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Hydroprocessing catalysts and methods for making thereof

A hydroprocessing and catalyst technology, applied in physical/chemical process catalysts, chemical instruments and methods, catalyst regeneration/reactivation, etc., can solve problems such as upgrading costs and operating costs

Inactive Publication Date: 2014-07-02
CHEVROU USA INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

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Problems solved by technology

However, there is an economic limit to how much catalyst can be used since high dosage will drive up cost and operating expenses

Method used

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  • Hydroprocessing catalysts and methods for making thereof
  • Hydroprocessing catalysts and methods for making thereof
  • Hydroprocessing catalysts and methods for making thereof

Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0087] Example 1 : Ni-Mo slurry catalyst as described in US Patent No. 7737072 and 7737073 was used in heavy oil upgrading process as described in US Patent No. 7390398. The catalyst was used at a high concentration of Mo relative to the VR feed (4 wt% Mo relative to VR), so it was a "slightly lost catalyst" with about 50% of the original catalytic activity relative to fresh catalyst. Live". The spent catalyst is subjected to a deoiling step similar to the procedure described in U.S. Patent Publication No. 20100163499 using a combination of settling and cross-flow filtration systems in which solvent is added to the filtered feed stream to produce metal sulfide-containing The deoiled solid coke product. The deoiled spent catalyst is slurried in VGO or VGO-based fresh slurry catalyst at a weight ratio of VGO to deoiled spent catalyst of 2:1-20:1 to form a slurry catalyst ("SCS" or spent catalyst slurry).

Embodiment 2

[0088] Example 2 : A second Ni-Mo deoiled spent catalyst was produced as in Example 1, except that the catalyst was used at a low concentration of Mo relative to the heavy oil feed (0.5 wt% Mo relative to VR) , retaining less than about 1 / 3 of said original catalytic activity. Table 1 summarizes the properties and characteristics of the deoiled spent catalyst samples. The deoiled spent catalyst is slurried in VGO or VGO-based fresh slurry catalyst at a weight ratio of VGO to deoiled spent catalyst of 2:1-20:1 to form a slurry catalyst ("SCS" or spent catalyst slurry).

[0089] Table 1

[0090]

Embodiment 3

[0091] Example 3 : A third Ni-Mo deoiled spent catalyst was produced as in Example 1, analysis of the deoiled catalyst solids showed 24.91 wt.% Mo, 4.42 wt.% Ni and 6.22 wt.% V (mainly in oxide form).

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Abstract

Methods for preparing and an improved slurry catalyst feed system for heavy oil upgraded are provided. The catalyst feed system comprises a fresh slurry catalyst and a deoiled spent catalyst in an amount of at least 10% the catalyst feed system. The deoiled spent catalyst is a slurry catalyst that has been used in a hydroprocessing operation with more than 10% but less than 80% of original catalytic activity, and containing less than 10 wt. % soluble hydrocarbons as unconverted heavy oil feed. In one embodiment, the deoiled spent catalyst is first treated with a solution containing at least one of plain water, a mineral acid, an oxidizing agent, and combinations thereof to reduce the concentration of at least one metal contaminant in the deoiled spent catalyst by at least 40%.

Description

[0001] Related Application Cross Reference [0002] This application claims priority to all of US Patent Application Nos. 13 / 233455, 13 / 233477, and 13 / 233491, filed September 15, 2011. This application claims priority and benefit from the foregoing, the disclosure of which is incorporated herein by reference. technical field [0003] The present invention generally relates to catalysts for use in the conversion of heavy oils and residues and methods for their manufacture. Background of the invention [0004] The petroleum industry is increasingly relying on heavy oil, residual oil, coal and tar sands as sources of feedstock. Feedstocks derived from these heavy materials contain more nitrogen and sulfur than materials derived from more traditional crude oils, requiring considerable upgrading to obtain usable products therefrom. These heavier and sour crude oils and residues are also problematic because they also invariably contain much higher metallic contamination of metal...

Claims

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Application Information

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IPC IPC(8): C10G47/02C10G45/04
CPCB01J27/30C10G47/26C10G47/02C10G2300/701B01J38/60C10G45/04C10G2300/205C10G2300/802B01J38/70B01J23/94B01J35/023C10G45/16B01J35/40
Inventor 杨树武J·查博特B·E·雷诺德斯寇波
Owner CHEVROU USA INC
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