Upgraded ebullated bed reactor with less fouling sediment

Abstract

An ebullated bed hydroprocessing system is upgraded using a dual catalyst system that includes a heterogeneous catalyst and dispersed metal sulfide particles to produce less fouling sediment. The dualcatalyst system more effectively converts sediment-forming precursors to produce sediment that is less fouling than sediment produced using only the heterogeneous catalyst and not the dispersed metalsulfide particles. The dual catalyst system provides for a lower rate of equipment fouling for a given sediment production rate and/or concentration. In some cases, sediment production rate and/or concentration can be maintained or increased while equipment fouling is reduced. In some cases, sediment production rate and/or concentration can be increased without increasing equipment fouling.

Description

technical field [0001] The present invention relates to heavy oil hydroprocessing methods and systems, such as ebullating bed hydroprocessing methods and systems, which utilize a dual catalyst system and operate with fewer fouling deposits. Background technique [0002] There is an increasing need to more efficiently utilize and extract fuel value from low-quality heavy oil feedstocks. Low quality feedstocks are characterized by including relatively high amounts of hydrocarbons that nominally boil at 524°C (975°F) or above. They also contain relatively high concentrations of sulfur, nitrogen and / or metals. High-boiling fractions derived from these low-quality feedstocks typically have high molecular weights (often indicated by higher densities and viscosities) and / or low hydrogen-to-carbon ratios, which are consistent with the presence of high concentrations of undesired components, including asphaltenes and carbon residue) related. Asphaltenes and carbon residues are dif...

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Problems solved by technology

In addition, sediment generation and equipment fouling

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