An integrated catalytic process for upgrading a feed oil comprises the steps of introducing a catalyst precursor solution to a supercritical water (SCW) process unit, where the catalyst precursor solution comprises a catalyst precursor dissolved in liquid water; introducing a feed water to the SCW process unit; introducing the feed oil to the SCW process unit; treating the catalyst precursor solution, the feed water, and the feed oil in the SCW process unit to produce a SCW effluent, where the catalyst precursor is converted to catalyst particles; separating the SCW effluent in a separator unit to produce a SCW distillate product, a SCW residue product; introducing the SCW residue product to a slurry hydroprocessing unit, where the SCW residue product comprises the catalyst particles; treating the SCW residue product and the hydrogen gas in the slurry hydroprocessing unit to produce a product gas stream and an upgraded oil product.

A process for treating a feed oil in the presence of in situ produced catalyst particles comprising the steps of mixing the supercritical water feed with the pressurized precursor solution in a catalyst mixer to produce a supercritical water stream; withdrawing the supercritical water stream to a process line, where the catalyst precursor is converted to catalyst particles in the process line; mixing the supercritical water stream and the hot oil stream in the mixer to produce a mixed stream; introducing the mixed stream to a reactor; processing the heavy oil in the reactor in the presence of the catalyst particles to produce a reactor effluent; reducing a temperature of the reactor effluent to produce a cooled effluent; reducing a pressure of the cooled effluent to produce a depressurized effluent; and separating the depressurized effluent to produce a product gas, a product oil, and a product water.

A process for treating a feed oil in the presence of in situ produced catalyst particles comprising the steps of mixing the supercritical water feed with the pressurized precursor solution in a catalyst mixer to produce a supercritical water stream; withdrawing the supercritical water stream to a process line, where the catalyst precursor is converted to catalyst particles in the process line; mixing the supercritical water stream and the hot oil stream in the mixer to produce a mixed stream; introducing the mixed stream to a reactor; processing the heavy oil in the reactor in the presence of the catalyst particles to produce a reactor effluent; reducing a temperature of the reactor effluent to produce a cooled effluent; reducing a pressure of the cooled effluent to produce a depressurized effluent; and separating the depressurized effluent to produce a product gas, a product oil, and a product water.

A process of producing a hydrocracking product in a slurry hydrocracking reactor. A pyrolysis oil, a hydrocarbon feedstock, and a hydrocracking catalyst is provided. The pyrolysis oil is combined with the hydrocarbon feedstock and the hydrocracking catalyst, the pyrolysis oil being maintained at a temperature of less than 100° C. until the pyrolysis oil contacts both the hydrocarbon feedstock and the hydrocracking catalyst. The hydrocarbon feedstock and the pyrolysis oil are hydrocracked in the slurry hydrocracking reactor in the presence of the hydrocracking catalyst and hydrogen gas. A fuel precursor obtainable by the process.

A process of producing a hydrocracking product in a slurry hydrocracking reactor. A pyrolysis oil, a hydrocarbon feedstock, and a hydrocracking catalyst is provided. The pyrolysis oil is combined with the hydrocarbon feedstock and the hydrocracking catalyst, the pyrolysis oil being maintained at a temperature of less than 100° C. until the pyrolysis oil contacts both the hydrocarbon feedstock and the hydrocracking catalyst. The hydrocarbon feedstock and the pyrolysis oil are hydrocracked in the slurry hydrocracking reactor in the presence of the hydrocracking catalyst and hydrogen gas. A fuel precursor obtainable by the process.

Systems and methods are provided for partial upgrading of heavy hydrocarbon feeds to meet transport specifications, such as pipeline transport specifications. The systems and methods can allow for one or more types of improvement in heavy hydrocarbon processing prior to transport. In some aspects, the systems and methods can produce a partially upgraded heavy hydrocarbon product that satisfies one or more transport specifications while incorporating an increased amount of vacuum gas oil and a reduced amount of pitch into the partially upgraded heavy hydrocarbon product. In other aspects, the systems and methods can allow for increased incorporation of hydrocarbons into the fraction upgraded for transport, thereby reducing or minimizing the amount of hydrocarbons requiring an alternative method of disposal or transport. In still other aspects, the systems and methods can allow for reduced incorporation of external streams into the final product for transport while still satisfying one or more target properties.

An upgraded crude composition is provided, along with systems and methods for making such a composition. The upgraded crude composition can include an unexpectedly high percentage of vacuum gas oil boiling range components while having a reduce or minimized amount of components boiling above 593° C. (1100° F.). In some aspects, based in part on the hydroprocessing used to form the upgraded crude composition, the composition can include unexpectedly high contents of nitrogen. Still other unexpected features of the composition can include, but are not limited to, an unexpectedly high nitrogen content in the naphtha fraction; and an unexpected vacuum gas oil fraction including an unexpectedly high content of polynuclear aromatics, an unexpectedly high content of waxy, paraffinic compounds, and/or an unexpectedly high content of n-pentane asphaltenes.

Systems and methods are provided for partial upgrading of heavy hydrocarbon feeds to meet transport specifications, such as pipeline transport specifications. The systems and methods can allow for one or more types of improvement in heavy hydrocarbon processing prior to transport. In some aspects, the systems and methods can produce a partially upgraded heavy hydrocarbon product that satisfies one or more transport specifications while incorporating an increased amount of vacuum gas oil and a reduced amount of pitch into the partially upgraded heavy hydrocarbon product. In other aspects, the systems and methods can allow for increased incorporation of hydrocarbons into the fraction upgraded for transport, thereby reducing or minimizing the amount of hydrocarbons requiring an alternative method of disposal or transport. In still other aspects, the systems and methods can allow for reduced incorporation of external streams into the final product for transport while still satisfying one or more target properties.

Systems and methods are provided for partial upgrading of heavy hydrocarbon feeds to meet transport specifications, such as pipeline transport specifications. The systems and methods can allow for one or more types of improvement in heavy hydrocarbon processing prior to transport. In some aspects, the systems and methods can produce a partially upgraded heavy hydrocarbon product that satisfies one or more transport specifications while incorporating an increased amount of vacuum gas oil and a reduced amount of pitch into the partially upgraded heavy hydrocarbon product. In other aspects, the systems and methods can allow for increased incorporation of hydrocarbons into the fraction upgraded for transport, thereby reducing or minimizing the amount of hydrocarbons requiring an alternative method of disposal or transport. In still other aspects, the systems and methods can allow for reduced incorporation of external streams into the final product for transport while still satisfying one or more target properties.

Systems and methods are provided for performing slurry hydroconversion of feeds that include substantial amounts of 1050° F+ (566° C+) components. The productivity of the slurry hydroconversion reaction is improved by recycling slurry hydroconversion pitch or bottoms back to the slurry hydroprocessing reaction system. The mass flow rate of the recycle stream can correspond to 50% or more of the mass flow rate of the fresh feed to the reaction system, and the recycle stream can include more than 50 wt % of 566° C+ components. It has been discovered that using a substantial recycle stream composed of a majority of unconverted 566° C+ bottoms can increase the productivity of the slurry hydroprocessing reaction system when operating at a net conversion relative to 524° C (975° F) of less than 90 wt %. Additionally, by using a recycle stream composed of a majority of 566° C+ components, the amount of lower boiling components (in the heavy hydrocarbon feed and/or in the recycle stream) that are exposed multiple times to the slurry hydroprocessing environment is reduced or minimized This can allow for formation of slurry hydroconversion products with increased amounts of vacuum gas oil boiling range components.