Chevron U.s.a. Inc.

Other

General Electric Company

Kaidong Chen

Bruce Edward Reynolds

Julie Chabot

Alexander E Kuperman

Oleg Mironov

Jaime R Lopez

Axel Brait

Grigorii Lev Soloveichik

Dan Hancu

Shuwu Yang

Darush Farshid

Jonathan Lloyd Male

Stanlee Teresa Buddle

Bo Kou

Pak C Leung

Teresa Grocela Rocha

Erin Maris

Eric George Budesheim

Alison Liana Palmatier

Jennifer Kathleen Redline

Vivion Andrew Brennan

Goutam Biswas

Aaron Simon

Sean Solberg

Gregory Lee Warner

A method to upgrade heavy oil feedstock using an ebullated bed reactor and a novel catalyst system is provided. The ebullated bed reactor system includes two different catalyst with different characteristics: an expanded catalyst zone containing particulate catalyst having a particle size of greater than 0.65 mm; and a slurry catalyst having an average particle size ranging from 1 to 300 &#x3bc;m. The slurry catalyst is introduced to the ebullated bed system with the heavy oil feedstock, and entrained in the upflowing hydrocarbon liquid passing through the ebullated bed reaction zone. The slurry catalyst reduces the formation of sediment and coke precursors in the ebullating bed reactor system. The slurry catalyst is prepared from at least a water-soluble metal precursor and pre-sulfided prior to being introduced with the heavy oil feedstock to the reactor system, or sulfided in-situ in the ebullated bed reactor in another embodiment.

Hydroprocessing catalysts and methods for making thereof

The instant invention is directed to a process employing slurry catalyst compositions in the upgrading of heavy oils. The slurry catalyst composition is not permitted to settle, which would result in possible deactivation. The slurry is recycled to an upgrading reactor for repeated use and products require no further separation procedures for catalyst removal.

Process for recycling an active slurry catalyst composition in heavy oil upgrading

A hydroprocessing bulk catalyst is provided. A process to prepare hydroprocessing bulk catalysts is also provided. The hydroprocessing catalyst has the formula (M)(L)(S)(C)(H)(O)(N), wherein M is at least one group VIB metal; promoter metal L is optional and if present, L is at least one Group VIII non-noble metal; t, u, v, w, x, y, z representing the total charge for each of the components (M, L, S, C, H, O and N, respectively); ta+ub+vd+we+xf+yg+zh=0; 0=&#x3c;b; and 0=&#x3c;b/a=&#x3c;5, (a+0.5b)&#x3c;=d&#x3c;=(5a+2b), 0&#x3c;=e&#x3c;=11(a+b), 0&#x3c;=f&#x3c;=7(a+b), 0&#x3c;=g&#x3c;=5(a+b), 0&#x3c;=h&#x3c;=0.5(a+b). The catalyst has an X-ray powder diffraction pattern with at least one broad diffraction peak at any of Bragg angles: 8 to 18&#xb0;, 32 to 40&#xb0;, and 55 to 65&#xb0; (from 0 to 70&#xb0; 2-&#x3b8; scale). In one embodiment, the catalyst is prepared by sulfiding at least one Group VIB metal compound and optionally at least one group VIII metal compound with a sulfiding agent forming a catalyst precursor; and mixing the catalyst precursor with a hydrocarbon compound to form the hydroprocessing catalyst composition.

Hydroprocessing bulk catalyst and uses thereof

Systems and methods for hydroprocessing a heavy oil feedstock, the system employs a plurality of contacting zones and separation zones with at least some of the fresh slurry catalyst being supplied to at least a contacting zone other than the first contacting zone. The contacting zones operate under hydrocracking conditions, employing the slurry catalyst for upgrading the heavy oil feedstock, forming upgraded products of lower boiling hydrocarbons. In the separation zones, upgraded products are removed overhead and optionally, further treated in an in-line hydrotreater. A least a portion of the non-volatile fractions recovered from the separation zones is recycled back to the first contacting zone in the system.

