The present invention relates to a slurry hydroconversion process of a heavy oil feedstock comprising: (a) preparing a first conditioned feedstock (103) by blending said heavy oil feedstock (101) with an organic chemical compound (102) comprising at least one carboxylic acid function and/or at least one ester function and/or an acid anhydride function; (b) preparing a second conditioned feedstock (105) by mixing a catalyst precursor composition (104) with said first conditioned feedstock so that a colloidal or molecular catalyst is formed when it reacts with sulfur; (c) heating the second conditioned feedstock in at least one preheating device; (d) introducing the heated second conditioned feedstock (106) into at least one slurry bed reactor and operating said slurry bed reactor in the presence of hydrogen and at hydroconversion conditions to produce an upgraded material (107), the colloidal or molecular catalyst being formed during step (c) and/or (d).

The present invention is related to the application of solid polymers or copolymers prepared from monomers having in their structure a polycyclic aromatic ring, an aromatic ring of the type of naphthalene, or polyesters, polyethers, polyamides or polyvynil derivatives having naphthalene units in their structure, in the hydrotreatment or hydrocracking of heavy hydrocarbons, such as heavy or extra-heavy crude oils or residues from the distillation of petroleum; these polymers or copolymers may be supported, anchored or in a physical mixture with metallic oxides such as alumina, silica, titania or kaolin, and they have an application as heterogeneous hydrogen donors in reactions of hydrotreatment or hydrocracking of heavy or extra-heavy crude oils, residues from the distillation of petroleum and cuts and streams deived from this distillation. These solid polymers or copolymers operate in the presence of hydrogen or methane-rich gas. These hydrogen donor polymers, being solid, may be recovered from the reaction mixture to be reused and have a thermal stability that allows for their use in reactions at temperatures above 450 C. These heterogeneous hydrogen donors improve the physical properties of crude oils, such as API gravity, viscosity, and distillates yield, inhibiting the formation of coke.

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.

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.

A hydrocracking system is upgraded by modifying an existing ebullated bed initially utilizing a supported ebullated bed catalyst to thereafter utilize a dual catalyst system that includes metal sulfide catalyst particles and supported ebullated bed catalyst. The upgraded hydrocracking system achieves at least one of: (1) hydroprocess lower quality heavy oil; (2) increase conversion of higher boiling hydrocarbons that boil at 524 C. (975 F.) or higher; (3) reduce the concentration of supported ebullated bed catalyst required to operate an ebullated bed reactor at a given conversion level; and/or (4) proportionally convert the asphaltene fraction in heavy oil at the same conversion level as the heavy oil as a whole. The metal sulfide catalyst may include colloidal or molecular catalyst particles less than 1 micron in size and formed in situ within the heavy oil using a catalyst precursor well-mixed within the heavy oil and decomposed to form catalyst particles.

A hydrocracking system is upgraded by modifying an existing ebullated bed initially utilizing a supported ebullated bed catalyst to thereafter utilize a dual catalyst system that includes metal sulfide catalyst particles and supported ebullated bed catalyst. The upgraded hydrocracking system achieves at least one of: (1) hydroprocess lower quality heavy oil; (2) increase conversion of higher boiling hydrocarbons that boil at 524 C. (975 F.) or higher; (3) reduce the concentration of supported ebullated bed catalyst required to operate an ebullated bed reactor at a given conversion level; and/or (4) proportionally convert the asphaltene fraction in heavy oil at the same conversion level as the heavy oil as a whole. The metal sulfide catalyst may include colloidal or molecular catalyst particles less than 1 micron in size and formed in situ within the heavy oil using a catalyst precursor well-mixed within the heavy oil and decomposed to form catalyst particles.

An oil-coal co-hydrotreating processing includes the following steps: pulverized coal, vacuum residue and recycle oil are mixed to prepare coal slurry. After mixed with hydrogen, catalyst and additive, oil-coal slurry is preheated into a slurry bed reactor with high reacting pressure for thermal cracking and hydrogenation reaction. After reaction, all the products go into the hot high pressure separator for separation of solid from the bottom and gas from the top. The gas obtained goes into the fixed bed reactor for further hydrocracking or refining, and the distillate obtained enter the fractionating tower. The vacuum gas oil from the bottom of fractionating tower is taken as recycle oil piped to the oil-coal slurry mixing device as solvent.

Systems and methods are provided for use of coking and slurry hydroconversion for conversion of heavy oil feeds. The combination of coking and slurry hydroconversion allows for improved yield of liquid products while reducing or minimizing the consumption of hydrogen in slurry hydroconversion reaction stages. Coking and slurry hydroconversion can be combined by segregating feeds based on Conradson carbon residue. Alternatively, slurry hydroconversion can be used to process unconverted bottoms from a coking process.

Systems and methods are provided for use of coking and slurry hydroconversion for conversion of heavy oil feeds. The combination of coking and slurry hydroconversion allows for improved yield of liquid products while reducing or minimizing the consumption of hydrogen in slurry hydroconversion reaction stages. Coking and slurry hydroconversion can be combined by segregating feeds based on Conradson carbon residue. Alternatively, slurry hydroconversion can be used to process unconverted bottoms from a coking process.

Systems and methods are provided for processing a heavy oil feed, such as an atmospheric or vacuum resid, using a combination of solvent assisted hydroprocessing and slurry hydroconversion of a heavy oil feed. The systems and methods allow for conversion and desulfurization/denitrogenation of a feed to form fuels and gas oil (or lubricant base oil) boiling range fractions while reducing the portion of the feed that is exposed to the high severity conditions present in slurry hydroconversion.