Hydroconversion multi-metallic catalyst and method for making thereof
First Claim
1. A process for forming a hydroprocessing catalyst composition, the method comprises:
- co-precipitating at reaction conditions at least a Group VIB metal precursor feed and at least a Promoter metal precursor feed selected from Group VIII, Group IIB, Group IIA, Group IVA and combinations thereof, to form a mixture comprising a catalyst precursor, wherein the reaction conditions comprise a temperature between 25-350°
C. and a pressure between 0 to 3000 psig and a pH of 0-12;
isolating the catalyst precursor from the mixture, forming a supernatant containing at least a Promoter metal residual and at least a Group VIB metal residual in a total amount of at least 10 mole % of metal ions in the metal precursor feeds;
contacting the supernatant with an ion exchange resin for a sufficient amount of time for at least 50 mole % of metal ions in the metal residuals to be bound onto the resin, forming a first effluent stream containing unbound metal residuals;
eluting the resin to produce an eluate stream containing the metals ions previously bound onto the resin;
treating the first effluent stream or the eluate stream to recover at least 80 mol % of metal ions in the stream to form at least a metal precursor feed;
recycling the metal precursor feed to the co-precipitating step; and
sulfiding the catalyst precursor forming the bulk catalyst.
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Abstract
In a process for forming a bulk hydroprocessing catalyst by sulfiding a catalyst precursor made in a co-precipitation reaction, up to 60% of metal ions in at least one of the metal precursor feeds do not react to form catalyst precursor and end up in the supernatant as metal residuals. In the present disclosure, the metals can be recovered via ion-exchange, wherein an exchange resin is provided for a portion of the metal ions in the supernatant to be exchanged and bound onto the resin. The previously resin-bound metals can be subsequently recovered, or the effluent stream for the exchange resin column can also be recovered, forming at least a metal precursor feed which can be used in the co-precipitation reaction.
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Citations
28 Claims
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1. A process for forming a hydroprocessing catalyst composition, the method comprises:
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co-precipitating at reaction conditions at least a Group VIB metal precursor feed and at least a Promoter metal precursor feed selected from Group VIII, Group IIB, Group IIA, Group IVA and combinations thereof, to form a mixture comprising a catalyst precursor, wherein the reaction conditions comprise a temperature between 25-350°
C. and a pressure between 0 to 3000 psig and a pH of 0-12;isolating the catalyst precursor from the mixture, forming a supernatant containing at least a Promoter metal residual and at least a Group VIB metal residual in a total amount of at least 10 mole % of metal ions in the metal precursor feeds; contacting the supernatant with an ion exchange resin for a sufficient amount of time for at least 50 mole % of metal ions in the metal residuals to be bound onto the resin, forming a first effluent stream containing unbound metal residuals; eluting the resin to produce an eluate stream containing the metals ions previously bound onto the resin; treating the first effluent stream or the eluate stream to recover at least 80 mol % of metal ions in the stream to form at least a metal precursor feed; recycling the metal precursor feed to the co-precipitating step; and sulfiding the catalyst precursor forming the bulk catalyst. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 27, 28)
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23. In a process for forming a bulk hydroprocessing catalyst, the process comprising:
- co-precipitating at reaction conditions at least a Group VIB metal precursor feed and at least a Promoter metal precursor feed selected from Group VIII, Group IIB, Group IIA, Group IVA and combinations thereof, to form a mixture comprising a catalyst precursor, wherein the reaction conditions comprise a temperature between 25-350°
C. and a pressure between 0 to 3000 psig and a pH of 0-12;
isolating the catalyst precursor from the mixture, forming a supernatant containing at least a Promoter metal residual and at least a Group VIB metal residual in an amount of at least 10 mole % of metal ions in the metal precursor feeds;
calcining the catalyst precursor to form a catalyst precursor of the formula (X)b(Mo)c(W)dOz;
wherein X is Ni or Co, the molar ratio of b;
(c+d) is 0.5/1 to 3/1, the molar ratio of c;
d is >
0.01/1, and z=[2b+6 (c+d)]/2; and
sulfiding the catalyst precursor forming the bulk catalyst, wherein the improvement comprising;contacting the supernatant with an ion exchange resin for a sufficient amount of time for at least 50% of metal ions in at least one of the metal residuals in the supernatant to be bound onto the resin, forming a first effluent stream containing unbound metal residuals; eluting the resin to produce an eluate stream containing metals ions previously bound onto the resin; and treating the first effluent stream or the eluate stream to recover at least 80 mol % of metal ions in the stream to form at least a metal precursor feed.
- co-precipitating at reaction conditions at least a Group VIB metal precursor feed and at least a Promoter metal precursor feed selected from Group VIII, Group IIB, Group IIA, Group IVA and combinations thereof, to form a mixture comprising a catalyst precursor, wherein the reaction conditions comprise a temperature between 25-350°
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24. A process for forming a hydroprocessing catalyst composition, the method comprises:
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co-precipitating at reaction conditions at least one of a Group VIB metal precursor feed and at least a Promoter metal precursor feed selected from Group VIII, Group IIB, Group IIA, Group IVA and combinations thereof, to form a mixture comprising a catalyst precursor, wherein the reaction conditions comprise a temperature between 25-350°
C. and a pressure between 0 to 3000 psig and a pH of 0-12;isolating the catalyst precursor from the mixture, forming a supernatant containing at least a Promoter metal residual and at least a Group VIB metal residual in an amount of at least 10% of the metal precursor feeds; treating the supernatant with at least an acid at a pre-selected pH to precipitate at least a Promoter metal residual and a Group VIB metal residual, forming a first effluent stream containing less than 50% of at least one of Promoter metal residual and a Group VIB metal residual; providing at least an exchange resin; contacting the supernatant with the ion exchange resin for a sufficient amount of time for at least 50 mole % of metal ions in at least one of the metal residuals in the supernatant to be bound onto the resin, forming a first effluent stream containing unbound metal residuals; eluting the resin to produce an eluate containing the metal ions previously bound onto the resin; recovering at least 80 mole % of metal ions in the unbound metal residuals in the first effluent stream or at least 80 mole % of the metal ions in the eluate to form at least a metal precursor feed; recycling the metal precursor feed to the co-precipitating step; and sulfiding the catalyst precursor forming the bulk catalyst. - View Dependent Claims (25, 26)
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Specification