Integrated process for hydrotreating heavy oil, then manufacturing an

Abstract

Use of a carbon-based catalyst composition, particularly activated-carbon, optionally containing at least one metal selected from Ni, Co, Mo, W, Fe, or mixtures thereof, for heavy oil hydroprocessing. Recovery and partial gasification of the catalyst to produce a synthesis gas and a partially gasified catalyst residue. Use of the synthesis gas in a process to produce synthetic hydrocarbons and use of the catalyst residue in steel or alloy production. Catalysts used for heavy oil hydrocarbon hydroprocessing frequently become contaminated with metals which increase the cost of disposal of the spent catalysts, e.g. landfills. This invention uses a specific catalyst for hydroprocessing which can then be partially gasified to produce a catalyst residue which can be further used in steel or alloy production, thereby reducing the need for expensive disposal.