Method for upgrading ebullated bed reactor and upgraded ebullated bed reactor

A method of upgrading a heavy oil hydroprocessing system, comprising:

• initially operating an ebullated bed reactor to hydroprocess heavy oil at an initial conversion level of heptane insoluble asphaltenes, the ebullated bed reactor including a liquid phase comprising the initial heavy oil, a solid phase comprising the supported ebullated bed catalyst, and a gaseous phase comprising hydrogen gas;
• thereafter upgrading the ebullated bed reactor by introducing heavy oil into the ebullated bed reactor that contains metal sulfide catalyst particles or a catalyst precursor that forms metal sulfide catalyst particles in situ within the heavy oil in order for the ebullated bed to contain a dual catalyst system comprised of metal sulfide catalyst particles and supported ebullated bed catalyst;
• and
• operating the upgraded ebullated bed reactor using the dual catalyst system to hydroprocess heavy oil and convert heptane insoluble asphaltenes at a conversion level of at least about 65% and that is higher than the initial conversion level of heptane insoluble asphaltenes without a significant increase in production of coke or sediment compared to when initially operating the ebullated bed reactor at the initial conversion level of heptane insoluble asphaltenes,
• the metal sulfide catalyst particles increasing the lifespan of the supported ebullated bed catalyst so that the upgraded ebullated bed reactor uses a reduced quantity of the supported ebullated bed catalyst over time.

A method of upgrading a heavy oil hydroprocessing system to increase conversion of asphaltenes in heavy oil, comprising:

• initially operating an ebullated bed reactor containing a supported ebullated bed catalyst to hydroprocess heavy oil and convert the heavy oil to lower boiling materials, the ebullated bed reactor converting heptane insoluble asphaltenes at a lower conversion level than a conversion level of hydrocarbons that boil at 524° C. (975° F.) or higher, the ebullated bed reactor including a liquid phase comprising the initial heavy oil, a solid phase comprising the supported ebullated bed catalyst, and a gaseous phase comprising hydrogen gas;
• thereafter upgrading the ebullated bed reactor by introducing heavy oil into the ebullated bed reactor that contains metal sulfide catalyst particles having a particle size smaller than about 1 micron or by dispersing a catalyst precursor within the heavy oil in a manner that forms metal sulfide catalyst particles having a particle size smaller than about 1 micron in situ within the heavy oil in order for the ebullated bed to contain a dual catalyst system comprised of metal sulfide catalyst particles having a particle size smaller than about 1 micron and supported ebullated bed catalyst;
• and
• operating the upgraded ebullated bed reactor using the dual catalyst system to hydroprocess heavy oil and convert the asphaltenes at a conversion level of at least about 65% and that is at least as high as the conversion level of hydrocarbons that boil at 524° C. (975° F.) or higher,
• the upgraded ebullated bed reactor, after upgrading to use the dual catalyst system, utilizing a reduced quantity of supported ebullated bed catalyst compared to when initially operating the ebullated bed reactor prior to upgrading to use the dual catalyst system.