This invention relates to a catalyst system comprising (a) at least one layer of a first catalyst comprising a dehydrogenation active metal on a solid support; (b) at least one layer of a second catalyst comprising a metal oxide; and (c) at least one layer of a third catalyst comprising a transition metal on an inorganic support; wherein the at least one layer of a second catalyst is sandwiched between the at least one layer of a first catalyst and the at least one layer of a third catalyst; and a process comprising contacting a hydrocarbon feed with the catalyst system.

The present disclosure provides a hydrocracking catalyst, a method for preparing the same and a use of the same, and a method for hydrocracking catalytic diesel oil. The catalyst comprises a support, an active metal component, and carbon, wherein, based on the total weight of the catalyst, the content of the support is 60 to 90 wt %, the content of the active metal component calculated in metal oxides is 15 to 40 wt %, and the content of carbon calculated in C element is 1 to 5 wt %; measured with an infrared acidimetric estimation method, the acid properties of the hydrocracking catalyst are: the total infrared acid amount is 0.4 to 0.8 mmol/g, wherein, the infrared acid amount of strong acid with desorption temperature greater than 350 C. is 0.08 mmol/g or lower, and the ratio of the total infrared acid amount to the infrared acid amount of strong acid with desorption temperature greater than 350 C. is 5 to 50.

The present disclosure provides a hydrocracking catalyst, a method for preparing the same and a use of the same, and a method for hydrocracking catalytic diesel oil. The catalyst comprises a support, an active metal component, and carbon, wherein, based on the total weight of the catalyst, the content of the support is 60 to 90 wt %, the content of the active metal component calculated in metal oxides is 15 to 40 wt %, and the content of carbon calculated in C element is 1 to 5 wt %; measured with an infrared acidimetric estimation method, the acid properties of the hydrocracking catalyst are: the total infrared acid amount is 0.4 to 0.8 mmol/g, wherein, the infrared acid amount of strong acid with desorption temperature greater than 350 C. is 0.08 mmol/g or lower, and the ratio of the total infrared acid amount to the infrared acid amount of strong acid with desorption temperature greater than 350 C. is 5 to 50.

Embodiments herein relate to a process flow scheme for the processing of gas oils and especially reactive gas oils produced by thermal cracking of residua using a split flow concept. The split flow concepts disclosed allow optimization of the hydrocracking reactor severities and thereby take advantage of the different reactivities of thermally cracked gas oils versus those of virgin gas oils. This results in a lower cost facility for producing base oils as well as diesel, kerosene and gasoline fuels while achieving high conversions and high catalyst lives.

Embodiments herein relate to a process flow scheme for the processing of gas oils and especially reactive gas oils produced by thermal cracking of residua using a split flow concept. The split flow concepts disclosed allow optimization of the hydrocracking reactor severities and thereby take advantage of the different reactivities of thermally cracked gas oils versus those of virgin gas oils. This results in a lower cost facility for producing base oils as well as diesel, kerosene and gasoline fuels while achieving high conversions and high catalyst lives.

Supercritical upgrading reactors and reactor systems are provided for upgrading a petroleum-based composition using one or more purging fluid inlets to prevent plugging of the catalyst layer in the reactor. Processes for upgrading petroleum-based compositions by utilizing a reactor having at least one purging fluid inlet are also provided.

Supercritical upgrading reactors and reactor systems are provided for upgrading a petroleum-based composition using one or more purging fluid inlets to prevent plugging of the catalyst layer in the reactor. Processes for upgrading petroleum-based compositions by utilizing a reactor having at least one purging fluid inlet are also provided.

A process for upgrading vacuum residuum and vacuum gas oil hydrocarbons is disclosed. The process may include: contacting a heavy distillate hydrocarbon fraction and hydrogen with a zeolite selective hydrocracking catalyst in a first ebullated bed hydrocracking reaction zone to convert at least a portion of the vacuum gas oil to lighter hydrocarbons. Contacting a residuum hydrocarbon fraction and hydrogen with a non-zeolite base metal hydroconversion catalyst in a second ebullated bed hydroconversion reaction zone may produce a vapor stream containing unconverted hydrogen, acid gases and volatilized hydrocarbons which may be fed along with the vacuum gas oil in the first ebullated bed hydrocracking zone.

A process for upgrading vacuum residuum and vacuum gas oil hydrocarbons is disclosed. The process may include: contacting a heavy distillate hydrocarbon fraction and hydrogen with a zeolite selective hydrocracking catalyst in a first ebullated bed hydrocracking reaction zone to convert at least a portion of the vacuum gas oil to lighter hydrocarbons. Contacting a residuum hydrocarbon fraction and hydrogen with a non-zeolite base metal hydroconversion catalyst in a second ebullated bed hydroconversion reaction zone may produce a vapor stream containing unconverted hydrogen, acid gases and volatilized hydrocarbons which may be fed along with the vacuum gas oil in the first ebullated bed hydrocracking zone.

A process for converting inferior feedstock oil includes several steps. In step a) the inferior feedstock oil is subjected to a low severity hydrogenation reaction. The reaction product is separated to produce a gas, a hydrogenated naphtha, a hydrogenated diesel and a hydrogenated residual oil. In step b) the hydrogenated residual oil obtained in step a) is subjected to a first catalytic cracking reaction, the reaction product is separated to produce a first dry gas, a first LPG, a first gasoline, a first diesel and a first FCC-gas oil. In step c) the first FCC-gas oil obtained in step b) is subjected to a hydrogenation reaction of gas oil, the reaction product is separated to produce a hydrogenated gas oil, and in step d) the hydrogenated gas oil obtained in step c) is subjected to the first catalytic cracking reaction of step b) or a second catalytic cracking reaction.