Hydroprocessing method with high liquid mass flux
In a method of hydroprocessing, hydrogen gas for the hydroprocessing reaction is combined with a liquid feed composition comprising a feedstock to be treated and a diluent to form a feed stream, at least a portion of the hydrogen gas being dissolved in the liquid feed composition of the feed stream, with non-dissolved hydrogen gas being present in the feed stream in an amount of from 1 to 70 SCF/bbl of the liquid feed composition. The feed stream is contacted with a hydroprocessing catalyst, within a reactor while maintaining a liquid mass flux within the reactor of at least 5000 lb/hr·ft 2 to form a hydroprocessed product.
1. A method of hydroprocessing comprising:
combining hydrogen gas for the hydroprocessing reaction with a liquid feed composition comprising a feedstock to be treated and a diluent to form a feed stream, a portion of the hydrogen gas being dissolved in the liquid feed composition of the feed stream, with non-dissolved hydrogen gas being present in the feed stream in an amount of from 1 SCF to 70 SCF per bbl of the liquid feed composition; and
contacting the feed stream with a hydroprocessing catalyst of a catalyst bed while the liquid feed composition flows through a volume of nearly stagnant gas within a reactor and while maintaining a liquid mass flux within the reactor of at least 5000 lb/hr·ft 2 or more to form a hydroprocessed product; and further comprising
separating gas from liquid hydroprocessed product in a separator located within the reactor downstream from the catalyst bed.
2. The method of claim 1 , wherein:
the feedstock comprises at least one of a petroleum feedstock, a non-petroleum feedstock, a bio oil, a pyrolysis oil, a high-contaminant feedstock, and a high-olefinic feedstock.
3. The method of claim 1 , wherein:
the feed stream is contacted with a hydroprocessing catalyst contained in at least two catalyst beds within the reactor.
4. The method of claim 1 , wherein:
the non-dissolved hydrogen gas in the feed stream is present in an amount of from 1 SCF to 50 SCF per bbl of the liquid feed composition.
5. The method of claim 1 , wherein:
the liquid mass flux within the reactor is maintained at from 5000 lb/hr·ft 2 to 100,000 lb/hr·ft 2 .
6. The method of claim 1 , wherein:
the liquid mass flux within the reactor is maintained at from 6000 lb/hr·ft 2 to 100,000 lb/hr·ft 2 .
7. The method of claim 1 , wherein:
the liquid mass flux within the reactor is maintained at from 10,000 lb/hr·ft 2 or more.
8. The method of claim 1 , wherein:
the liquid mass flux within the reactor is maintained at from 30,000 lb/hr·ft 2 or more.
9. The method of claim 1 , wherein:
at least a portion of the hyroprocessed product is used to form the diluent.
10. The method of claim 1 , wherein:
the liquid mass flux within the reactor is maintained at greater than 10,000 lb/hr·ft 2 .
11. The method of claim 1 , wherein:
the separated gas is removed from the reactor at a rate so that the volume of gas within the reactor is maintained in a near stagnant condition.
12. The method of claim 1 , further comprising:
maintaining a liquid level within the reactor by controlling the amount of hydrogen gas added to the feedstream.
13. The method of claim 1 , wherein:
the volume of nearly stagnant gas has a flow rate of from 5 ACF/hr or less per ft 3 of reactor volume.
14. A method of hydroprocessing comprising:
combining hydrogen gas for the hydroprocessing reaction with a liquid feed composition comprising a feedstock to be treated and a diluent to form a feed stream, a portion of the hydrogen gas being dissolved in the liquid feed composition of the feed stream, with non-dissolved hydrogen gas being present in the feed stream in an amount of from 1 SCF to 50 SCF per bbl of the liquid feed composition; and
contacting the feed stream with a hydroprocessing catalyst contained in at least two catalyst beds contained within a reactor while the liquid feed composition flows through a volume of nearly stagnant gas and while maintaining a liquid mass flux within the reactor of from 10,000 lb/hr·ft 2 to 100,000 lb/hr·ft 2 to form a hydroprocessed product; and further comprising
separating gas from liquid hydroprocessed product in a separator located within the reactor downstream from at least one of the catalyst beds.
15. The method of claim 14 , wherein:
the feedstock comprises at least one of a petroleum feedstock, a non-petroleum feedstock, a bio oil, a pyrolysis oil, a high-contaminant feedstock, and a high-olefinic feedstock.
16. The method of claim 14 , wherein:
the liquid mass flux within the reactor is maintained from 30,000 lb/hr·ft 2 to 100,000 lb/hr·ft 2 .
17. The method of claim 14 , wherein:
at least a portion of the hyroprocessed product is used to form the diluent.
18. The method of claim 14 , wherein:
the separated gas is removed from the reactor at a rate so that the volume of gas within the reactor is maintained in a near stagnant condition.
19. The method of claim 14 , wherein:
the volume of nearly stagnant gas has a flow rate of from 5 ACF/hr or less per ft 3 of reactor volume.
20. The method of claim 14 , further comprising:
maintaining a liquid level within the reactor by controlling the amount of hydrogen gas added to the feedstream.