Hydroprocessing catalysts and methods for making thereof
AssigneeChevron U.S.A. Inc.
InventorsJoseph V. Nguyen, Julie Chabot, Ling Jiao, Christopher Paul Dunckley, Shuwu Yang
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Abstract
An improved process to make a slurry catalyst for the upgrade of heavy oil feedstock is provided. The sulfiding of the metal precursor/catalyst precursor is carried out at least twice (“enhanced sulfiding”) in the improved process to form a slurry catalyst with improved surface area and porosity value. The slurry catalyst under an enhanced sulfiding scheme is characterized as having increased catalytic activities over a slurry catalyst without an enhanced sulfidation step.
Claims20
A process for preparing a slurry catalyst for use in upgrading heavy oil feedstock, comprising:
- providing at least a first metal precursor comprising a metal salt of a Primary metal selected from Group VIB metals, Group VIII metals, and Group IIB metals;
- sulfiding the first metal precursor with a first sulfiding agent at a sulfur to Primary metal molar ratio of at least 1.5 to 1 to form a sulfided catalyst precursor;
- sulfiding the sulfided catalyst precursor with a second sulfiding agent at a molar ratio of sulfur to metal in the sulfided catalyst precursor of at least 1.5 to 1 for an enhanced sulfided catalyst precursor;
- mixing the enhanced sulfided catalyst precursor with a hydrocarbon diluent forming a slurry catalyst having an average particle size of 1 to 300 μm.
A process for preparing a slurry catalyst for use in upgrading heavy oil feedstock, comprising:
- providing a first metal precursor comprising water-soluble salt of a Primary metal selected from Group VIB metals, Group VIII metals, and Group IIB metals;
- sulfiding the metal precursor with a first sulfiding agent to form a first sulfided precursor;
- combining the first sulfided precursor with a second metal precursor comprising a metal salt of a Promoter metal selected from the group of Group VIII metals, Group VIB metals, Group IVB metals, and Group IIB metals, and mixtures thereof wherein the Promoter metal is different from the Primary metal, for a promoted sulfided precursor;
- sulfiding the promoted sulfided precursor with a second sulfiding agent at a molar ratio of sulfur to total metals in the promoted sulfided precursor of at least 1.5 to 1 for an enhanced sulfided catalyst precursor;
- mixing the enhanced sulfided catalyst precursor with a hydrocarbon diluent forming a slurry catalyst having an average particle size of 1 to 300 μm.
Dependencies are inferred from the claim text.