Process for hydrocracking heavy oil

Abstract

The catalyst comprises a mixture of hydrocracked residual asphaltene and metal-doped coke. The catalyst is produced by mixing an oil-soluble metal compound catalyst precursor (e.g. Mo or Ni soap) with heavy oil containing asphaltene and hydrocracking the mixture, producing solid coke as a byproduct. The residual asphaltene fraction in the hydrocracked oil is then precipitated, for example with n-pentane. The mixture of solid coke and precipitated asphaltene is separated and used as the catalyst for hydrocracking a new batch of non-hydrocracked oil. The coke and asphaltene mixture provides as effective a catalyst as the original metal soap catalyst precursor. The coke and asphaltene mixture recovered from a second stage of coke and asphaltene mixture catalysed hydrocracking of heavy oil is still an effective catalyst and can be used again without significant loss in catalytic activity. Similarly, coke and asphaltene mixture from non-catalytic hydrocracking of bitumen displays a catalytic effect which, however, is lower than that described above.