Process for converting a heavy hydrocarbon feedstock with initial boiling point of at least 300 C. comprising: a) hydroconverting at least part of said feedstock; b) separating the effluent from stage a) to obtain light and heavy liquid fractions; c) at least two stages of deasphalting in series at least part of the heavy liquid fraction originating from stage b), allowing to separate at least one fraction of asphalt, at least one fraction of heavy deasphalted oil (heavy DAO) and at least one fraction of light deasphalted oil (light DAO), at least one deasphalting stage being carried out using a mixture of at least one polar solvent and at least one apolar solvent, said deasphalting stages being under subcritical conditions of the mixture of solvents; d) recycling at least part of said heavy deasphalted oil cut from stage c) upstream of hydroconverting a) and/or of the inlet of separating b).

Process for converting a heavy hydrocarbon feedstock with initial boiling point of at least 300 C. comprising: a) hydroconverting at least part of said feedstock; b) separating the effluent from stage a) to obtain light and heavy liquid fractions; c) at least two stages of deasphalting in series at least part of the heavy liquid fraction originating from stage b), allowing to separate at least one fraction of asphalt, at least one fraction of heavy deasphalted oil (heavy DAO) and at least one fraction of light deasphalted oil (light DAO), at least one deasphalting stage being carried out using a mixture of at least one polar solvent and at least one apolar solvent, said deasphalting stages being under subcritical conditions of the mixture of solvents; d) recycling at least part of said heavy deasphalted oil cut from stage c) upstream of hydroconverting a) and/or of the inlet of separating b).

Systems and methods are provided for upgrading blends of catalytic slurry oil and steam cracker tar to form fuel and/or fuel blending products. The steam cracker tar can optionally correspond to a fluxed steam cracker tar that includes steam cracker gas oil and/or another type of gas oil or other diluent. It has been unexpectedly discovered that blends of catalytic slurry oil and steam cracker tar can be hydroprocessed under fixed bed conditions while reducing or minimizing the amount of coke formation on the hydroprocessing catalyst and/or while reducing or minimizing plugging of the fixed bed, as would be conventionally expected during fixed bed processing of a feed containing a substantial portion of steam cracker tar. Additionally or alternately, it has been unexpectedly discovered that formation of coke fines within steam cracker tar can be reduced or minimized by blending steam cracker tar with catalytic slurry oil. This can facilitate fixed bed processing of the steam cracker tar, as after removal of particles the blend of catalytic slurry oil and steam cracker tar can maintain a reduced or minimized level of coke fines and/or other particles.

Systems and methods are provided for upgrading blends of catalytic slurry oil and steam cracker tar to form fuel and/or fuel blending products. The steam cracker tar can optionally correspond to a fluxed steam cracker tar that includes steam cracker gas oil and/or another type of gas oil or other diluent. It has been unexpectedly discovered that blends of catalytic slurry oil and steam cracker tar can be hydroprocessed under fixed bed conditions while reducing or minimizing the amount of coke formation on the hydroprocessing catalyst and/or while reducing or minimizing plugging of the fixed bed, as would be conventionally expected during fixed bed processing of a feed containing a substantial portion of steam cracker tar. Additionally or alternately, it has been unexpectedly discovered that formation of coke fines within steam cracker tar can be reduced or minimized by blending steam cracker tar with catalytic slurry oil. This can facilitate fixed bed processing of the steam cracker tar, as after removal of particles the blend of catalytic slurry oil and steam cracker tar can maintain a reduced or minimized level of coke fines and/or other particles.

A hydrogenation method and distillate two-phase hydrogenation reactor in which the size of an upper space of the reactor is greater than that of a lower catalyst bed part. The reactor comprises 2 to 4 catalyst beds. An inner component for gas replenishment and for stripping a liquid-phase stream containing impurities is arranged between at least one adjacent catalyst bed and comprises a separator plate and exhaust pipes. The separator plate is provided with multiple downcomer through holes. The separator plate is connected with a plurality of exhaust pipes. The exhaust pipes are vertically arranged above the separator plate. The top parts of the exhaust pipes are in contact with the lower part of the upper catalyst bed.

A hydrogenation method and distillate two-phase hydrogenation reactor in which the size of an upper space of the reactor is greater than that of a lower catalyst bed part. The reactor comprises 2 to 4 catalyst beds. An inner component for gas replenishment and for stripping a liquid-phase stream containing impurities is arranged between at least one adjacent catalyst bed and comprises a separator plate and exhaust pipes. The separator plate is provided with multiple downcomer through holes. The separator plate is connected with a plurality of exhaust pipes. The exhaust pipes are vertically arranged above the separator plate. The top parts of the exhaust pipes are in contact with the lower part of the upper catalyst bed.

The specification discloses a highly macroporous catalyst for hydroprocessing and hydroconversion of heavy hydrocarbon feedstocks. The high macroporosity catalyst incudes an inorganic oxide, molybdenum, and nickel components. It has a pore structure such that at least 18% of its total pore volume is in pores of a diameter greater than 5,000 angstroms and at least 25% of its total pore volume is in pores of a diameter greater than 1,000 angstroms. Preferably, the pore structure is bimodal. The catalyst is made by co-mulling the catalytic components with a high molecular weight polyacrylamide followed by forming the co-mulled mixture into a particle or an extrudate. The particle or extrudate is dried and calcined under controlled calcination temperature conditions to yield a calcined particle or extrudate of the high macroporosity catalyst composition.

The specification discloses a highly macroporous catalyst for hydroprocessing and hydroconversion of heavy hydrocarbon feedstocks. The high macroporosity catalyst incudes an inorganic oxide, molybdenum, and nickel components. It has a pore structure such that at least 18% of its total pore volume is in pores of a diameter greater than 5,000 angstroms and at least 25% of its total pore volume is in pores of a diameter greater than 1,000 angstroms. Preferably, the pore structure is bimodal. The catalyst is made by co-mulling the catalytic components with a high molecular weight polyacrylamide followed by forming the co-mulled mixture into a particle or an extrudate. The particle or extrudate is dried and calcined under controlled calcination temperature conditions to yield a calcined particle or extrudate of the high macroporosity catalyst composition.

A hydroconversion process of a heavy oil feedstock including (a) preparing a first conditioned feedstock (103) by blending heavy oil feedstock (101) with an organic chemical compound (102) containing 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 the first conditioned feedstock in a manner such that a colloidal or molecular catalyst is formed when it reacts with sulfur; (c) heating the second conditioned feedstock in at least a preheating device; (d) introducing the heated second conditioned feedstock (106) into at least one hybrid ebullated-entrained bed reactor containing a hydroconversion porous supported catalyst and operating the 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).

A hydroconversion process of a heavy oil feedstock including (a) preparing a first conditioned feedstock (103) by blending heavy oil feedstock (101) with an organic chemical compound (102) containing 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 the first conditioned feedstock in a manner such that a colloidal or molecular catalyst is formed when it reacts with sulfur; (c) heating the second conditioned feedstock in at least a preheating device; (d) introducing the heated second conditioned feedstock (106) into at least one hybrid ebullated-entrained bed reactor containing a hydroconversion porous supported catalyst and operating the 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).