The present invention relates to a process for the hydroconversion of a feedstock including a plastic fraction (102), notably derived from plastic waste, and a heavy hydrocarbon fraction (101), notably a heavy hydrocarbon fraction containing a portion of at least 50% by weight, preferably at least 80% by weight, having a boiling temperature of at least 300 C. Hydroconversion involves one or more ebullated bed or hybrid ebullated-entrained bed reactors (20), and preferably two successive hydroconversion steps, in order to produce higher-quality, lower-boiling materials, for example for fuel production purposes, while at the same time allowing waste plastics to be upgraded.

The present invention relates to a process for the hydroconversion of a feedstock including a plastic fraction (102), notably derived from plastic waste, and a heavy hydrocarbon fraction (101), notably a heavy hydrocarbon fraction containing a portion of at least 50% by weight, preferably at least 80% by weight, having a boiling temperature of at least 300 C. Hydroconversion involves one or more ebullated bed or hybrid ebullated-entrained bed reactors (20), and preferably two successive hydroconversion steps, in order to produce higher-quality, lower-boiling materials, for example for fuel production purposes, while at the same time allowing waste plastics to be upgraded.

The invention relates to a composition formed of bitumen bases which comprises at least from 70% to 99% by weight of at least one bitumen base having a penetrability at 25 C. of less than or equal to 220.10-1 mm and a softening point of greater than or equal to 35 C. and from 1% to 30% by weight of at least one slurry residue resulting from a slurry-phase hydroconversion process. The slurry residue may have a penetrability at 25 C. of less than or equal to 50.10-1 mm and a softening point of greater than or equal to 50 C. Embodiments of the invention make it possible to upgrade a final vacuum residue slurry for use in the manufacture of a road bitumen.

The invention relates to a composition formed of bitumen bases which comprises at least from 70% to 99% by weight of at least one bitumen base having a penetrability at 25 C. of less than or equal to 220.10-1 mm and a softening point of greater than or equal to 35 C. and from 1% to 30% by weight of at least one slurry residue resulting from a slurry-phase hydroconversion process. The slurry residue may have a penetrability at 25 C. of less than or equal to 50.10-1 mm and a softening point of greater than or equal to 50 C. Embodiments of the invention make it possible to upgrade a final vacuum residue slurry for use in the manufacture of a road bitumen.

Improved yields of fuels and/or lubricants from a resid or other heavy oil feed can be achieved using slurry hydroconversion to convert at least about 90 wt % of the feed. The converted portion of the feed can then be passed into one or more hydroprocessing stages. An initial processing stage can be a hydrotreatment stage for additional removal of contaminants and for passivation of high activity functional groups that may be created during slurry hydroconversion. The hydrotreatment effluent can then be fractionated to separate naphtha boiling range fractions from distillate fuel boiling range fractions and lubricant boiling range fractions. At least the lubricant boiling range fraction can then be hydrocracked to improve the viscosity properties. The hydrocracking effluent can also be dewaxed to improve the cold flow properties. The hydrocracked and/or dewaxed product can then be optionally hydrofinished.

Improved yields of fuels and/or lubricants from a resid or other heavy oil feed can be achieved using slurry hydroconversion to convert at least about 90 wt % of the feed. The converted portion of the feed can then be passed into one or more hydroprocessing stages. An initial processing stage can be a hydrotreatment stage for additional removal of contaminants and for passivation of high activity functional groups that may be created during slurry hydroconversion. The hydrotreatment effluent can then be fractionated to separate naphtha boiling range fractions from distillate fuel boiling range fractions and lubricant boiling range fractions. At least the lubricant boiling range fraction can then be hydrocracked to improve the viscosity properties. The hydrocracking effluent can also be dewaxed to improve the cold flow properties. The hydrocracked and/or dewaxed product can then be optionally hydrofinished.

A hydroprocessing system involves introducing heavy oil and in situ formed metal sulfide catalyst particles, or a catalyst precursor capable of forming metal sulfide catalyst particles in situ within the heavy oil, into a hydroprocessing reactor. The metal sulfide catalyst particles are formed in situ by 1) premixing a catalyst precursor with a hydrocarbon diluent to form a precursor mixture, 2) mixing the precursor mixture with heavy oil to form a conditioned feedstock, and 3) heating the conditioned feedstock to decompose the catalyst precursor and cause or allow metal from the precursor to react with sulfur in the heavy oil to form the metal sulfide catalyst particles in situ in the heavy oil. The in situ formed metal sulfide catalyst particles catalyze beneficial upgrading reactions between the heavy oil and hydrogen and eliminates or reduces formation of coke precursors and sediment.

A hydroprocessing system involves introducing heavy oil and in situ formed metal sulfide catalyst particles, or a catalyst precursor capable of forming metal sulfide catalyst particles in situ within the heavy oil, into a hydroprocessing reactor. The metal sulfide catalyst particles are formed in situ by 1) premixing a catalyst precursor with a hydrocarbon diluent to form a precursor mixture, 2) mixing the precursor mixture with heavy oil to form a conditioned feedstock, and 3) heating the conditioned feedstock to decompose the catalyst precursor and cause or allow metal from the precursor to react with sulfur in the heavy oil to form the metal sulfide catalyst particles in situ in the heavy oil. The in situ formed metal sulfide catalyst particles catalyze beneficial upgrading reactions between the heavy oil and hydrogen and eliminates or reduces formation of coke precursors and sediment.

Systems and methods are provided for sequential slurry hydroconversion of heavy oil feedstocks. One or more low pressure slurry hydroconversion stages can be used to perform a majority of the conversion of a heavy oil feedstock. The bottoms from the low pressure stages can then be slurry hydroconverted in one or more high pressure stages to further convert the feedstock.

Systems and methods are provided for sequential slurry hydroconversion of heavy oil feedstocks. One or more low pressure slurry hydroconversion stages can be used to perform a majority of the conversion of a heavy oil feedstock. The bottoms from the low pressure stages can then be slurry hydroconverted in one or more high pressure stages to further convert the feedstock.