Ebullated bed process for high conversion of heavy hydrocarbons with a low sediment yield

1. A process that uses an ebullated bed reactor system for the hydroconversion of a heavy hydrocarbon feedstock providing for the conversion of said heavy hydrocarbon feedstock with a low sediment yield, wherein said process comprises:

introducing said heavy hydrocarbon feedstock into an ebullated bed reaction zone contained within a reactor volume defined by an ebullated bed reactor vessel,

wherein said reactor volume includes an upper zone above said ebullated bed reaction zone and a lower zone below said ebullated bed reaction zone; and

wherein said ebullated bed reaction zone comprises a catalyst bed of shaped hydroprocessing catalyst particles having a macroporosity of greater than 10% and a geometry, wherein said shaped hydroprocessing catalyst particles have a trilobed shape including a trilobed particle length and a nominal trilobed diameter, and wherein said geometry provides for a first ratio of the cross section perimeter-to-cross sectional area that is in the range of from 5 mm −1 to 8 mm −1 , and a second ratio of the particle external surface area divided by the particle volume in the range of from 5 mm −1 to 15 mm −1 ;

contacting under hydroconversion reaction conditions, including a contacting temperature in the range of from 316° C. (600° F.) to 538° C. (1000° F.), a contacting pressure in the range of from 500 psia to 6,000 psia, a hydrogen-to-oil ratio in the range of from 500 scf/bbl to 10,000 scf/bbl, and liquid hourly space velocity (LHSV) in the range of from 0.1 hr −1 to 5 hr −1 , said heavy hydrocarbon feedstock with said shaped hydroprocessing catalyst particles within said ebullated bed reaction zone; and

yielding from said upper zone a heavy hydrocarbon conversion product having a low sediment content of less than 0.5 wt % as determined by testing method ASTM-4870.

2. A process as recited in claim 1 , wherein said trilobe shape is characterized by a trilobe cross section having a perimeter that is defined by three circles each having a center and a radius (r), wherein said radii of each of said three circles are equal in length, and wherein said centers of each of said three circles are oriented in a spaced relationship to each other such that the distances between each said center of said three circles are equal, and wherein the distances between each said center of said three circles are in the range of from one radius (r) to two radii (2r).

3. A process as recited in claim 2 , wherein said nominal trilobe diameter of said trilobe shape is the sum of the distance between each said center of said three circles and two radii (2r).

4. A process as recited in claim 3 , wherein said radius is in the range of from 0.1 mm to 1 mm.

5. A process as recited in claim 4 , wherein said nominal trilobe diameter is in the range of from 0.5 mm to 1.5 mm.

6. A process as recited in claim 5 , wherein said trilobe particle length is in the range of from 0.1 mm to 5 mm.

7. A process that uses an ebullated bed reactor system for the hydroconversion of a heavy hydrocarbon feedstock providing for the conversion of said heavy hydrocarbon feedstock with a low sediment yield, wherein said process comprises:

introducing said heavy hydrocarbon feedstock into an ebullated bed reaction zone contained within a reactor volume defined by an ebullated bed reactor vessel,

wherein said reactor volume includes an upper zone above said ebullated bed reaction zone and a lower zone below said ebullated bed reaction zone; and

wherein said ebullated bed reaction zone comprises a catalyst bed of shaped hydroprocessing catalyst particles having a macroporosity of greater than 10% and a geometry, wherein said shaped hydroprocessing catalyst particles have a trilobed shape including a trilobed particle length and a nominal trilobed diameter, and wherein said geometry provides for a first ratio of the cross section perimeter-to-cross sectional area that is in the range of from 5 mm −1 to 8 mm −1 , and a second ratio of the particle external surface area divided by the particle volume in the range of from 5 mm −1 to 15 mm −1 , wherein said trilobe shape is characterized by a trilobe cross section having a perimeter that is defined by three circles each having a center and a radius (r), wherein said radii of each of said three circles are equal in length, and wherein said centers of each of said three circles are oriented in a spaced relationship to each other such that the distances between each said center of said three circles are equal, and wherein the distances between each said center of said three circles are in the range of from one radius (r) to two radii (2r), wherein said nominal trilobe diameter of said trilobe shape is the sum of the distance between each said center of said three circles and two radii (2r), wherein said radius is in the range of from 0.1 mm to 1 mm, wherein said nominal trilobe diameter is in the range of from 0.5 mm to 1.5 mm, wherein said trilobe particle length is in the range of from 0.1 mm to 5 mm, wherein said shaped hydroprocessing catalyst particles comprise an extrudate of a co-mulled mixture, comprising an inorganic oxide powder, a molybdenum compound and a nickel compound, wherein said extrudate has been calcined to provide said shaped hydroprocessing catalyst particles, and wherein said shaped hydroprocessing catalyst particles have a molybdenum content in the range of from 3 wt. % to 15 wt. %, a nickel content in the range of from 0.5 wt. % to 6 wt. %, and said inorganic oxide in the range of from about 75 wt. % to 96 wt. %, wherein each wt. % is based on the total weight of said shaped hydroprocessing catalyst particle and the metal as an oxide regardless of its actual form;

contacting under hydroconversion reaction conditions, including a contacting temperature in the range of from 316° C. (600° F.) to 538° C. (1000° F.), a contacting pressure in the range of from 500 psia to 6,000 psia, a hydrogen-to-oil ratio in the range of from 500 scf/bbl to 10,000 scf/bbl, and liquid hourly space velocity (LHSV) in the range of from 0.1 hr −1 to 5 hr −1 , said heavy hydrocarbon feedstock with said shaped hydroprocessing catalyst particles within said ebullated bed reaction zone; and

yielding from said upper zone a heavy hydrocarbon conversion product having a low sediment content of less than 0.5 wt % as determined by testing method ASTM-4870.

8. A process as recited in claim 7 , wherein said shaped hydroprocessing catalyst particles further are characterized as having a macroporosity exceeding 12% of the total pore volume of said shaped hydroprocessing catalyst particles is in the pores having a diameter greater than 350 Å.

9. A process as recited in claim 8 , wherein said hydroconversion reaction conditions include a contacting temperature in the range of from 316° C. (600° F.) to 510° C. 950° F.), a contacting pressure in the range of from 1000 psia to 3500 psia, a hydrogen-to-oil ratio in the range of from 500 scf/bbl to 10,000 scf/bbl, and liquid hourly space velocity (LHSV) in the range of from 0.2 hr −1 to 4 hr −1 .