Patent ID: 8309041
Filing Date: 2012-11-13
Classification: C10G

Abstract:
1. A system for use in hydrocracking a heavy oil feedstock and that employs a colloidally or molecularly dispersed catalyst, the system comprising: mixing means for blending a catalyst precursor with a heavy oil feedstock, which includes a significant fraction of hydrocarbons having a boiling point above 343° C. and/or asphaltenes, at a temperature below a decomposition temperature of the catalyst precursor to form a conditioned feedstock composition; heating means for heating the conditioned feedstock composition to above the decomposition temperature to form a colloidally or molecularly dispersed catalyst in situ within the heavy oil feedstock; a first gas-liquid two or more phase hydrocracking reactor configured to received the conditioned feedstock before or after being heated to above the decomposition temperature, the first hydrocracking reactor comprising hydrogen (H a pressure differential interstage separator configured to receive an effluent from the first hydrocracking reactor and separate the effluent into a lower boiling volatile gaseous vapor fraction and a higher boiling liquid fraction in a manner so that the colloidally or molecularly dispersed catalyst remains in the higher boiling liquid fraction and has increased concentration compared to a concentration of the colloidally or molecularly dispersed catalyst within the first hydrocracking reactor, a valve positioned between the first gas-liquid two or more phase hydrocracking reactor and the pressure differential interstage separator that is configured to induce a pressure drop in a range of about 100 psi to about 1000 psi; and a second gas-liquid two or more phase hydrocracking reactor configured to receive at least a portion of the higher boiling liquid fraction from the pressure differential interstage separator and additional hydrogen (H