Systems and methods for producing a crude product

A hydroprocessing catalyst is provided. The hydroprocessing catalyst has the formula (M)(X)(S)(C)(H)(O)(N), wherein M is at least one group VIB metal; X is at least one Group VIII non-noble metal; t, u, v, w, x, y, z representing the total charge for each of the components (M, X, S, C, H, O and N, respectively); ta+ub+vd+we+xf+yg+zh=0; and 0=&#x3c;b/a=&#x3c;5, (a+0.5b)&#x3c;=d&#x3c;=(5a+2b), 0&#x3c;=e&#x3c;=11(a+b), 0&#x3c;=f&#x3c;=7(a+b), 0&#x3c;=g&#x3c;=5(a+b), 0&#x3c;=h&#x3c;=0.5(a+b). The catalyst has an X-ray powder diffraction pattern with at least one broad diffraction peak at any of Bragg angles: 8 to 18&#xb0;, 32 to 40&#xb0;, and 55 to 65&#xb0; (from 0 to 70&#xb0; 2-&#x3b8; scale). In one embodiment, the at least one diffraction peak is greater than 2 degrees wide at &#xbd; height.

The instant invention is directed to the preparation of a slurry catalyst composition. The slurry catalyst composition is prepared in a series of steps, involving mixing a Group VIB metal oxide and aqueous ammonia to form an aqueous mixture and sulfiding the mixture to form a slurry. The slurry is then promoted with a Group VIII metal. Subsequent steps involve mixing the slurry with a hydrocarbon oil, and combining the resulting mixture with hydrogen gas (under conditions which maintain the water in a liquid phase) to produce the active slurry catalyst.

Highly active slurry catalyst composition

The instant invention is directed to the preparation of a catalyst composition suitable for the hydroconversion of heavy oils. The catalyst composition is prepared by a series of steps, involving mixing a Group VIB metal oxide particularly molybdenum oxide and aqueous ammonia to form an aqueous mixture, and sulfiding the mixture to form a slurry. The slurry is then promoted with a Group VIII metal. Subsequent steps involve mixing the slurry with a hydrocarbon oil and combining the resulting mixture with hydrogen gas and a second hydrocarbon oil having a lower viscosity than the first oil. An active catalyst composition is thereby formed.

A catalyst system comprising a catalyst and a reductant is disclosed. The catalyst comprises a metal oxide catalyst support, a catalytic metal oxide, and a promoting metal. The catalytic metal oxide comprises gallium oxide, indium oxide or a combination of the two. The promoting metal comprises at least one of silver, cobalt, vanadium, molybdenum, tungsten, zinc, tin and bismuth. The catalyst comprises about 5 to about 31 mol % catalytic metal oxide and about 0.5 to about 9 mol % promoting metal. The reductant comprises a fluid hydrocarbon having at least 4 carbon atoms. Also disclosed is a process for reducing NOto Nusing the disclosed catalyst system by mixing NOwith a reductant and passing the mixture through a catalyst of the disclosed catalyst system.

[object Object]

The instant invention is directed to the preparation of a slurry catalyst composition. The slurry catalyst composition is prepared in a series of steps, involving mixing a Group VIB metal oxide, particularly molybdenum and aqueous ammonia to form an aqueous mixture and sulfiding the mixture to form a slurry. The slurry is then promoted with a Group VIII metal. Subsequent steps involve mixing the slurry with a hydrocarbon oil, and combining the resulting mixture with hydrogen gas (under conditions which maintain the water in a liquid phase) to produce the active slurry catalyst.

The instant invention is directed to a process for upgrading heavy oils using a slurry composition. The slurry composition is prepared by a series of steps, involving mixing a Group VIB metal oxide and aqueous ammonia to form an aqueous mixture, and sulfiding the mixture to form a slurry. The slurry is then promoted with a Group VIII metal. Subsequent steps involve mixing the slurry with a hydrocarbon oil and combining the resulting mixture with hydrogen gas and a second hydrocarbon oil having a lower viscosity than the first oil. An active catalyst composition is thereby formed.

Process for upgrading heavy oil using a highly active slurry catalyst composition

The instant invention is directed to a process for upgrading heavy oils using a slurry composition. The slurry composition is prepared in a series of steps, involving mixing a Group VIB metal oxide with aqueous ammonia to form an aqueous mixture and sulfiding the mixture to form a slurry. The slurry is then promoted with a Group VIII metal compound. Subsequent steps involve mixing the slurry with a hydrocarbon oil, and combining the resulting mixture with hydrogen gas (under conditions which maintain the water in a liquid phase) to produce the active slurry catalyst.

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Albany, CA, United States of America

Kaidong Chen