Hydroprocessing bulk catalyst and methods of making thereof
First Claim
1. A process for preparing a catalyst composition comprising:
- i) providing at least two metal precursors of different “
d”
block element metals;
ii) combining the at least two metal precursors with a sulfiding agent, forming at least a sulfided catalyst precursor; and
iii) mixing the at least a sulfided catalyst precursor with a hydrocarbon compound to transform the sulfided catalyst precursor into a catalyst composition having formula (Rp)i(Mt)a(Lu)b(Sv)d(Cw)e(Hx)f(Oy)g(Nz)h, whereinR is optional, R is at least a lanthanoid element metal or an alkaline earth metal;
M is at least a “
d”
block element metal;
L is at least a “
d”
block element metal different from the “
d”
block element metal M;
0<
=i<
=1;
0<
b/a=<
5,0.5(a+b)<
=d<
=5(a+b),0<
e<
=11(a+b),0<
f<
=7(a+b),0<
g<
=5(a+b),0<
h<
=2(a+b),p, t, u, v, w, x, y, z, each representing total charge for each of;
M, L, S, C, H, O and N, respectively, wherein pi+ta+ub+vd+we+xf+yg+zh=0;
wherein the “
d”
block element is selected from the group consisting of iron, zinc, titanium, nickel, copper, cobalt, chromium, and manganese.
1 Assignment
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Accused Products
Abstract
A hydroprocessing bulk catalyst is provided. A process to prepare hydroprocessing bulk catalysts is also provided. The hydroprocessing catalyst has the formula (Rp)i(Mt)a(Lu)b(Sv)d(Cw)e(Hx)f(Oy)g(Nz)h, wherein M is at least at least a “d” block element metal; L is also at least a “d” block element metal, but different from M; 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); R is optional and in one embodiment, R is a lanthanoid element metal; 0<=i<=1; pi+ta+ub+vd+we+xf+yg+zh=0; 0<b; 0<b/a=<5; 0.5(a+b)<=d<=5(a+b); 0 <e<=11(a+b); 0<f<=7(a+b); 0<g<=5(a+b); 0<h<=2(a+b). The catalyst has an X-ray powder diffraction pattern with at least three diffractions peak located at 2-θ angles of greater than 25°. In one embodiment, the catalyst is prepared by forming at least a sulfided catalyst precursors from at least two “d” block element metals; and mixing the catalyst precursor with a hydrocarbon compound to form the hydroprocessing catalyst composition. In another embodiment, the catalyst is prepared by the thermal decomposition of an oil dispersible sulfur containing organic metal precursor upon contact with a hydrocarbon oil, generating a slurry catalyst. In yet another embodiment, the catalyst is prepared from an in-situ or ex-situ sulfidation of “d block element metal precursors in a solvent carrier.
-
Citations
34 Claims
-
1. A process for preparing a catalyst composition comprising:
-
i) providing at least two metal precursors of different “
d”
block element metals;ii) combining the at least two metal precursors with a sulfiding agent, forming at least a sulfided catalyst precursor; and iii) mixing the at least a sulfided catalyst precursor with a hydrocarbon compound to transform the sulfided catalyst precursor into a catalyst composition having formula (Rp)i(Mt)a(Lu)b(Sv)d(Cw)e(Hx)f(Oy)g(Nz)h, wherein R is optional, R is at least a lanthanoid element metal or an alkaline earth metal; M is at least a “
d”
block element metal;L is at least a “
d”
block element metal different from the “
d”
block element metal M;0<
=i<
=1;0<
b/a=<
5,0.5(a+b)<
=d<
=5(a+b),0<
e<
=11(a+b),0<
f<
=7(a+b),0<
g<
=5(a+b),0<
h<
=2(a+b),p, t, u, v, w, x, y, z, each representing total charge for each of;
M, L, S, C, H, O and N, respectively, wherein pi+ta+ub+vd+we+xf+yg+zh=0;wherein the “
d”
block element is selected from the group consisting of iron, zinc, titanium, nickel, copper, cobalt, chromium, and manganese. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 30, 31, 32, 33, 34)
-
-
13. A process for preparing a catalyst composition comprising:
-
i) providing at least two metal precursors of different “
d”
block element metals, a first metal precursor and a second metal precursor;ii) sulfiding the first metal precursor with a sulfiding agent forming a first sulfided catalyst precursor; and iii) combining the first sulfided catalyst precursor and the second metal precursor with a hydrocarbon compound to transform the precursors into a catalyst composition having formula (Rp)i(Mt)a(Lu)b(Sv)d(Cw)e(Hx)f(Oy)g(Nz)h, wherein R is optional, R is at least a lanthanoid element metal or an alkaline earth metal; M is at least a “
d”
block element metal;L is at least a “
d”
block element metal different from the “
d”
block element metal M;0<
=i<
=1;0<
b/a=<
5,0.5(a+b)<
=d<
=5(a+b),0<
e<
=11(a+b),0<
f<
=7(a+b),0<
g<
=5(a+b),0<
h<
=2(a+b),p, t, u, v, w, x, y, z, each representing total charge for each of;
M, L, S, C, H, O and N, respectively, wherein pi+ta+ub+vd+we+xf+yg+zh=0;wherein the “
d”
block element is selected from the group consisting of iron, zinc, titanium, nickel, copper, cobalt, chromium and manganese. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20)
-
-
21. A process for preparing a catalyst composition comprising:
-
i) providing at least two metal precursors of different “
d”
block element metals;ii) sulfiding a first metal precursor with a sulfiding agent forming a first sulfided catalyst precursor; iii) sulfiding a second metal precursor with a sulfiding agent forming a second sulfided catalyst precursor; and iv) combining the first sulfided catalyst precursor and the second sulfided metal precursor with a hydrocarbon compound to transform the precursors into a catalyst composition having the formula (Rp)i(Mt)a(Lu)b(Sv)d(Cw)e(Hx)f(Oy)g(Nz)h, wherein R is optional, R is at least a lanthanoid element metal or an alkaline earth metal; M is at least a “
d”
block element metal;L is at least a “
d”
block element metal different from the “
d”
block element metal M;0<
=i<
=1;0<
b/a=<
5,0.5(a+b)<
=d<
=5(a+b),0<
e<
=11(a+b),0<
f<
=7(a+b),0<
g<
=5(a+b),0<
h<
=2(a+b),p, t, u, v, w, x, y, z, each representing total charge for each of;
M, L, S, C, H, O and N, respectively, wherein pi+ta+ub+vd+we+xf+yg+zh=0;wherein the “
d”
block element is selected from the group consisting of iron, zinc, titanium, nickel, copper, cobalt, chromium and manganese. - View Dependent Claims (22, 23, 24, 25, 26, 27, 28, 29)
-
Specification