DE3500574A1 - Multi-stage catalytic process for converting heavy hydrocarbon liquid charges - Google Patents

Abstract

In a process for the hydroconversion in good yield of heavy liquid hydrocarbons such as, for example, petroleum residue charges which contain at least about 25% by volume of material boiling above about 520 DEG C<+)<975 DEG F<+>), using multi-stage catalytic reactions at elevated temperature and pressure to produce increased yields of lower-boiling hydrocarbon liquids and hydrocarbon gas, the charge is fed in the liquid phase with hydrogen under elevated temperature and pressure conditions into a staged catalyst reactor system preferably containing catalytic fluidised beds, from which a vacuum bottom fraction having a nominal boiling point above about 430 DEG C(800 DEG F) is recycled to the reactor of the last stage and not to that of the first stage, in order to improve the conversion of the 520 DEG C<+)<975 DEG F<+>) fraction to lower-boiling liquid products. If desired, three stages of the catalytic reaction can be used, the vacuum bottom material fraction being recycled to the third-stage reactor.

Description

description

This invention relates to a method for catalytic conversion of heavy hydrocarbon liquid feeds in high yield using of catalytic reactors in several stages connected in series flow arrangement are. In particular, it relates to such a multi-stage hydroconversion process for heavy petroleum charges that are at least about 25 volume percent above 520 OC (975 OF) boiling material and in which a vacuum bottom material fraction is recycled to the last stage of the catalytic reactor to achieve a increased hydroconversion of the feed to lower boiling hydrocarbon liquid and manufacture gas products.

The percent hydroconversion of a hydrocarbon feed for one-time operations in a single catalytic reactor for manufacture of lower boiling hydrocarbon liquids and gases is common limited to only about 75 vol .-%. To achieve a higher conversion of petroleum residues a heavy residue fraction is recycled to the reactor, and in two stages Reactor systems, the residual fraction was recycled to the reactor of the first stage. It has been found, however, that in such a two-stage catalytic mode of operation, applied to hydrocarbon liquid feeds, the conversion in the reactor the first stage generally does not exceed about 60% by volume and that the addition a heavy fraction of recycle liquor to the first stage reactor is not very effective because of the relatively small change in residual concentration, which occurs in it, in connection with a decreased total residence time of the Residual fraction under reactor conditions.

The catalytic hydrogenation and conversion of petroleum residues in a single-stage catalytic fluidized bed reactor with recycling of the vacuum bottom fraction on the reactor is well known, for example from US Pat. No. 2,987,465 (Johanson) and US Pat U.S. Patent 3,412,010 to Alpert. In US Pat. No. 3,184,402 (Kozlowski) a two-stage catalytic hydrocracking process with intermediate fractionation and some Recycle a still bottoms fraction to either a first or a second catalytic cracking zone described. Also in US Pat. No. 3,775,293 (Watkins) a two-stage desulfurization process with recycling of the entire Heavy oil fraction that boils above the diesel fuel oil to a fixed bed reactor described in a second stage. However, these processes are relatively low-boiling Materials are being recycled and further process improvements are needed to increase conversion of heavy, higher boiling hydrocarbon liquid feeds, such as petroleum residues with a nominal boiling range above about 430 0c (800 OF). It has now surprisingly been found that the effect of recycling a heavy fraction of liquid on overall conversion heavy hydrocarbon feed becomes more effective when the heavy Liquid fraction to the reactor of the last stage of a multi-stage catalytic Reactor system is recycled.

The present invention provides a multi-step catalytic process ready for hydroconversion of heavy hydrocarbon liquid feeds, which is at least 25% by volume of one normally boiling above about 520 OC (975 OF) Material, for the production of lower boiling hydrocarbon liquid and gas products in increased yields. In this process, the liquid Feed material catalytically in the liquid phase with hydrogen at increased Temperatures and pressures in one multi-stage catalytic reactor system implemented in which a heavy vacuum soil fraction with a nominal intersection from above about 430 OC (800 OF) and preferably above about 450 OC (850 OF) is recycled to a catalytic fluidized bed reactor of a last stage in a multi-stage reactor system to convert the feed and specially the fraction of the 520 OC + (9750F + material and thereby improve the yields of C4 to 5200e (975 OF) liquid products.

