Graded catalyst bed for split-feed hydrocracking/hydrotreating

Abstract

A method for hydroprocessing hydrocarbon products, preferably Fischer-Tropsch products, and a reactor useful for performing the method, are disclosed. The reactor includes one or more first catalyst beds comprising a catalyst useful for conducting relatively severe hydroprocessing and one or more second catalyst beds comprising a catalyst useful for conducting relatively mild hydroprocessing. The second catalyst beds are located at a position in the reactor where they can receive the products from the first catalyst bed(s), at least one of each of the first and second catalyst bed(s) comprises a catalyst grading scheme sufficient to remove at least a portion of any particulates from their respective feeds, and the reactor is set up to receive hydrocarbon feeds at a position above or within the first catalyst bed(s) and above or within the second catalyst bed(s). A first hydrocarbon feed with a relatively high boiling point is introduced to the first catalyst bed(s) and is subjected to relatively severe hydroprocessing. A feed comprising 1) the products from the hydroprocessing of the first hydrocarbon feed and 2) a second hydrocarbon feed with a relatively low boiling point is introduced to the second catalyst beds and is subjected to relatively mild hydroprocessing. The catalyst grading scheme minimizes pressure drop build-up through the catalyst beds. The hydrocarbon feeds are preferably derived, in whole or in part, from Fischer-Tropsch synthesis, although they can include products from petroleum refining or other suitable sources. In one embodiment, the relatively high boiling fraction is a predominantly C + fraction and the relatively low boiling fraction is a predominantly C fraction.