Dispersed anion-modified iron oxide catalysts for hydroconversion

Abstract

A dispersed fine-sized anion-modified iron oxide slurry catalyst having high surface area exceeding about 100 m.sup.2 /gm and high catalytic activity, and which is useful for hydrogenation and hydroconversion reactions for carbonaceous feed materials is disclosed. The catalyst is synthesized by rapid aqueous precipitation from saturated salt solutions such as ferric alum or ferric sulfate, and is promoted with at least one active metal such as cobalt, molybdenum, nickel, tungsten and combinations thereof. The iron-based dispersed catalysts are modified during their preparation with anionic modifiers such as molybdate (MoO.sub.4.sup.2-), phosphate (PO.sub.4.sup.3-), sulfate (SO.sub.4.sup.2-), or tungstate (WO.sub.4.sup.2-). The resulting catalyst usually has primary particle size smaller than about 50 Angstrom units, and may be used in the form of a gel or wet cake which can be easily mixed with a hydrocarbonaceous feed material such as coal, heavy petroleum fractions, mixed waste plastics or mixtures thereof. Alternatively, the catalyst can be dried and/or calcined so as to be in a fine dry particulate form suitable for adding to the feed material. The invention includes methods for making the catalyst and processes for using the catalyst for hydroprocessing of the carbonaceous feed materials.