Hydroprocessing catalysts and methods for making thereof
AssigneeChevron U.S.A. Inc.
InventorsOleg Mironov, Alexander E. Kuperman
Life of this patent
Estimating the term…
Abstract
A process for making an improved slurry catalyst for the upgrade of heavy oil feedstock is provided. In the process, a metal precursor solution comprising at least a water-soluble molybdenum compound and a water-soluble metal zinc compound is mixed under high shear mixing conditions to generate an emulsion. The emulsion is subsequently sulfided with a sulfiding agent ex-situ, or in-situ in a heavy oil feedstock to form the slurry catalyst. The in-situ sulfidation in heavy oil is under sufficient condition for the heavy oil feedstock to generate the sulfiding source needed for the sulfidation.
Claims18
A process for preparing a slurry catalyst for use in upgrading a heavy oil feedstock, comprising:
- providing a metal precursor solution comprising at least a water-soluble molybdenum compound and a water-soluble metal zinc compound in water;
- mixing the metal precursor solution with a hydrocarbon diluent under sufficiently high shear mixing to generate an emulsion with droplet sizes ranging from 0.1 to 300 μm;
- sulfiding the emulsion with at least a sulfiding agent to form a slurry catalyst having a particle size ranging from 1 to 300 μm;
- wherein the emulsion is subjected to reduction at a temperature above ambient either before or after the sulfiding step;
- and
- wherein the zinc compound is present in the slurry catalyst in a sufficient amount for a zinc to molybdenum weight ratio ranging from 1:10 to 10:1.
A process for preparing a slurry catalyst for use in upgrading heavy oil feedstock, comprising:
- providing a metal precursor solution comprising at least a water-soluble molybenum salt selected from molybdates, alkali metal heptamolybdates, alkali metal orthomolybdates, alkali metal isomolybdates, phosphomolybdic acid, molybdenum oxide, molybdenum carbide, molybdenum nitride, aluminum molybdate, molybdic acid, and mixtures thereof, and a water -soluble zinc salt, at a zinc to molybdenum weight ratio ranging from 1:30 to 5:1;
- mixing the metal precursor solution with a hydrocarbon diluent under high shear mixing and under reducing conditions to generate an emulsion comprising droplets having a size of 0.1to 300 μm, the hydrocarbon diluent selected from gasoline, diesel, vacuum gas oil (VGO), cycle oil (MCO or HCO), jet oil, fuel oil, heavy oil feedstock, and mixtures thereof;
- mixing the emulsion with at least a heavy oil feedstock under in-situ sulfiding conditions for the heavy oil feedstock to provide at least a sulfiding agent to sulfide the emulsion forming a slurry catalyst.
Dependencies are inferred from the claim text.