Processing of heavy hydrocarbon feeds

Abstract

Systems and methods are provided for hydroconversion of a heavy oil feed under slurry hydroprocessing conditions and/or solvent assisted hydroprocessing conditions. The systems and methods for slurry hydroconversion can include the use of a configuration that can allow for improved separation of catalyst particles from the slurry hydroprocessing effluent. In addition to allowing for improved catalyst recycle, an amount of fines in the slurry hydroconversion effluent can be reduced or minimized. This can facilitate further processing or handling of any “pitch” generated during the slurry hydroconversion. The systems and methods for solvent assisted hydroprocessing can include processing of a heavy oil feed in conjunction with a high solvency dispersive power crude.

1 .- 20 . (canceled) 
     
     
         21 . A process for producing a hydroprocessed product, comprising:
 passing a feedstock comprising resid to a first reactor operating at about 1000 psig (˜6.9 MPag) or less,   demetallizing at least about 60 wt % and up of the feedstock to create a liquid product,   passing the liquid product from the first reactor to a fractionator,   separating out in the fractionator a heavy residuum fraction having a boiling point of about 1050° F. (˜566° C.),   passing the heavy residuum fraction from the fractionator to a second reactor operating at from about 1500 psig (˜10.4 MPag) to about 3400 psig (˜23.5 MPag).   
     
     
         22 . The process of  claim 21 , wherein the temperature of first reactor is between 650° F. (˜343° C.) and 850° F. (˜454° C.). 
     
     
         23 . The process of  claim 21 , wherein demetallizing further comprises exposing the feedstock to a demetallization catalyst at a pressure of about 300 psig (˜2.1 MPag) to about 800 psig (˜5.6 MPag) and a temperature of about 600° F. (˜316° C.) to about 1000° F. (˜538° C.). 
     
     
         24 . The process of  claim 23 , wherein
 a) the demetallization catalyst has a mean pore diameter of 60 Å or less,   b) the demetallization catalyst comprises a catalyst with a surface area of at least about 1000 m 2 /g and a micro pore volume of at least 0.1 cm 3 /g, the catalyst optionally having a support that is substantially free of alumina, or   c) a combination of a) and b).   
     
     
         25 . The process of  claims 23 , wherein the demetallization catalyst comprises an activated carbon catalyst or an aluminum catalyst. 
     
     
         26 . The process of  claim 23 , wherein the demetallization catalyst comprises a regenerated catalyst. 
     
     
         27 . The process of  claim 26 , wherein the regenerated catalyst is an activated carbon catalyst or an aluminum catalyst. 
     
     
         28 . The process of  claim 21 , further comprising exposing the feedstock to a catalyst in the first reactor.