Hydroconversion multi-metallic catalyst and method for making thereof
First Claim
1. A process for forming a bulk hydroprocessing catalyst, 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 product mixture comprising a first catalyst precursor and a first 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 the metal precursor feeds, 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;
adding at least a precipitant to the product mixture at a molar ratio of precipitant to metal residuals ranging from 1.5;
1 to 20;
1 to precipitate at least 50 mole % of metal ions in the residuals forming additional catalyst precursor;
isolating the catalyst precursors from the product mixture, forming a second supernatant containing less than 5000 ppm of metal ions in the metal residuals; and
sulfiding the catalyst precursors forming the bulk catalyst.
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Abstract
In a process for forming a bulk hydroprocessing catalyst by sulfiding a catalyst precursor in a co-precipitation reaction, up to 60% of the metal precursor feeds do not react to form catalyst precursor and stay in the supernatant. In one embodiment, at least a precipitant is added to the product mixture at a molar ratio of precipitant to metal residuals in the supernatant ranging from 1.5:1 to 20:1 to precipitate at least 50 mole % of metal ions in the residuals forming additional catalyst precursor. The remaining metal residuals 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 at least one of the metal residuals. In one embodiment, at least one of the metal residuals is recovered and recycled for use as a metal precursor feed in the co-precipitation reaction.
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Citations
22 Claims
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1. A process for forming a bulk hydroprocessing catalyst, 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 product mixture comprising a first catalyst precursor and a first 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 the metal precursor feeds, 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;adding at least a precipitant to the product mixture at a molar ratio of precipitant to metal residuals ranging from 1.5;
1 to 20;
1 to precipitate at least 50 mole % of metal ions in the residuals forming additional catalyst precursor;isolating the catalyst precursors from the product mixture, forming a second supernatant containing less than 5000 ppm of metal ions in the metal residuals; and sulfiding the catalyst precursors 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)
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Specification