Multi-stage process and device utilizing structured catalyst beds and reactive distillation for the production of a low sulfur heavy marine fuel oil

A structured catalyst bed comprising:

• a. At least two catalyst retention structures, wherein each catalyst retention structure is composed of at least one flat fluid permeable metal sheet and at least one corrugated fluid permeable metal sheet aligned to be co-planar and spatially arranged to define at least one catalyst rich space and at least one catalyst lean space, wherein within the catalyst rich space there is one or more catalyst material selected from the group consisting of:
• a porous inorganic oxide catalyst carrier impregnated with at least one transition metal catalyst and having hydrodemetallization activity;
• a porous inorganic oxide catalyst carrier impregnated with at least one transition metal catalyst and having hydrodenitrogenation activity, a porous inorganic oxide catalyst carrier impregnated with at least one transition metal catalyst and having hydrodesulfurization activity, a porous inorganic oxide catalyst carrier impregnated with at least one transition metal catalyst and having a combination of hydrodemetallization and hydrodesulfurization activity, and combinations of these, and wherein the porous inorganic oxide catalyst carrier is at least one carrier selected from the group consisting of alumina, alumina/boria carrier, a carrier containing metal-containing aluminosilicate, alumina/phosphorus carrier, alumina/alkaline earth metal compound carrier, alumina/titania carrier and alumina/zirconia carrier, and wherein the transition metal catalyst is one or more metals selected from the group consisting of group 6, 8, 9 and 10 of the Periodic Table, and wherein the at least one catalyst lean space optionally contains catalytically inert materials;
• and
• b. wherein the at least two adjacent catalyst retention structures are aligned in parallel X-Y planes, but the catalyst rich spaces of each catalyst retention structure define an angle of radial alignment in the X-Y plane of greater than 0° and less than 180°.