Patent ID: 8440071

Claim:
A method of hydroprocessing a heavy oil feedstock, comprising: preparing a heavy oil feedstock comprised of a substantial quantity of hydrocarbons having a boiling point greater than 343° C. and a colloidal or molecular catalyst dispersed throughout the heavy oil feedstock, the colloidal or molecular catalyst in the heavy oil feedstock being formed by: mixing a diluent and a catalyst precursor below a temperature at which a significant portion of the catalyst precursor decomposes to form a diluted precursor mixture; after forming the diluted catalyst precursor mixture and prior to heating the diluted catalyst precursor mixture to a temperature at which a substantial portion of the catalyst precursor decomposes, mixing the diluted precursor mixture with a heavy oil feedstock in a manner so as to yield a conditioned feedstock containing the catalyst precursor; and heating the conditioned feedstock so as to decompose the catalyst precursor and so as to cause or allow metal liberated from the decomposed catalyst precursor to react with sulfur liberated from the heavy oil feedstock and form the colloidal or molecular catalyst in situ within the heavy oil feedstock; heating or maintaining the heavy oil feedstock at a hydrocracking temperature within a hydrocracking reactor in the presence of hydrogen to form an upgraded hydrocarbon material, the colloidal or molecular catalyst catalyzing reactions between the hydrogen and free radicals formed in the hydrocracking reactor and reducing or eliminating formation of coke precursors and sediment in the hydrocracking reactor.