In particular, the method of the invention comprises feeding a heavy hydrocarbon liquid feed with hydrogen into a catalytic A first stage reactor containing a particulate catalyst, wherein the reactor at a temperature of 410 to 450 OC (780 to 850 OF), a hydrogen partial pressure from 70 to 210 bar (1000 to 3000 psi) and at a total room velocity of 0.20 to 2.0 VFl / h / VRe (volume of fresh feed per hour per reactor volume) is held to partially hydroconvert the feed under manufacture an effluent material; directing the partially hydroconverted effluent Material in all subsequent stages of catalytic reactors including a catalytic fluidized bed reactor of a final stage operating at a temperature from 410 to 450 OC (780 to 850 OF), a hydrogen partial pressure from 70 to 210 bar (1000 to 3000 psi) and at an overall space velocity of 0.20 to 2.0 VF / h / VRe is held, and further hydroconverting the material to manufacture of hydrocarbon gases and lower boiling liquid fractions; the removal of the hydrocarbon gases and liquid fractions from the reactor the last Stage and the separation of the hydrocarbon gases from the liquid fractions and withdrawing the liquid fractions; distilling the liquid fractions for the production of mid-range boiling hydrocarbon liquid products with normal boiling ranges from around 200 to 4000C (400 to 750 OF), 400 to 520 OC (750 to 975 OF) and a vacuum soil material with a nominal intersection above about 520 OC (975 OF); and recycling at least a portion of the Vacuum bottom material to the last stage fluid catalytic reactor Manufacture of mid-range boiling hydrocarbon liquid products in increased yields.

The present invention is useful for hydroconverting Petroleum residues, bitumen from tar sands and crude shale oil. In the process three catalytic reactors can be connected in series, but are preferred two in series, catalytic fluidized bed reactors used with a recycle the heavy vacuum bottom fraction into the second stage reactor. Although this Processes can be used in a catalytic reactor system of any type catalytic fluidized bed type reactors are usually preferred, particularly for liquid feeds that contain solid particles and / or metal compounds in significant quantities contain.

Advantages of the present invention, in which at least a part the heavy hydrocarbon liquid fraction to the reactor of the second or last Stage recycled include a higher hydroconversion of the feed, to produce distillate hydrocarbon fraction products in increased yield.

The invention is explained in more detail below on the basis of exemplary embodiments with reference to the drawing; It shows: Figures 1 and 2 graphical representations of the comparative effects of recycling a vacuum soil fraction to either the first or the Stage of a catalytic reactor in percent hydroconversion of the feed versus the results of once-through operations the first stage reactor, and heavy liquid recycling to the second stage reactor, Figure 4 is a schematic diagram of a two stage catalytic hydroconversion process for heavy hydrocarbon liquid feeds using recycle of vacuum bottoms fraction to the last stage reactor according to the invention.

In a preferred embodiment of the present invention a heavy hydrocarbon liquid load, such as petroleum residues, pressurized, heated and introduced into a catalytic with hydrogen gas First stage reactor of a two stage catalytic reactor system. Of the The first stage reactor can be either a fixed bed catalytic reactor or a fluidized bed catalytic reactor, the reactor being of the fluidized bed type is especially preferred for feeds that have greater than about 300 ppm total metals which are usually mainly vanadium and nickel compounds. The first stage reaction zone conditions are at a temperature of 410 up to 450 OC (780 to 850 ° F), a hydrogen partial pressure of 70 to 210 bar (1000 up to 3000 psi) and at a total room velocity of 0.2 to 2.0 VFl / hPVRe held to achieve a partial catalytic hydroconversion of the Feed. Preferred reaction conditions are a temperature of 420 to 445 OC (790 to 840 ob), a hydrogen partial pressure of 84 to 200 bar (1200 to 2800 psi) and a total room velocity of 0.25 to 1.8 VFl / h / VRe.

From the reactor of the first stage, the resulting gas and the partially converted liquid material along with additional hydrogen passed into a catalytic fluidized bed reactor of a second stage for further Hydroconversion reactions. The second stage reactor can at essentially maintained under the same conditions as the first stage reactor, depending on of the batch to be processed and the percentage of the desired Conversion. If the feed is total metals, such as vanadium and Nickel, in an amount greater than about 300 ppm, is preferred a demetallization type catalyst, for example an inexpensive catalyst material to remove vanadium and nickel, preferably via sulfur, in the fluidized bed reactor the first stage used because of its lower cost, and a catalyst of the hydroconversion or desulfurization type is used in the fluidized bed reactor second stage used. The demetallization type catalyst may be composed of a particulate, naturally occurring bauxite or alumina material, the lower amounts of other metal oxides, such as iron or molybdenum, may contain, as is known per se. The hydroconversion catalyst or desulfurization type contains active metal oxides of metals consisting of the following selected are: cadmium, chromium, cobalt, iron, molybdenum, nickel, tin, and / or Tungsten, each deposited on a carrier material made of aluminum oxide and / or Silicon dioxide.

