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 mixture comprising a catalyst precursor;
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 the metal precursor feeds;
supplying the supernatant to a reactor vessel having a plurality of electrodes having a positive or a negative charge provided by a power supply, wherein the electrodes dissolve in water generating an electrode dissolution product;
reacting the electrode dissolution product with at least one of the metal residuals, forming a slurry containing insoluble metal compounds;
isolating the insoluble metal compounds from the slurry, forming a first effluent stream containing less than 50 mole % of metal ions in the metal residuals;
treating the first effluent stream to recover at least 80 mol % of the metal ions 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 the metal precursor feeds do not react to form catalyst precursor and end up in the supernatant. In the present disclosure, the metals can be recovered in an electro-coagulation reactor, wherein portion of the metal residuals in the supernatant reacts with the electrodes to form a slurry containing insoluble metal compounds. The insoluble metal compounds are isolated and recovered, forming an effluent stream. The insoluble metal compounds and/or the effluent stream can be further treated to form at least a metal precursor feed which can be used in the co-precipitation reaction.
117 Citations
28 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 mixture comprising a catalyst precursor; 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 the metal precursor feeds; supplying the supernatant to a reactor vessel having a plurality of electrodes having a positive or a negative charge provided by a power supply, wherein the electrodes dissolve in water generating an electrode dissolution product; reacting the electrode dissolution product with at least one of the metal residuals, forming a slurry containing insoluble metal compounds; isolating the insoluble metal compounds from the slurry, forming a first effluent stream containing less than 50 mole % of metal ions in the metal residuals; treating the first effluent stream to recover at least 80 mol % of the metal ions 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)
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20. In a process for forming a bulk hydroprocessing catalyst, the process comprising:
- 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;
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 the metal precursor feeds; and
sulfiding the catalyst precursor forming the bulk catalyst;
the improvement comprising;supplying the supernatant to a reactor vessel having a plurality of electrodes having a positive or a negative charge provided by a power supply; reacting the electrodes with at least one of the metal residuals, forming a slurry containing insoluble metal compounds; recovering the insoluble metal compounds, forming a first effluent stream containing less than 50 mole % of at least one of the Promoter metal residual and a Group VIB metal residual; and treating the first effluent stream to recover at least 80 mol % of the metal ions to form at least a metal precursor feed; and recycling the at least a metal precursor feed to the co-precipitating step. - View Dependent Claims (21, 22, 23, 24, 25, 26, 27, 28)
- 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;
Specification