Patent ID: 8314276

Claim:
A hydroprocessing reaction system having a substantially liquid-phase throughout a hydroprocessing reaction zone for hydroprocessing hydrocarbons, the system comprising: a reaction zone having an inlet for receiving a substantially liquid-phase hydrocarbonaceous stream and an outlet for providing an effluent, the reaction zone configured to have a substantially liquid-phase throughout the reaction zone; a first catalyst bed contained in the reaction zone and having a hydroprocessing catalyst therein with a first maximum operating temperature range; a second catalyst bed contained in the reaction zone in fluid communication with the first catalyst bed and having a hydroprocessing catalyst therein with a second maximum operating temperature range; a fluid-to-fluid heat exchanger mounted in the reaction zone between the first and second catalyst beds in fluid communication the catalyst beds positioned to receive the process flow exiting the first catalyst bed and to substantially maintain the hydrocarbon process flow from the first catalyst bed at or below the maximum operating temperature range of the hydroprocessing catalysts in the first bed and positioned to supply the hydrocarbon process flow to the second catalyst bed at a temperature effective to limit a temperature rise of the hydrocarbon process flow across the second catalyst bed to a temperature at or below the maximum operating temperature range of the hydroprocessing catalyst in the second bed; a heat exchange surface in said heat exchanger for recovering heat generated in the catalyst beds to generate high pressure steam from water passed through said fluid-to-fluid heat exchanger; and a separation zone in communication with an effluent from said reaction zone for separating said effluent into a gas phase and a liquid phase, said separation zone in communication with said high pressure steam from said fluid-to-fluid heat exchanger to enhance the separation.