The outflowing material is phase separated from the reactor of the second stage, and the liquid fraction obtained becomes a distillation stage at a lower pressure directed. The resulting vacuum bottom fraction is placed in the catalytic fluidized bed reactor the second stage recycled where the concentration of the residue in the reactor is much less than in the first stage, in order to get the effect of the heavy in this way Recycle Fluid to maximize the percent conversion of the feed.

According to the present invention, it was found that although the effect the recycling of a vacuum soil fraction to the conversion of the heavy ones Hydrocarbon loading at conversion levels less than about 60% zero is, as indicated in Fig. 1, for conversions that are higher than about 60 vol .-% are, the effect of vacuum bottom material recycling on percent conversion Is more beneficial if the recycle fraction in the reactor the last Stage of a multi-stage catalytic reactor system is fed, as in the Fig. 2 shown.

The effect on percent conversion of a heavy hydrocarbon feed, by recycling a vacuum bottom material into the reactor of a first Stage is shown in Fig. 1, in which the percentage conversion results applied to the single-stage reactor when recycling a vacuum bottom material oppose single-stage conversion achieved without such recycling will. As can be seen from the graph, line A, at below about 60% conversion the effect of recycling heavy liquid in the reactor to the percentage conversion zero because of the relatively low The change in the concentration of residues occurring in the reactor decreased Residual time of the residue not under reactor conditions balance can. However, as soon as the percentage conversion is increased, for example by Increasing the severity of the reaction conditions decreases the concentration of the residual fraction (usually 520 OC + (975 0F +) in the reactor liquid. This way is the change in concentration of the residue fraction in the reactor caused by the addition a vacuum bottom fraction is effected into the reactor, greater than that at conditions there is a low conversion. Even if there is less dwell time than the once-through type operation, this recycling arrangement results in an increased conversion percentage of the feed. This result will shown by the data of Figure 1 through which line B has been drawn.

When operating a two-stage catalytic reactor, the conversion is usually less than about 60 volume percent in the first stage reactor. thats why the recycling of a heavy liquid to the first stage reactor is effective to improve residual conversion only above about 60% conversion, like in Fig. 2, line B shown. However, as mentioned above, it has been found that the Conversion can be vastly improved by recycling the heavy liquid or the residual fraction to the second stage reactor in place of the reactor to the first stage, as shown in FIG. 2, line C. This conversion increase occurs even when the residue recycle to the first stage reactor causes a higher residue concentration in both the first and second stages, whereas if the redisuum is only recycled to the second stage reactor is, only this reactor is favored by a higher residue concentration in it will.

The overall conversion is nonetheless higher with a recycling of the residual fraction only in the second stage in comparison with a recycling to the first stage because increasing the residual residence time has the advantages of a decreased Concentration more than compensates. Hence, the net result sees a higher level of conversion before when the residual fraction is recycled into the reactor of the second or last stage becomes as if it is recycled to the first stage reactor.

After an attempt to explain these recycling relationships becomes the percentage hydroconversion of the heavy liquid fraction in the Feed mainly influenced by three factors, i.e. the reactor temperature, the concentration of the heavy liquid or residual fraction in the reactor and the residence time of the residue in the reactor. Raising the level of one Each of these factors will convert the residual to varying degrees raise. When a concentrated portion of unconverted heavy liquid is recycled to a catalytic reactor, the concentration of this Residual material is raised in the reactor.

However, the residual residence time will actually decrease wherever the residence time is defined as the volumetric fraction of the residual in the Liquid feed to the total reactor multiplied by the reactor volume divided by the total liquid volumetric feed rate in the reactor. This decrease in residence time results from the loading of more residue per Unit of time through the same reactor volume.

To demonstrate these changes in dwell times, three Flow arrangements for hydroconversion operations in two stage catalytic Reactors are presented in Figure 3 showing these three types of operations.

