Catalytic system for the hydroconversion of heavy oils

Abstract

The present invention relates to a process for the hydroconversion of heavy crude oil and an improved regenerable catalyst for use therein. The process broadly comprises (a) introducing into a hydroconversion reaction zone a feedstock of crude oil, hydrogen, from about 10 to about 1000 wppm of an active phase source selected from the group consisting of Group VB metals, Group VIB metals, Group VIIB metals, Group VIIIB metals, Group IA metals, Group IIA metals, and mixtures thereof, and from about 0.1 to about 20.0 wt. % of a refractory carrier material having a surface area in the range of from about 10 to about 700 m.sup.2 /g, a total pore volume of from about 0.1 to about 2.0 cm.sup.3 /g, an average pore diameter in the range of from about 20 to about 4,000 .ANG., a particle size diameter in the range of from about 1 to about 1000 .mu.m and pore size distribution according to the following: ______________________________________ Pores of radius r (.ANG.) % Total Pore Volume ______________________________________ >1000 about 0.5 - about 30 1000-300 about 2 - about 50 300-100 about 5 - about 60 100-40 about 5 - about 60 <40 about 5 - about 30 ______________________________________ (b) mixing the refractory carrier material with the active phase source, the oil feedstock, and the hydrogen under hydroconversion conditions; (c) separating a solid phase from a liquid product and a gas product; (d) recovering a regenerable catalyst from the solid phase; and (e) recycling the regenerable catalyst into the hydroconversion zone. In a preferred embodiment, the catalyst recovery step comprises washing the separated solid phase containing the used catalyst with a refinery solvent at a temperature in the range of from about 20.degree. to about 150.degree. C., drying the solid phase at a temperature in the range of from about 50.degree. to 200.degree. C., and burning off deposited coke in an oxygen-containing atmosphere at temperatures in the range of about 300.degree. to about 700.degree. C. and pressures in the range of from about 0.5 to about 50 atmospheres to leave a recyclable catalyst material.

Dependencies are inferred from the claim text.