Chevron U.s.a. Inc.

Soy Uckung

Alexander E Kuperman

Theodorus Maesen

Dennis Dykstra

Darren P Fong

Ping Wang

Darren Fong

In a process for forming a bulk hydroprocessing catalyst by sulfiding a catalyst precursor made in a co-precipitation reaction, up to 60% of the metal precursor feeds end up in the supernatant. The metals can be recovered via any of chemical precipitation, ion exchange, electro-coagulation, and combinations thereof to generate an effluent stream containing less than 50 mole % of metal ions in at least one of the metal residuals, and for at least one of the metal residuals recovered as a metal precursor feed for use in the co-precipitation reaction. In one embodiment, the resin functions as an anion exchange resin with an acidic supernatant to recover Group VIB metal residuals, and a cation exchange resin with a basic supernatant to recover Promoter metal residuals. An effluent stream from the process to waste treatment contains less than 50 ppm metals.

Hydroconversion multi-metallic catalyst and method for making thereof

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.

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.

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Richmond, CA, United States of America

Soy Uckung