Chevron U.s.a. Inc.

Darren P Fong

Alexander E Kuperman

Theodorus Maesen

Dennis Dykstra

Soy Uckung

Joseph A Biscardi

Paul J Marcantonio

Theodorus Ludovicus Michael Maesen

This invention is directed to hydrocracking catalysts and hydrocracking processes employing a magnesium aluminosilicate clay and a zeolite. The magnesium aluminosilicate clay has a characteristicSi NMR spectrum. The magnesium aluminosilicate clay is the product of a series of specific reaction steps. The resulting magnesium aluminosilicate clay combines high surface area and activity for use in hydrocracking catalysts and processes.

Hydrocracking catalyst and process using a magnesium aluminosilicate clay

This invention is directed to hydrocracking catalysts and hydrocracking processes employing a magnesium aluminosilicate clay. The magnesium aluminosilicate clay has a characteristicSi NMR spectrum. The magnesium aluminosilicate clay is the product of a series of specific reaction steps. Briefly, the magnesium aluminosilicate clay employed in the catalyst and process of the present invention is made by combining a silicon component, an aluminum component, and a magnesium component, under aqueous conditions and at an acidic pH, to form a first reaction mixture and subsequently the pH of the first reaction mixture is adjusted to greater than about 7.5 to form a second reaction mixture. The second reaction mixture is allowed to react under conditions sufficient to form the magnesium aluminosilicate clay. The resulting magnesium aluminosilicate clay combines high surface area and activity for use in hydrocracking catalysts and processes.

A catalyst precursor for preparing a bulk multi-metallic catalyst upon sulfidation is provided. The precursor has an essentially monomodal pore volume distribution with at least 90% of the pores being macropores, and a total pore volume of at least 0.08 g/cc. The bulk multi-metallic prepared from the precursor is particularly suitable for hydrotreating heavy oil feeds having a boiling point in the range of 343&#xb0; C. (650&#xb0; F.)&#x2014;to 454&#xb0; C. (850&#xb0; F.), an average molecular weight Mn ranging from 300 to 400, and an average molecular diameter ranging from 0.9 nm to 1.7 nm.

Hydroconversion multi-metallic catalyst and method for making thereof

A method for preparing a bulk multi-metallic suitable for hydrotreating heavy oil feeds is provided. In the process of preparing the catalyst precursor which is subsequently sulfided to form the bulk catalyst, non-agglomerative drying is employed to keep the catalyst precursor from aggregating/clumping, resulting in a catalyst precursor with optimum porosity with at least 90% of the pores being macropores, and having a total pore volume of at least 0.08 g/cc.

A stable catalyst with low volumetric shrinkage and a process for making the stable catalyst with low volumetric shrinkage is disclosed. The catalyst is made by sulfiding a catalyst precursor containing at least a Group VIB metal compound; at least a promoter metal compound selected from Group VIII, Group IIB, Group IIA, Group IVA and combinations thereof, having an oxidation state of either +2 or +4; optionally at least a ligating agent; optionally at least a diluent. In the process of making the catalyst, the catalyst precursor is first shaped then heat treated at a temperature of 50&#xb0; C. to 200&#xb0; C. for about 15 minutes to 12 hours, wherein the catalyst precursor still has a low (less than 12%) volumetric shrinkage after exposure to a temperature of at least 100&#xb0; C. for at least 30 minutes, e.g., in sulfidation or in a hydrotreating reactor.

A method for preparing a bulk multi-metallic suitable for hydrotreating heavy oil feeds is provided. In the process of preparing the catalyst precursor which is subsequently sulfided to form the bulk catalyst, a catalyst precursor filter cake is treated with at least a chelating agent, resulting in a catalyst precursor with optimum porosity with at least 90% of the pores being macropores, and having a total pore volume of at least 0.12 g/cc.

A process for preparing a bulk multi-metallic catalyst for hydrotreating heavy oil feeds is provided. The catalyst is particularly suitable for hydrotreating heavy oil feeds having a boiling point in the range of 343&#xb0; C. (650&#xb0; F.)- to 454&#xb0; C. (850&#xb0; F.), an average molecular weight Mn ranging from 300 to 400, and an average molecular diameter ranging from 0.9 nm to 1.7 nm. The bulk multi-metallic catalyst is prepared by sulfiding a catalyst precursor that has an essentially monomodal pore volume distribution with at least 95% of the pores being macropores, and having a total pore volume of at least 0.08 g/cc.

A catalyst precursor composition and methods for making such catalyst precursor are disclosed. The catalyst precursor comprises at least a metal compound selected from Group VIII, Group IIB, Group IIA, Group IVA and combinations thereof, at least one Group VIB metal, at least one organic, oxygen-containing ligand, and a cellulose-containing material. Catalysts prepared from the sulfidation of such catalyst precursors are used in the hydroprocessing of hydrocarbon feeds. In one embodiment, the sulfidation is carried out by contacting the catalyst precursor with hydrogen and a sulfur containing compound in a 'slow' process with the sulfidation taking place over a few days up to two weeks, e.g., for at least over 96 hours. In another embodiment, the sulfidation is in a 'quick' process with the sulfidation taking place in less than 72 hours. The catalyst prepared from the slow sulfidation process gives a 700&#xb0; F.+ conversion rate of at least 25% higher than the 700&#xb0; F.+ conversion rate of a catalyst prepared from a quick sulfidation process.

Hydroconversion processes employing multi-metallic catalysts and method for making thereof

The invention is directed to a method of making a catalyst comprising an intermediate pore size molecular sieve, preferably a zeolite of the MTT or TON type. SSZ-32 and ZSM-22 are examples of such molecular sieves. This catalyst is modified with a metal or metals selected from the group consisting of Ca, Cr, Mg, La, Ba, Pr, Sr, K and Nd. The catalyst is additionally loaded with a Group VIII metal or metals for hydrogenation purposes. The catalyst is suitable for use in a process whereby a feed including straight chain and slightly branched paraffins having 10 or more carbon atoms is isomerized.

Metal loaded microporous material for hydrocarbon isomerization processes

The invention is directed to a method of making a catalyst comprising an intermediate pore size molecular sieve, preferably a zeolite of the MTT or TON type. SSZ-32 and ZSM-22 are examples of such molecular sieves. This catalyst is modified with a metal or metals selected from the group consisting of Ca, Cr, Mg, La, Ba, Pr, Sr, K and Nd. The catalyst is additionally loaded with a Group VII metal or metals for hydrogenation purposes. The catalyst is suitable for use in a process whereby a feed including straight chain and slightly branched paraffins having 10 or more carbon atoms is isomerized.

A base oil feed having a tendency to form a haze at ambient or sub-ambient temperatures is contacted with a solid adsorbent to remove at least a portion of the haze precursors, thereby reducing the haze-forming tendency of the base oil feed.

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Oakland, CA, United States of America

Darren P Fong