Chevron U.s.a. Inc.

Christopher Paul Dunckley

Julie Chabot

Shuwu Yang

Joseph V Nguyen

Ling Jiao

Alexander E Kuperman

Bruce Edward Reynolds

Oleg Mironov

Erin Maris

Axel Brait

Rahul Shankar Bhaduri

Bo Kou

Kenneth Kwik

Erin P Maris

A method for preparing an improved slurry catalyst for the upgrade of heavy oil feedstock is provided. In one embodiment, the process comprises: sulfiding at least a metal precursor solution with at least a sulfiding agent forming a sulfided Group VIB catalyst precursor, the metal precursor solution having a pH of at least 4 and a concentration of less than 10 wt. % of Primary metal in solution; and mixing the catalyst precursor with a hydrocarbon diluent to form the slurry catalyst composition. The slurry catalyst prepared therefrom has a BET total surface area of at least 100 m/g, a total pore volume of at least 0.5 cc/g and a polymodal pore distribution with at least 80% of pore sizes in the range of 5 to 2,000 Angstroms in diameter.

Hydroprocessing catalysts and methods for making thereof

An improved hydroprocessing slurry catalyst is provided for the upgrade of heavy oil feedstock. The catalyst comprises dispersed particles in a hydrocarbon medium with the dispersed particles have an average particle size ranging from 1 to 300 &#x3bc;m. The catalyst has a total pore volume of at least 0.5 cc/g and a polymodal pore distribution with at least 80% of pore sizes in the range of 5 to 2,000 Angstroms in diameter. The catalyst is prepared from sulfiding and dispersing a metal precursor solution in a hydrocarbon diluent, the metal precursor comprising at least a Primary metal precursor and optionally a Promoter metal precursor, the metal precursor solution having a pH of at least 4 and a concentration of less than 10 wt. % of Primary metal in solution.

An improved process to make a slurry catalyst for the upgrade of heavy oil feedstock is provided. The sulfiding of the metal precursor/catalyst precursor is carried out at least twice ('enhanced sulfiding') in the improved process to form a slurry catalyst with improved surface area and porosity value. The slurry catalyst under an enhanced sulfiding scheme is characterized as having increased catalytic activities over a slurry catalyst without an enhanced sulfidation step.

Growing community of inventors

Menlo Park, CA, United States of America

Christopher Paul Dunckley