Exxonmobil Research and Engineering Company

Exxonmobil Chemical Patents Inc.

Ramanathan Sundararaman

Thomas Francis Degnan, Jr

Randolph John Smiley

Rustom Merwan Billimoria

Manuel Anthony Francisco

Roby Bearden, Jr

William Ernest Lewis

John P Greeley

James Richardson Lattner

Ajit Bhaskar Dandekar

David T Ferrughelli

Jeevan Sahib Abichandani

Paul Podsiadlo

Anjaneya Sarma Kovvali

Michael W Weber

Federico Barrai

Mainak Ghosh

Natalie Ann Fassbender

Colin L Beswick

Keith Wilson

Saurabh S Maduskar

Jacob Johannes Thiart

Amitava Sarkar

Thomas Francis Degnan

Processes and systems for upgrading a hydrocarbon feed. The process can include feeding a hydrocarbon feed, catalyst particles, and molecular hydrogen (H) into a separation zone. The hydrocarbon feed and Hcan be contacted in the presence of the catalyst particles under hydrotreating conditions in the separation zone that can include contacting under a total pressure of less than 3,500 kilopascals-gauge. The Hcan be fed into the separation zone at a rate of no greater than 270 cubic meters of Hper cubic meter of the hydrocarbon feed, where the volume of Hand hydrocarbon feed are based on a temperature of 25 C and a pressure of 101 kilopascals-absolute. A vapor phase hydrocarbon stream and a liquid phase hydrocarbon stream can be obtained from the separation zone. At least a portion of the vapor phase hydrocarbon stream can be fed into a pyrolysis reaction zone to produce a pyrolysis effluent.

Process and system for upgrading a hydrocarbon feed

Systems and methods are provided for slurry hydroconversion of a heavy oil feed, such as an atmospheric or vacuum resid. The systems and methods allow for slurry hydroconversion using catalysts with enhanced activity and/or catalysts that can be recycled as a side product from a complementary refinery process.

Slurry hydroconversion using enhanced slurry catalysts

Systems and methods are provided for slurry hydroconversion of a heavy oil feedstock, such as an atmospheric or vacuum resid, in the presence of an enhanced or promoted slurry hydroconversion catalyst system. The slurry hydroconversion catalyst system can be formed from a) a Group VIII non-noble metal catalyst precursor/concentrate (such as an iron-based catalyst precursor/concentrate) and b) a Group VI metal catalyst precursor/concentrate (such as a molybdenum-based catalyst precursor/concentrate) and/or a Group VI metal sulfided catalyst.

Slurry hydroconversion catalysts

A heavy petroleum oil feed is upgraded by having its amenability to cracking improved by subjecting the oil to selective partial oxidation with a catalytic oxidation system to partially oxidize aromatic ring systems in the heavy oil. The partially oxidized oil can then be cracked in the conventional manner but at lower severities to lower molecular weight cracking products. The cracking following the partial oxidation step may be thermal in nature as by thermal cracking, delayed, contact or fluid coking or fluid catalytic cracking or hydrogenative as in hydrocracking.

Upgrading heavy oils by selective oxidation

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.

Integrated hydrocracking and slurry hydroconversion of heavy oils

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.

Sequential slurry hydroconversion of heavy oils

Systems and methods are provided for slurry hydroconversion of a heavy oil feed, such as an atmospheric or vacuum resid. The systems and methods allow for slurry hydroconversion using catalysts with enhanced activity. The catalysts with enhanced activity can be used in conjunction with demetallization catalysts or catalysts that can be recycled as a side product from a complementary refinery process.

Slurry hydroconversion with high activity catalysts

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Frederick, MD, United States of America

Ramanathan Sundararaman