Highly active slurry catalyst composition

Abstract

The instant invention is directed to the preparation of a slurry catalyst composition. The slurry catalyst composition is prepared in a series of steps, involving mixing a Group VIB metal oxide and aqueous ammonia to form an aqueous mixture and sulfiding the mixture to form a slurry. The slurry is then promoted with a Group VIII metal. Subsequent steps involve mixing the slurry with a hydrocarbon oil, and combining the resulting mixture with hydrogen gas (under conditions which maintain the water in a liquid phase) to produce the active slurry catalyst.

1 . A catalyst composition suitable for the hydroconversion of heavy oils, which is prepared by: 
 (a) mixing a Group VI B metal oxide and aqueous ammonia to form a Group VI B metal compound aqueous mixture;    (b) sulfiding, in a first reaction zone, the aqueous mixture of step (a) with a gas comprising hydrogen sulfide to a dosage greater than 8 SCF of hydrogen sulfide per pound of Group VI B metal to form a slurry;    (c) promoting the slurry with a Group VIII metal compound;    (d) mixing the slurry of step (c) with hydrocarbon oil having a viscosity of at least 2 cSt @ 212° F. to form Mixture X;    (e) combining Mixture X with hydrogen gas in a second reaction zone, under conditions which maintain the water in Mixture X in a liquid phase, thereby forming an active catalyst composition admixed with a liquid hydrocarbon; and    (f) recovering the active catalyst composition.    
     
     
         2 . The catalyst composition of  claim 1 , wherein conditions in the first reaction zone comprise a temperature in the range from at least about 80° F. to about 200° F., and a pressure in the range from at least about 100 psig to about 3000 psig.  
     
     
         3 . The catalyst composition of  claim 2 , wherein conditions in the first reaction zone comprise a temperature in the range from at least about 100° F. to about 180° F., and a pressure in the range from at least about 200 psig to about 1000 psig.  
     
     
         4 . The catalyst composition of  claim 3 , wherein conditions in the first reaction zone comprise a temperature in the range from at least about 130° F. to about 160° F. and a pressure in the range from at least about 300 psig to about 500 psig.  
     
     
         5 . The catalyst composition of  claim 1 , wherein the hydrocarbon oil viscosity ranges from at least about 2 cSt @ 212° F. to about 15 cSt @ 212° F.  
     
     
         6 . The catalyst composition of  claim 1 , wherein the Group VIII metal compound of step (c) is selected from the group consisting of nickel sulfates and cobalt sulfates.  
     
     
         7 . The catalyst composition of  claim 20 , wherein high shear mode occurs, in the range from 100 RPM to 1600 RPM.  
     
     
         8 . The catalyst composition of  claim 6 , in which the weight ratio of nickel or cobalt to Group VI B metal oxide ranges from 1:100 to about 1:2.  
     
     
         9 . The catalyst composition of  claim 1 , wherein the ratio of Group VI B metal oxide to oil is at least less than 1.0.  
     
     
         10 . The catalyst composition of  claim 1 , wherein the hydrocarbon oil is a vacuum gas oil.  
     
     
         11 . The catalyst composition of  claim 1 , wherein the conditions of the second reaction zone comprise a temperature in the range from at least about 350° F. to about 600° F. and a pressure in the range from at least about 100 psig to about 3000 psig.  
     
     
         12 . The catalyst composition of  claim 11 , wherein the conditions of the second reaction zone comprise a temperature in the range from at least about 350° F. to about 600° F. and the pressure in the range from at least about 200 psig to about 1000 psig.  
     
     
         13 . The compositions of  claim 12 , wherein hydrogen is continuously added to the second reaction zone, and high shear mixing is employed in order to maintain a homogenous slurry.  
     
     
         14 . The catalyst composition of  claim 1 , which is recovered by means of a high pressure separator.  
     
     
         15 . The catalyst composition of  claim 1 , which exist in an active and concentrated state.  
     
     
         16 . The catalyst of  claim 14 , which is continuously mixed in a storage tank to maintain a homogenous slurry.  
     
     
         17 . The catalyst composition of  claim 9 , wherein the ratio of Group VI B metal oxide to oil is at least less than 0.5.  
     
     
         18 . The catalyst composition of  claim 17 , wherein the ratio of Group VI B metal oxide to oil is at least less than 0.1.  
     
     
         19 . The catalyst composition of  claim 8 , wherein the Group VI B metal is selected from the group consisting of tungsten and molybdenum.  
     
     
         20 . A catalyst composition suitable for the hydroconversion of heavy oils, which is prepared by: 
 (a) mixing a Group VI B metal oxide and aqueous ammonia to form a Group VI B metal compound aqueous mixture;    (b) sulfiding, in a first reaction zone, the aqueous mixture of step (a) with a gas comprising hydrogen sulfide to a dosage greater than 8 SCF of hydrogen sulfide per pound of Group VI B metal to form a slurry;    (c) promoting the slurry with a Group VIII metal compound;    (d) mixing, at high shear mode, the slurry of step (c) with a first hydrocarbon oil having a viscosity of at least 2 cSt @ 212° F. to form Mixture X;    (e) combining Mixture X at high shear mode with hydrogen gas in a second reaction zone, under conditions which maintain the water in Mixture X in a liquid phase, thereby forming an active catalyst composition admixed with a liquid hydrocarbon; and    (f) recovering the active catalyst composition.