A matching base is used in each arrangement; H. both reactors have the same temperature and volume and fresh feed rate in the reactor system is also the same for each. It was found that for the two Recycle arrangements B and C the residence times both lower are than those for single-through operation according to arrangement A. However, im In the case of recycling to the second stage according to arrangement C, the residence time is longer than with a recycling to the first stage according to arrangement B.

A preferred embodiment of the present invention is shown in 4 shown. Referring now to the diagram of FIG. 4, there will be a severe one Petroleum loading, such as Kuwait Vacuum Residuum or Safaniya Vacuum Bottom Material, provided at 10, pressurized by pump 12 and by the preheater 14 directed to heat the charge to at least about 260 OC (500 OF), but not at a temperature high enough to cause any coking of the feed stream to cause in the preheater. The heated feed stream at 15 is then fed into a catalytic, fluidized bed reactor 20 of the first stage. Heated hydrogen is provided at 16 and also fed into reactor 20.

The reactor 20 contains an inlet flow manifold and a catalyst support grate 21 so that the feed liquid and gas uniformly up through the Reactor 20 are passed and the catalyst bed 22 is expanded to at least about 10%, and usually no more than about 50%, above its set-off height, and sets the catalyst in a random motion in the liquid. This Reactor is typical of the type disclosed in U.S. Patent No.

Re. 25 770, in which a liquid phase reaction occurs in the presence of a reactant gas and a particulate catalyst in one Way that the catalyst bed is expanded.

The catalyst particles in bed 22 usually have a relative narrow size range for uniform bed expansion under controlled upward fluid flow and gas flow conditions. While a suitable catalyst particle size one The size corresponds to a clear mesh size of 3.36 to 0.15 mm (6 and 100 mesh US Sieve Series), the catalyst preferably has a particle size accordingly a mesh size of 3.36-0.30 mm (6 and 50 mesh) inclusive Extrudates approximately 0.25 to 2.5 mm in diameter. In the reactor are the density the catalyst particle, the liquid upward velocity and the lift the upward flowing liquid and the hydrogen gas are important factors the expansion and operation of the catalyst bed.

By controlling the catalyst particle size and density and the speed of the liquid and gas flowing upwards and taking into account the viscosity of the liquid at the reactor operating conditions, the catalyst bed 22 is in expands to a desired extent to an upper level or interface in the Liquid as shown at 22a.

The hydroconversion reaction in bed 22 is enhanced by use an effective catalyst greatly facilitated.

The catalyst used is a typical hydrogenation catalyst, contains activated metal oxides, which are supported on a carrier material made of aluminum oxide and / or silica are deposited. Fresh catalyst becomes periodic added directly into reactor 20 through suitable inlet connection means 25 at a rate between about 0.28 to 5.6 grams of catalyst per quarter of petroleum charge (0.10 to 2.0 lbs ca'balyst / barrel petroleum feed), and used catalyst is withdrawn through suitable extraction devices 26 to the desired amount of catalyst and maintain activity in the reactor. In the case of hydrocarbon feeds, which contain more than about 300 ppm total vanadium and nickel should be in a demetallization type catalyst is used in the first stage reactor will.

A recycling of the reactor liquid from above Solid interface 22a downstream of a flow distributor 21 is usually necessary for construction an upflow liquid velocity sufficient to remove the catalyst in the to keep the desired expanded statistical distribution in the liquid and to facilitate the effective reactions. Such a liquid recycling is preferably accomplished through the use of a central downpipe 18, which is connected to a recycling pump 19 below the flow distributor 21 extends to allow a positive and controlled upward flow of the liquid through it to ensure the catalyst bed 22.

The recycling of the reactor liquid through the internal line 18 has some mechanical advantages and allows the number of external high pressure connections that are used in a hydrogenation reactor, however, liquid recycle up through the catalyst bed can alternatively are produced by a recycling line and pump that are located outside of the reactor. In a fluidized bed reactor system, there is a vapor space 23 above the liquid level 23a.

The operability of catalytic fluidized bed reactor systems for Ensure good contact and a uniform (isothermal) temperature in it to achieve the desired hydroconversion results does not depend only from the statistical distribution of the catalyst particles in the liquid environment, resulting from the buoyancy effect of the liquid and gas flowing upwards, but also requires suitable reaction conditions. If the reaction conditions are unsuitable only insufficient hydroconversion is achieved, resulting in non-uniform Distribution of the liquid flow and usually in excessive coke deposits results on the catalyst.

