A multi-stage
catalytic hydrogenation and hydroconversion process for heavy
hydrocarbon feed materials such as
coal, heavy
petroleum fractions, and
plastic waste materials. In the process, the feedstock is reacted in a first-stage, back-mixed catalytic reactor with a highly dispersed iron-based catalyst having a
powder, gel or liquid form. The reactor
effluent is pressure-reduced, vapors and light distillate fractions are removed overhead, and the heavier
liquid fraction is fed to a second stage back-mixed catalytic reactor. The first and second stage catalytic reactors are operated at 700-850.degree. F. temperature, 1000-3500 psig
hydrogen partial pressure and 20-80 lb. / hr per ft.sup.3 reactor
space velocity. The vapor and light distillates liquid fractions removed from both the first and second stage reactor
effluent streams are combined and passed to an in-line, fixed-
bed catalytic hydrotreater for
heteroatom removal and for producing high quality
naphtha and mid-distillate or a full-range distillate product. The remaining separator bottoms liquid fractions are distilled at successive atmospheric and vacuum pressures, low and intermediate-boiling
hydrocarbon liquid products are withdrawn, and heavier distillate fractions are recycled and further upgraded to provide additional low-boiling
hydrocarbon liquid products. This catalytic multistage
hydrogenation process provides improved flexibility for hydroprocessing the various carbonaceous feedstocks and adjusting to desired product structures and for improved economy of operations.