초록 ▼

A process for catalytic multi-stage hydrogenation of heavy carbonaceous feedstocks using catalytic ebullated bed reactors is operated at selected flow and operating conditions so as to provide improved reactor operations and produce increased yield of lower boiling hydrocarbon liquid and gas product

A process for catalytic multi-stage hydrogenation of heavy carbonaceous feedstocks using catalytic ebullated bed reactors is operated at selected flow and operating conditions so as to provide improved reactor operations and produce increased yield of lower boiling hydrocarbon liquid and gas products. The disclosed process advantageously takes advantage of an external gas/liquid separation unit associated with the first stage reactor to allow for a more efficient and effective catalytic hydrocracking process. The more efficient process is primarily a result of the increased catalyst loading and lower gas hold-up in the ebullated reactors.

대표청구항 ▼

[ We claim:] [1.]1. A process for catalytic multi-stage ebullated bed hydrogenation of heavy hydrocarbonaceous feedstocks for producing lower boiling hydrocarbon liquids and gases, the process comprising:(a) feeding a heavy hydrocarbonaceous liquid vacuum residue feedstock having contaminant metal u

[ We claim:] [1.]1. A process for catalytic multi-stage ebullated bed hydrogenation of heavy hydrocarbonaceous feedstocks for producing lower boiling hydrocarbon liquids and gases, the process comprising:(a) feeding a heavy hydrocarbonaceous liquid vacuum residue feedstock having contaminant metal up to 1000 wppm, 10-50 wt. % Conradson Carbon Residue; and 50%-90 vol % normally boiling above 975.degree. F. together with hydrogen gas into a first stage catalytic ebullated bed reactor, said first stage catalytic ebullated bed reactor having no internal gas/liquid separation device, at liquid space velocity of 0.2-2.0 volume of feed per hour per volume of reactor (Vf/hr/Vr), a catalyst replacement rate of 0.05-0.5 Lb/Bbl (per stage), catalyst bed expansion of 25-75%, and at catalyst space velocity of 0.03-0.33 bbl/day/lb catalyst, providing upward superficial gas velocity of 0.02-0.30 ft/sec while maintaining reaction temperatures of 700-850.degree. F., and 800-3,000 psi hydrogen partial pressure at the reactor outlet, and producing a first stage reactor effluent material;(b) phase separating the first stage effluent using an external gas/liquid separator, into a gas portion and a first liquid portion, and passing the first liquid portion to a second stage catalytic ebullated bed reactor maintained at near the reaction conditions of step (a), and producing a second stage effluent material;(c) phase separating the second stage effluent material into a gas and a liquid second portion;(d) fractionating said second liquid portion to produce a medium-boiling hydrocarbon liquid fraction product having normal boiling range of 400-650.degree. F. and a vacuum bottoms fraction material having a normal boiling point above about 650.degree. F.; and(e) recycling said vacuum bottoms fraction material directly to said first stage catalytic ebullated bed reactor to provide a recycle volume ratio of the vacuum bottoms material to fresh feedstock of 0-1.0/1; reby steps a-e result in greater than 50% vol. % conversion of the 975.degree. F..sup.- fraction in the feedstock to lower-boiling hydrocarbon liquid and a desulfurization of greater than 65 wt. %.