For hydroconversion of petroleum charges using of this invention, the operating conditions are in the range of a temperature of 410 to 450 OC (780 to 850 OF), a hydrogen partial pressure of 70 to 210 bar (1000 to 3000 psi) and an overall room velocity of 0.2 to 2.0 VFl / h / VRe (Volume of fresh feed per hour per volume of the reactor). Preferred reactor conditions are a temperature of 420 to 445 OC (790 to 840 OF), a hydrogen partial pressure from 84 to 200 bar (1200 to 2800 psi) and an overall space velocity of 0.25 up to 1.8 VFl / h / VRe. The feed hydroconversion achieved is at least about 60 vol% for once-through type operations.

From the reactor 20 of the first stage, an overhead stream, which is a mixture contains from both gas and liquid fractions, withdrawn at 27 and passed into the lower end of the second stage reactor 30, which is a fluidized bed 32 of a contains particulate catalyst. This catalyst 32 usually has the same Size than that used in reactor 20, but can also be and has a little larger preferably a particle size corresponding to an effective diameter of 0.75 up to 1.75 mm (0.030 to 0.070 inch).

The operation of this second stage fluidized bed reactor 30 is complete similar to that of reactor 20, with the reactor liquid being recycled through downcomer 34 and pump 35 and then up through flow manifold 31 to ensure a uniform and controlled expansion and surge of the catalyst bed 32. Appropriate reaction conditions used in the reactor 30 are a temperature of 410 to 450 OC (780 to 850 OF), a hydrogen partial pressure from 70 to 210 bar (1000 to 3000 psi) and an overall space velocity of 0.2 up to 2.0 VFe / h / VRe.

Preferred reaction conditions are a temperature of 420 to 445 OC (790 to 840 OF), a hydrogen partial pressure of 8 to 20 bar (1200 to 2800 psi) and a total room velocity from 0.25 to 1.8 VFl / h / VRe . Fresh catalyst is added and used catalyst is removed from the Reactor 30 withdrawn as needed to keep the desired catalyst activity therein similar to that in reactor 20 to be maintained.

From the reactor 30 there is an outflow 39, the gas and lower containing boiling hydrocarbon liquid fractions, withdrawn and sent to the high pressure phase separator 40 headed. The resulting gas fraction 41 contains mainly hydrogen, which is recovered in the gas cleaning stage 42. A flue gas that is mainly Containing H2, CO2, H2S, light hydrocarbon gases and water is removed at 43.

The so-called hydrogen at 44 is usually recycled through the compressor 44a through the line 45 and heated at the heater 46, as required, then it is fed in at the bottom of reactor 20 along with additional hydrogen at 45a, as needed. Also, a portion of the hydrogen flow becomes 45 at the heater 47 reheated as required and fed in with the outflowing stream 27 in the reactor 30.

The remaining liquid fraction 48 is reduced in pressure by the separator 40 at 49 to a pressure below about 14 bar (200 psig) and sent to the fractionation stage 50, from which a low pressure hydrocarbon vapor stream 51 is withdrawn. This Vapor stream is phase separated at 52 to provide a low pressure product gas 53 and a liquid stream 54 to bring a reflux liquid to the fractionator 50 and a naphtha product stream 55 to be provided. One boiling in the middle Distillate liquid product stream is withdrawn at 56 and a heavy fuel oil liquid stream is deducted at 58.

From the fractionator 50, the heavy bottom oil stream 58, which is common has a normal boiling temperature range of 340 to 520 OC (650 to 975 OF), depending heated in the heater as required 59 and passed to the vacuum distillation stage 60. A vacuum gas oil product stream is withdrawn at 62 and a vacuum bottoms stream is deducted at 64. A portion 65 of the vacuum bottom material that has a nominal Boiling point or intersection point above about 430 OC (800 OF) and preferably above about 450 OC (850 OF) r is pressurized at 66, in heater 67 as needed heated and recycled to reactor 30 for further hydroconversion reactions therein so as to convert 75 to 95 volume percent of the feed to lower to achieve boiling hydrocarbon materials.

Depending on the percentage conversion and the desired Process products are at least about 50% by volume, and preferably all Vacuum bottom material at 64 recycles at 65 to reactor 30. The volume ratio of the recycled 520 0c + (975 OF +) material for fresh loading should be within be a range from about 0.2 to 1.5.

A heavy vacuum pitch material is withdrawn at 68 for further use Processing or use as required.

The examples illustrate the invention.

