Patent ID: 8722556

Claim:
A method of recovering unsupported fine catalyst from a slurry comprising unsupported fine catalyst in heavy oil to generate a concentrated catalyst slurry, the method comprising: providing a deoiling zone comprising a cross-flow microfiltration unit having a membrane that is rapidly displaced in a horizontal direction; providing to the deoiling zone a solvent and a slurry comprising unsupported fine catalyst in heavy oil having a first volume concentration of solids as unsupported fine catalyst; recovering from the deoiling zone a permeate stream comprising heavy oil and solvent, and a retentate stream as a concentrated slurry comprising unsupported fine catalyst having a second volume concentration of solids as unsupported fine catalyst greater than the first volume concentration; and transporting the concentrated slurry to a heavy oil upgrading site; and reconstituting the concentrated slurry to a solids content of about 5 weight % prior to the deoiling zone for use as unsupported catalyst in heavy oil upgrading.