Method for multi-staged hydroprocessing using quench

Abstract

Methods for processing a hydrocarbonaceous feedstock flows are provided. In one embodiment, the method includes providing two or more hydroprocessing stages disposed in sequence, each hydroprocessing stage having a hydroprocessing reaction zone with a hydrogen requirement and each stage in fluid communication with the preceding stage. The hydrocarbonaceous feedstock flow may be separated into portions of fresh feed for each hydroprocessing stage, and the first portion of fresh feed to the first hydroprocessing stage is heated. The heated first portion of fresh feed may be supplied with hydrogen from the hydrogen source in an amount satisfying substantially all of the hydrogen requirements of the hydroprocessing stages to a first hydroprocessing zone. The unheated second portion of fresh feed is injected counter current to the process flow as quench at one or more locations in one or more of the reaction zones.

1 . A method of processing a hydrocarbonaceous feedstock comprising:
 hydroprocessing a feed in two or more hydroprocessing stages disposed in sequence and in fluid communication, each hydroprocessing stage having a hydroprocessing reaction zone with and each stage disposed to receive a process flow comprising at least a liquid and to produce a hydroprocessed effluent; and   controlling the temperature of the hydroprocessing stages using mixed vapor and liquid quench streams wherein a mixed vapor phase and liquid phase quench stream is injected into each hydroprocessing reaction zone counter current to the process flow, wherein the mixed vapor phase and liquid phase quench stream from the first stage hydroprocessing reaction zone provides a portion of the process flow to a second stage hydroprocessing reaction zone and wherein the mixed vapor phase and liquid phase quench streams comprise at least a portion of the feed.   
     
     
         2 . The method of  claim 1  wherein the mixed vapor and liquid quench streams comprises at least a portion of one of the hydroprocessed effluents. 
     
     
         3 . The method of  claim 1  wherein the mixed vapor and liquid quench streams are injected into the reaction zone using spray nozzles arranged in a pattern so that the spray coverage from a first nozzle overlaps with the spray coverage of a second nozzle. 
     
     
         4 . The method of  claim 3  wherein the pattern of spray nozzles provide uniform spray coverage across the cross sectional area of the reaction zone. 
     
     
         5 . The method of  claim 1  wherein at least one reaction zone comprises multiple catalyst beds and multiple mixed vapor and liquid quench streams are injected into the reaction zone with at least one quench stream injected in between each pair of catalyst beds. 
     
     
         6 . The method of  claim 1  wherein the hydroprocessing stages are three-phase reaction zones. 
     
     
         7 . The method of  claim 1  wherein the injection of the mixed vapor and liquid quench streams into a reaction zone results in counter current axial flow of the mixed vapor and liquid quench streams.