EXAMPLE 1 The Benefit of Total Conversion of Feed and of the yields achieved by the heavy liquid recycling arrangement of The present invention is summarized in Table I below. In this For example, the vacuum bottom fraction that boils above 430 OC (800 OF) is recycled to the reactor of the first stage of a two-reactor system in case 1 and to the reactor the second stage in case 2.

Table I Comparison of 2-stage hydroconversion operations Loading used Safaniya vacuum bottom material spec. Weight. OAPI 4,5 sulfur, Wt.% 5.6 carbon, wt.% 83.9 hydrogen, wt.% 10.0 vanadium, ppm 157 nickel, ppm 49 Ramsboden carbon residue, wt.% 22 5200C (9750F) fraction, vol .-% of the Charge 95 Case No. 1 2 Reactor Temperature, OC (OF) 4400C (8250F) 4400C (8250F) Used Co-Moly catalyst on Al203 total liquid space velocity, WFl / h / VRe 0.37 0.37 Number of stages 2 2 Vacuum soil fraction recycling to Level 1. 2.

Recycle ratio VvB / V fresh charge 0.5 0.5 + 5200C + (975 F) conversion of liquid volume 82 88 Distillation yield,% by volume of the feed c4-2000C (4000F) naphtha 22.0 25.0 200 to 3400C (400 to 6500F) distillate 27.5 30.0 650 to 9750F (340 to 5200C) -heavy fuel oil 41.3 41.7 total 90.8 96.7 As can be seen from the results in Table I under the same operating conditions, the conversion of the feed, which is achieved by recycling the vacuum bottom fraction to the second stage reactor is achieved, about 6% higher than that of recycling to the first stage reactor. A comparable one Improvement is also shown for the distillate yields where the overall yield of C4-5200C (9750F) material is also about 5.9% by volume larger when considering the present Invention used.

Example 2 The heavy fluid recycling arrangement of the present invention The invention can also advantageously be applied to a three-stage reactor system and a corresponding one Operation can be expanded with the same heavy petroleum charge as in example 1 using a three-step catalytic reaction process developed at the same reaction conditions is operated in each stage. The vacuum soil recycling material becomes either the first stage reactor of the three stage reactor system, for Second stage reactor or added to third stage reactor. They achieved comparable conversion results using a recycling of the Vacuum bottom fractions at each stage of the reactor are in the table below II shown.

Table II Comparison of 3-stage hydroconversion operations Case No. 3 4 5 Feed properties as in Table I Reaction conditions as in table I number of stages 3 3 3 vacuum bottom material recycling to stage 1. 2. 3.

520 ° C (975 ° F) conversion, * of liquid volume 82 86 88 All other operating conditions are the same in all three cases.

It can be seen from the above results that a significantly higher percent conversion of the 520 OC + (975 0F +) material is achieved together with higher yields of products with a boiling range from 200 to 520 CC (400 to 9750F) if one recycles the vacuum bottom fraction according to this invention to the third stage reactor, rather than a conventional single stage Reactor or to a catalytic reactor of the second stage.

- blank page -

Claims (16)

