle size ranging from 1 to 20 microns. In the upgrade process, spent slurry catalyst in heavy oil is generated as an effluent stream, which is subsequently recovered/separated from the heavy oil via a filtration assembly. The filtration assembly has a least a filtration unit employing at least a membrane for separating heavy oil from the catalyst particles. Valuable metals can be recovered from catalyst particles for subsequent re-use in a catalyst synthesis unit, generating a fresh slurry catalyst. | 06-25-2009 |
20090163350 | HEAVY OIL UPGRADE PROCESS INCLUDING RECOVERY OF SPENT CATALYST - A process to upgrade heavy oil and convert the heavy oil into lower boiling hydrocarbon products is provided. The process employs a catalyst slurry comprising catalyst particles with an average particle size ranging from 1 to 20 microns. In the upgrade process, spent slurry catalyst in heavy oil is generated as an effluent stream, which is subsequently recovered/separated from the heavy oil via membrane filtration. In one embodiment, dynamic filtration is used for the separation of the heavy oil from the catalyst particles. Valuable metals can be recovered from catalyst particles for subsequent re-use in a catalyst synthesis unit, generating a fresh slurry catalyst. | 06-25-2009 |
20090200204 | Hydroprocessing Bulk Catalyst and Uses Thereof - A hydroprocessing catalyst is provided. The hydroprocessing catalyst has the formula (M | 08-13-2009 |
20100065471 | Systems and Methods for Producing a Crude Product - Systems and methods for hydroprocessing a heavy oil feedstock, the system employs a plurality of contacting zones and separation zones with at least some of the fresh slurry catalyst being supplied to at least a contacting zone other than the first contacting zone. The contacting zones operate under hydrocracking conditions, employing the slurry catalyst for upgrading the heavy oil feedstock, forming upgraded products of lower boiling boiling hydrocarbons. In the separation zones, upgraded products are removed overhead and optionally, further treated in an in-line hydrotreater. A least a portion of the non-volatile fractions recovered from the separation zones is recycled back to the first contacting zone in the system. | 03-18-2010 |
20100234212 | HYDROPROCESSING BULK CATALYST AND USES THEREOF - A hydroprocessing bulk catalyst is provided. A process to prepare hydroprocessing bulk catalysts is also provided. The hydroprocessing catalyst has the formula (M | 09-16-2010 |
20110017635 | Systems and Methods for Producing a Crude Product - A process for hydroprocessing heavy oil feedstock is disclosed. The process operates in once-through mode, employing 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. In the once-through upgrade system, little if any of the unconverted material and slurry catalyst mixture is recycled back to the system for further upgrading. The contacting zones operate under hydrocracking conditions, employing a slurry catalyst for upgrading the heavy oil feedstock. The slurry catalyst feed comprises an active metal catalyst having an average particle size of at least 1 micron in a hydrocarbon oil diluent, at a concentration of greater than 500 wppm of active metal catalyst to heavy oil feedstock. | 01-27-2011 |
20110017637 | Systems and Methods for Producing a Crude Product - A process for hydroprocessing heavy oil feedstock is disclosed. The process operates in once-through mode, employing a plurality of contacting zones and separation zones in sequential mode, parallel mode, or combinations thereof 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. In one embodiment, the effluent stream from the contacting zone is sent to a separation zone in series operating at a pressure drop of at most 100 psi from the contacting zone. In another embodiment, the effluent from a contacting zone to the next contacting zone in series for further upgrade, with the next contacting zone having a pressure drop of at most 100 psi, with the pressure drop is not due to a pressure reducing device as in the prior art. | 01-27-2011 |
20110017638 | Systems and Methods for Producing a Crude Product - 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. The plurality of contacting zones and separation zones are configured in a permutable fashion allowing the once-through process to be flexible operating in various modes: a sequential mode; a parallel mode; a combination of parallel and sequential mode; all online; some online and some on stand-by; some online and some off-line; a parallel mode with the effluent stream from the contacting zone being sent to at least a separation zone in series with the contacting zone; a parallel mode with the effluent stream from the contacting zone being combined with an effluent stream from at least another contacting zone and sent to the separation zone; and combinations thereof. | 01-27-2011 |
20110210045 | Systems and Methods for Producing a Crude Product - Systems and methods 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. In one embodiment, water and/or steam being injected into at least a contacting zone. The contacting zones operate under hydrocracking conditions, employing at least a slurry catalyst. In one embodiment, at least a portion of the non-volatile fractions recovered from at least one of the separation zones is recycled back to at least a contacting zone (“recycled mode”). In one embodiment, the number of separation zones is less than the number of contacting zones in the system. In the separation zones, upgraded products are removed overhead and optionally treated in an in-line hydrotreater; and the bottom stream is optionally further treated in a fractionator. | 09-01-2011 |