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Hydroconversion multi-metallic catalyst and method for making thereof

  • US 9,168,519 B2
  • Filed: 10/18/2011
  • Issued: 10/27/2015
  • Est. Priority Date: 11/11/2010
  • Status: Active Grant
First Claim
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1. A process for forming a bulk hydroprocessing catalyst, 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 a total amount of at least 10 mole % of the metal precursor feeds;

    mixing the supernatant with at least one of an acid, a sulfide-containing compound, a base, and combinations thereof under mixing conditions at a temperature from ambient to 90°

    C. for a sufficient amount of time to precipitate at least 50 mole % of metal ions in at least one of the metal residuals, wherein the precipitation is carried out at a pre-select pH;

    isolating the precipitate to recover a first effluent containing less than 50 mole % of metal ions in at least one of the metal residuals in the supernatant;

    converting the metal ions in the precipitate or the first effluent into at least a metal precursor feed;

    recycling the at least a metal precursor feed from the converting step to the co-precipitating step; and

    sulfiding the catalyst precursor forming the bulk catalyst.

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