US2006058175A1PendingUtilityA1

Highly active slurry catalyst composition

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Assignee: CHEVRON USA INCPriority: Sep 10, 2004Filed: Sep 10, 2004Published: Mar 16, 2006
Est. expirySep 10, 2024(expired)· nominal 20-yr term from priority
Inventors:Kaidong ChenPak LeungBruce Reynolds
C10G 2300/1074C10G 2300/207C10G 2300/1033B01J 27/053C10G 65/04C10G 2300/1022B01J 37/20B01J 27/0515C10G 2300/1003C10G 49/04C10G 67/0454C10G 2300/703C10G 47/26C10G 49/12B01J 27/02B01J 31/00B01J 27/051B01J 35/27
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Claims

Abstract

The instant invention is directed to the preparation of a catalyst composition suitable for the hydroconversion of heavy oils. The catalyst composition is prepared by 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 and a second hydrocarbon oil having a lower viscosity than the first oil. An active catalyst composition is thereby formed.

Claims

exact text as granted — not AI-modified
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 a first hydrocarbon oil having a viscosity of at least 2 cSt @ 212° F. to form Mixture X;    (e) combining Mixture X with hydrogen gas and a second hydrocarbon oil in a second reaction zone, the second hydrocarbon oil having a boiling point in the range from 50° F. to 300° F. and having a lower viscosity that the first hydrocarbon oil, thereby forming an active catalyst composition admixed with a light hydrocarbon; and    (f) recovering the active catalyst composition by separation from the light hydrocarbon oil.    
     
     
         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 first 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 4 , 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 second hydrocarbon oil boils in the range from at least about 50° F. to about 300° F.  
     
     
         10 . The catalyst composition of  claim 9 , wherein the second hydrocarbon oil boils in the range from at least about 75° F. to about 250° F.  
     
     
         11 . The catalyst composition of  claim 1 , wherein the ratio of the volume of the second oil to the first oil is greater than 1.  
     
     
         12 . The catalyst composition of  claim 1 , wherein the ratio of Group VI B metal oxide to oil is at least less than 1.0.  
     
     
         13 . The catalyst composition of  claim 1 , wherein the first hydrocarbon oil is a vacuum gas oil.  
     
     
         14 . The catalyst composition of  claim 1 , wherein the second hydrocarbon oil possess a kinetic viscosity of less than 0.3 cSt at 212° F.  
     
     
         15 . The catalyst composition of  claim 1 , wherein the second hydrocarbon oil is a light naphtha.  
     
     
         16 . The catalyst composition of  claim 15 , 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 1000 psig to about 3500 psig.  
     
     
         17 . The catalyst composition of  claim 16 , 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 1500 psig to about 3000 psig.  
     
     
         18 . The catalyst composition of  claim 1 , wherein the light hydrocarbon comprises a mixture of the first hydrocarbon oil and the second hydrocarbon oil.  
     
     
         19 . The catalyst composition of  claim 1 , which is recovered by means of a high pressure separator.  
     
     
         20 . The catalyst composition of  claim 1 , which exists in an active and concentrated state.  
     
     
         21 . The catalyst composition of  claim 11 , wherein the ratio of the volume of the second oil to the first oil is greater than 5.  
     
     
         22 . The catalyst composition of  claim 21 , wherein the ratio of the volume of the second oil to the first oil is greater than 10.  
     
     
         23 . The catalyst composition of  claim 12 , wherein the ratio of Group VI B metal oxide to oil is at least less than 0.5.  
     
     
         24 . The catalyst composition of  claim 23 , wherein the ratio of Group VI B metal oxide to oil is at least less than 0.1.  
     
     
         25 . The catalyst composition of  claim 8 , wherein the Group VI B metal is selected from the group consisting of tungsten and molybdenum.  
     
     
         26 . 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) sulfide 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 and a second hydrocarbon oil in a second reaction zone, the second hydrocarbon oil having a boiling point in the range from 50° F. to 300° F. and having a lower viscosity that the first hydrocarbon oil, thereby forming an active catalyst composition admixed with a light hydrocarbon; and    (f) recovering the active catalyst composition by separation from the light hydrocarbon oil.

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