US 11,732,203 B2
Ebullated bed reactor upgraded to produce sediment that causes less equipment fouling
David M. Mountainland, Princeton, NJ (US); Brett M. Silverman, Salt Lake City, UT (US); Michael A. Rueter, Plymouth Meeting, PA (US); and Lee Smith, Pleasant Grove, UT (US)
Assigned to HYDROCARBON TECHNOLOGY & INNOVATION, LLC, Lawrenceville, NJ (US)
Filed by HYDROCARBON TECHNOLOGY & INNOVATION, LLC, Lawrenceville, NJ (US)
Filed on Aug. 16, 2021, as Appl. No. 17/403,257.
Application 17/403,257 is a continuation in part of application No. 15/908,111, filed on Feb. 28, 2018, granted, now 11,118,119.
Claims priority of provisional application 62/466,011, filed on Mar. 2, 2017.
Prior Publication US 2021/0371762 A1, Dec. 2, 2021
This patent is subject to a terminal disclaimer.
Int. Cl. C10G 75/00 (2006.01); B01J 35/02 (2006.01); B01J 27/04 (2006.01); B01J 35/00 (2006.01); B01J 8/26 (2006.01); B01J 37/04 (2006.01); B01J 27/051 (2006.01); C10G 65/02 (2006.01)
CPC C10G 75/00 (2013.01) [B01J 8/26 (2013.01); B01J 27/04 (2013.01); B01J 27/051 (2013.01); B01J 35/0006 (2013.01); B01J 35/023 (2013.01); B01J 37/04 (2013.01); C10G 65/02 (2013.01); B01J 2208/00707 (2013.01); B01J 2208/025 (2013.01); C10G 2300/1077 (2013.01); C10G 2300/208 (2013.01); C10G 2300/4006 (2013.01); C10G 2300/4018 (2013.01); C10G 2300/4075 (2013.01); C10G 2300/708 (2013.01)] 25 Claims
OG exemplary drawing
 
1. A method of upgrading an ebullated bed hydroprocessing system that includes one or more ebullated bed reactors to produce sediment that is less fouling, comprising:
operating an ebullated bed reactor using a heterogeneous catalyst to hydroprocess heavy oil at initial conditions to yield an initial process stream containing converted products and sediment, including hydroprocessing heavy oil at initial production rate of converted products, initial sediment production rate and/or initial sediment concentration in the initial process stream, and initial rate of equipment fouling;
thereafter upgrading the ebullated bed reactor to operate using a dual catalyst system comprised of dispersed metal sulfide catalyst particles and heterogeneous catalyst; and
operating the upgraded ebullated bed reactor using the dual catalyst system to hydroprocess heavy oil and produce a modified process stream that contains sediment that is less fouling than the sediment in the initial process stream, resulting in at least 5% less equipment fouling at a given sediment production rate and/or concentration compared to when operating the ebullated bed reactor at the initial conditions.