Multi-stage catalytic process for the conversion of heavy Hydrocarbon liquid feed claims 1. Process for multi-stage catalytic conversion of heavy hydrocarbon liquid feed in lower boiling hydrocarbon liquids and gases in high yield, not indicated by (a) feeding a hydrocarbon feed together with hydrogen in a catalytic reactor of a first stage, the containing a particulate catalyst, the reactor being at a temperature from 410 to 450 OC (780 to 850 OF), a hydrogen partial pressure from 70 to 210 bar (1000 to 3000 psig) and at a Overall room velocity from 0.20 to 2.0 VFl / h / VRe is kept for partially hydroconverting the feed for the production of an outflowing material, (b) guiding the partially hydroconverted, effluent to all subsequent catalytic reactor stages, including a final stage with a catalytic fluidized bed reactor operating at a temperature from 410 to 450 OC (780 to 850 ° F), a hydrogen partial pressure of 70 to 210 bar (1000 to 3000 psi) and at an overall space velocity of 0.20 to 2.0 VFl / h / VRe is held, and further hydroconverting the material to produce of hydrocarbon gases and lower boiling liquid fractions, (c) removal of the hydrocarbon gases and liquid fractions from the reactor the last Step and separate the hydrocarbon gases from the liquid fractions and withdraw them the liquid fractions, (d) distilling the liquid fractions to produce a medium boiling hydrocarbon liquid product with a normal boiling range of 200 to 430 OC (400 to 800 OF) and a vacuum bottom material with a nominal boiling point above about 430 OC (800 OF) and (e) recycle at least a portion of the vacuum bottom material directly into the final stage of the catalytic Fluidized bed reactor to achieve a YoP-OC + at least about 75% conversion the 520 ° C (975 OF +) fraction in lower boiling material and for manufacture of this mid-range boiling hydrocarbon liquid product in increase yields. 2. The method according to claim 1, characterized in that the reactor the first stage contains a fixed bed of particulate catalyst. 3. The method according to claim 1, characterized in that the reactor the first stage contains a fluidized bed of particulate hydrogenation catalyst. 4. The method according to claim 1, characterized in that in the reactor for the first stage, a temperature of 420 to 445 OC (790 to 840 ° F), a partial pressure of hydrogen from 84 to 200 bar (1200 to 2800 psig) and an overall space velocity of 0.25 up to 1.8 VFl / h / VRe is maintained. 5. The method according to claim 1, characterized in that in the last Reaction stage a temperature of 420 to 445 OC (790 to 840 OF), a hydrogen partial pressure from 84 to 200 bar (1200 to 2800 psig) and an overall space velocity of 0.25 up to 1.8 VFl / h / VRe is maintained. 6. The method according to claim 1, characterized in that the recycled Vacuum floor material has a nominal boiling point above about 450 OC (850 OF) Has. 7. The method according to claim 1, characterized in that the volume ratio of the vacuum bottom material recycled in the last stage for fresh loading in the first stage is about 0.2 to 1.5. 8. The method according to claim 1, characterized in that the catalyst active metal oxides of cadmium, chromium, cobalt, iron, molybdenum, nickel, tin and / or Contains tungsten on a carrier material of aluminum oxide and / or silicon dioxide. 9. The method according to claim 1, characterized in that the catalyst in the reactor of the first and the last catalytic stage cobalt / molybdenum on one Is alumina carrier. 10. The method according to claim 1, characterized in that the catalyst in the catalytic reactor of the first and last stage nickel / molybdenum on one Is alumina carrier. 11. The method according to claim 1, characterized in that the charge is a petrocum residue. 12. The method according to claim 1, characterized in that the charge is bitumen derived from tar sands. 13. The method according to claim 1, characterized in that the charge raw shale oil is. 14. The method according to claim 1, characterized in that the reaction system contains two reactors. 15. The method according to claim 3, characterized in that the charge Contains total metals in an amount greater than 300 ppm and that the catalyst, that is of the demetallization type and is essentially particulate alumina comprises, is used in the reactor of the first stage. 16. A process for the 2-stage, catalytic conversion of petroleum feeds to produce lower boiling hydrocarbon liquids and gases in increased yields, characterized by (a) feeding a hydrocarbon feed together with hydrogen into a first stage catalytic reactor containing a fluidized bed of particulate catalyst , with the reactor maintained at a temperature of 420 to 445 OC (790 to 840 OF) and an overall space velocity of 0.25 to 1.8 VFl / h / VRe to partially hydroconvert the feed to obtain an effluent, ( b) Passing the partially hydroconverted effluent into a second stage fluidized catalytic reactor operating at a temperature of 410 to 450 OC (780 to 850 ° F), a hydrogen partial pressure of 70 to 210 bar (1000 to 3000 psig) and at a Overall room velocity of 0.20 to 2.0 VFl / h / VRe is maintained, and more s hydroconverting the material to produce hydrocarbon gases and lower boiling liquid fractions, (c) removing the hydrocarbon gas and liquid fractions from the second stage reactor and separating the hydrocarbon gases from the liquid fractions and withdrawing the liquid fractions, (d) distilling the liquid fractions to produce an im medium range boiling hydrocarbon liquid product with a normal boiling range of 200 to 450 OC (400 to 850 OF) and also a vacuum soil material with a nominal boiling point above about 450 OC (850 OF) and (e) recycling at least a portion of the vacuum soil material directly into the catalytic Fluidized bed reactor of the second stage providing a recycle ratio of recycled material to fresh feed of about 0.2 to 1.5, by at least about 75% by volume - To achieve conversion of the 520 OC + (975 OF +) fraction to lower boiling material and to produce the mid-range boiling hydrocarbon liquid product in increased yields.