An ebullated bed hydroprocessing system is upgraded using a dual catalyst system that includes a heterogeneous catalyst and dispersed metal sulfide particles to increase rate of production of converted products. The rate of production is achieved by increasing reactor severity, including increasing the operating temperature and at least one of throughput or conversion. The dual catalyst system permits increased reactor severity and provides increased production of converted products without a significant increase in equipment fouling and/or sediment production. In some cases, the rate of production of conversion products can be achieved while decreasing equipment fouling and/or sediment production.

An ebullated bed hydroprocessing system is upgraded using a dual catalyst system that includes a heterogeneous catalyst and dispersed metal sulfide particles to hydroprocess opportunity feedstocks (i.e., lower quality heavy oils or lower quality feedstock blends) while maintaining or increasing the rate of production of converted products. The dual catalyst system improves the ability of the upgraded ebullated bed hydroprocessing system to accommodate and withstand negative effects of periodic use of opportunity feedstocks (e.g., without significantly increasing equipment fouling and/or sediment production). In some cases, an upgraded ebullated bed reactor using the dual catalyst system can hydroprocess opportunity feedstocks while decreasing equipment fouling and/or sediment production.

An ebullated bed hydroprocessing system is upgraded using a dual catalyst system that includes a heterogeneous catalyst and dispersed metal sulfide particles to hydroprocess opportunity feedstocks (i.e., lower quality heavy oils or lower quality feedstock blends) while maintaining or increasing the rate of production of converted products. The dual catalyst system improves the ability of the upgraded ebullated bed hydroprocessing system to accommodate and withstand negative effects of periodic use of opportunity feedstocks (e.g., without significantly increasing equipment fouling and/or sediment production). In some cases, an upgraded ebullated bed reactor using the dual catalyst system can hydroprocess opportunity feedstocks while decreasing equipment fouling and/or sediment production.

Heavy hydrocarbon feedstocks including crude oil are upgraded under relatively low pressure conditions in an ebullated-bed hydroprocessing zone to remove the heteroatom containing hydrocarbons. Catalyst particles are regenerated/rejuvenated and recycled back to the ebullated-bed hydroprocessing reaction zone. The regeneration/rejuvenation is effective to restore catalytic activity while minimizing leaching of the active components(s).

Heavy hydrocarbon feedstocks including crude oil are upgraded under relatively low pressure conditions in an ebullated-bed hydroprocessing zone to remove the heteroatom containing hydrocarbons. Catalyst particles are regenerated/rejuvenated and recycled back to the ebullated-bed hydroprocessing reaction zone. The regeneration/rejuvenation is effective to restore catalytic activity while minimizing leaching of the active components(s).

The specification discloses a highly macroporous catalyst for hydroprocessing and hydroconversion of heavy hydrocarbon feedstocks. The high macroporosity catalyst includes 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 present invention relates to a three-phase reactor for the reaction of a hydrocarbon feedstock with hydrogen and to a hydroconversion process, for example of H-Oil™ type, employing it, comprising a chamber with an upper end and a gas/liquid separation device comprising: a recycle cup, above the catalytic reaction zone and delimiting, with the upper end, a recycle zone, comprising a cylindrical upper part extended by a lower part of decreasing section and of variable angle of inclination, provided with vertical pipes for the passage of a gas/liquid mixture originating from a catalytic reaction zone, and having a fixed angle of inclination β of between 50° and 85° with respect to the axis of the cylindrical part, a pipe for recycle of the liquid at the apex of the lower part, in fluidic communication with the lower end of the chamber by recirculation means.

An ebullated bed hydroprocessing system is upgraded using a dual catalyst system that includes a heterogeneous catalyst and dispersed metal sulfide particles, which permits recycling of vacuum bottoms without recycle buildup of asphaltenes. The dual catalyst system more effectively converts asphaltenes in the ebullated bed reactor and increases asphaltene conversion by an amount that at least offsets higher asphaltene concentration resulting from recycling of vacuum bottoms. In this way, there is no recycle buildup of asphaltenes in upgraded ebullated bed reactor notwithstanding recycling of vacuum bottoms. In addition, residual dispersed metal sulfide catalyst particles in the vacuum bottoms can maintain or increase the concentration of the dispersed metal sulfide catalyst in the ebullated bed reactor.

In the hydroconversion processes of heavy hydrocarbon oils, in which the hydrogen is introduced at the reactor base by bubbling, the low diffusion rate of hydrogen, from the gas phase to the reaction liquid, limits the degree of conversion. The process circumvents the obstacle of the limited amount of reactant hydrogen by using a slurry bubble column reactor which reduces the formation of light hydrocarbon products, and therefore the hydrogen required for the hydroconversion, allowing to operate at full conversion.

A skid-mounted depressurizing system includes a main process module, a mechanical control system, a thermodynamic balance system and an intelligent control system. The main process module includes multiple main process pipelines, each of the multiple main process pipelines is provided with a pressure reducing valve set. During depressurization, process medium enters at least one of the multiple main process pipelines, the mechanical control system outputs a torque according to the control instruction of the intelligent control system to control each valve of the multiple main process pipelines to perform an action switch and an opening degree adjustment, the thermodynamic balance system is configured to provide the medium of different properties to the multiple main process pipelines according to the control instruction of the intelligent control system to control temperature, pressure, cleanliness degree and/or sealing degree of the main process module.