The hydrogenation capacity of an upflow hydrocarbon hydrotreatment reactor is increased by expanding the gas-liquid contact surface.

A method of upgrading an overflash stream from a vacuum distillation unit comprising the steps of separating the overflash stream from an atmospheric residue stream, the overflash stream comprises an overflash fraction having a T10% between 475 and 530° C. and a T90% between 600 and 700° C.; introducing the reactor feed to a supercritical reactor at a temperature between 380° C. and 500° C. and a pressure between 25 MPa and 30 MPa; maintaining upgrading reactions in the supercritical reactor to upgrade the overflash fraction such that a reactor effluent comprises upgraded hydrocarbons relative to the overflash fraction; reducing a temperature of a reactor effluent in a cooling device to produce a cooled stream; reducing a pressure of the cooled stream in a depressurizing device to produce a discharged stream; and separating the discharged stream in a gas-liquid separator to produce a liquid phase product.

A process for hydroprocessing a hydrocarbon feed of the present disclosure includes contacting the hydrocarbon feed with hydrogen in the presence of at least one hydroprocessing catalyst in a two-phase hydroprocessing unit, where the at least one hydroprocessing catalyst is a solid catalyst and contacting produces a hydroprocessed effluent having a reduced concentration of one or more of metals, nitrogen, sulfur, aromatic compounds, or combinations of these. The process further includes combining the hydroprocessed effluent with make-up hydrogen downstream of the two-phase hydroprocessing unit to produce a hydrogen saturated hydroprocessed effluent, separating the hydrogen saturated hydroprocessed effluent in a separation system to produce a hydrogen-saturated high-pressure bottom stream, a hydroprocessed product stream, and a gaseous effluent, and passing at least a portion of the hydrogen-saturated high-pressure bottom stream back to the two-phase hydroprocessing unit.

A supercritical water separation process and system is disclosed for the removal of metals, minerals, particulate, asphaltenes, and resins from a contaminated organic material. The present invention takes advantage of the physical and chemical properties of supercritical water to effect the desired separation of contaminants from organic materials and permit scale-up. At a temperature and pressure above the critical point of water (374° C., 22.1 MPa), nonpolar organic compounds become miscible in supercritical water (SCW) and polar compounds and asphaltenes become immiscible. The process and system disclosed continuously separates immiscible contaminants and solids from the supercritical water and clean oil product solution. The present invention creates a density gradient that enables over 95% recovery of clean oil and over 99% reduction of contaminants such as asphaltenes and particulate matter depending on the properties of the contaminated organic material.

An hydroconverted effluent composition is provided, along with systems and methods for making such a composition. The hydroconverted effluent composition can have 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 hydroconverted effluent 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

Naphthenic process oils are made by blending one or more naphthenic vacuum gas oils in one or more viscosity ranges with a high C.sub.A content distilled aromatic extract feedstock to provide at least one blended oil, and hydrotreating the at least one blended oil to provide an enhanced C.sub.A content naphthenic process oil. The order of the vacuum distillation and blending steps may be reversed.

The process comprises hydrocracking a hydrocarbon feed in a single stage. The catalyst comprises a base impregnated with metals from Group 6 and Groups 8 through 10 of the Periodic Table, as well as citric acid. The base of the catalyst used in the present hydrocracking process comprises alumina, an amorphous silica-alumina (ASA) material, a USY zeolite, and a beta zeolite.

A catalyst has a carrier and a hydrogenation active metal component supported on the carrier. The hydrogenation active metal component contains at least one Group VIB metal component and at least one Group VIII metal component, and the carrier is composed of phosphorus-containing alumina. When the hydrogenation catalyst is measured using a hydrogen temperature programmed reduction method (H.sub.2-TPR), the ratio of the peak height of the low-temperature reduction peak, P.sub.low-temp peak, at a temperature of 300-500° C. to the peak height of the high-temperature reduction peak, P.sub.hi-temp peak, at a temperature of 650-850° C., i.e. S=P.sub.low-temp peak/P.sub.hi-temp peak, is 0.5-2.0; preferably 0.7-1.9, and more preferably 0.8-1.8. The hydrogenation catalyst shows excellent heteroatom removal effect and excellent stability when used in hydrotreatment.

For the shipping industry, these fuels provide solutions to long outstanding technical problems that heretofore hindered supply of low sulfur marine fuels in quantities needed to meet worldwide sulfur reduction goals. When ships on the open seas burn cheap low grade heavy bunker oils high in sulfur, nitrogen and metals, the SOx, NOx, and metal oxides go to the environment. This invention converts essentially all of each barrel of crude feed to a single ultraclean fuel versus conventional refining where crude feed is cut into many pieces, and each piece is sent down a separate market path meeting various different product specifications. When in port, ships can generate and sell electricity to land based electrical grids to offset fuel cost in an environment-friendly manner.

Oxidized disulfide oil (ODSO) compounds or ODSO compounds and disulfide oil (DSO) compounds are reacted with a hydrogen addition feed in a hydroprocessing complex. The hydrogen addition process can include naphtha hydrotreatment, middle distillate hydrotreatment, vacuum gas oil hydrocracking, and vacuum gas oil hydrotreatment. The ODSO or ODSO and DSO components are converted to hydrogen sulfide, water and alkanes.