Slurry hydrocracking process using spent hydroprocessing catalyst

Abstract

A slurry hydrocracking process using spent hydroprocessing catalyst is described. The process includes obtaining the spent hydroprocessing catalyst from a hydroprocessing zone; reducing the size of the spent hydroprocessing catalyst; and introducing a heavy hydrocarbon feed and a hydrogen stream into a slurry hydrocracking zone in the presence of the reduced size spent hydroprocessing catalyst under slurry hydrocracking conditions to form a slurry hydrocracking effluent.

What is claimed is: 
     
         1 . A slurry hydrocracking process using spent hydroprocessing catalyst comprising:
 obtaining the spent hydroprocessing catalyst from a hydroprocessing zone;   reducing the size of the spent hydroprocessing catalyst; and   introducing a heavy hydrocarbon feed and a hydrogen stream into a slurry hydrocracking zone in the presence of the reduced size spent hydroprocessing catalyst under slurry hydrocracking conditions to form a slurry hydrocracking effluent.   
     
     
         2 . The process of  claim 1  wherein the spent hydroprocessing catalyst comprises at least one Group VIII metal and at least one Group VI metal on a support. 
     
     
         3 . The process of  claim 2  wherein the at least one Group VIII metal comprises iron, cobalt, and nickel, wherein the Group VI metal comprises molybdenum and tungsten, and wherein the support comprises a metal oxide. 
     
     
         4 . The process of  claim 1  wherein the spent hydroprocessing catalyst comprises at least one Group VIII or Group VI metals on an amorphous base or a zeolite base. 
     
     
         5 . The process of  claim 4  wherein the at least one Group VIII metal comprises iron, cobalt, and nickel, wherein the Group VI metal comprises molybdenum and tungsten, and wherein the zeolite base comprises alumina and silica. 
     
     
         6 . The process of  claim 1  wherein the reduced size spent hydroprocessing catalyst is present in an amount of about 200 wppm to about 1 wt %. 
     
     
         7 . The process of  claim 1  wherein reducing the size of the spent hydroprocessing catalyst comprises one or more of grinding the spent hydroprocessing catalyst, ball milling the spent hydroprocessing catalyst, and jet milling the spent hydroprocessing catalyst. 
     
     
         8 . The process of  claim 1  wherein the reduced size spent hydroprocessing catalyst has an average size of less than 500 μm. 
     
     
         9 . The process of  claim 1  wherein the reduced size spent hydroprocessing catalyst has an average size of less than 100 μm. 
     
     
         10 . The process of  claim 1  further comprising recovering the reduced size spent hydroprocessing catalyst from the slurry hydrocracking effluent. 
     
     
         11 . The process of  claim 10  further comprising recycling the recovered catalyst. 
     
     
         12 . A slurry hydrocracking process using spent hydroprocessing catalyst comprising:
 obtaining the spent hydroprocessing catalyst from a hydroprocessing zone, the spent hydroprocessing catalyst comprising at least one Group VIII metal and at least one Group VI metal on a support or at least one Group VIII or Group VI metals on an amorphous base or a zeolite base;   grinding the spent hydroprocessing catalyst to reduce the size of the spent hydroprocessing catalyst to less than 500 μm; and   introducing a heavy hydrocarbon feed and a hydrogen stream into a slurry hydrocracking zone in the presence of the ground spent hydroprocessing catalyst under slurry hydrocracking conditions to form a slurry hydrocracking effluent.   
     
     
         13 . The process of  claim 12  wherein the at least one Group VIII metal comprises iron, cobalt, and nickel and wherein the Group VI metal comprises molybdenum and tungsten, and wherein the support comprises a metal oxide. 
     
     
         14 . The process of  claim 13  wherein the metal oxide comprises alumina, silica, titania, zirconia, or mixtures thereof. 
     
     
         15 . The process of  claim 12  wherein the at least one Group VIII metal comprises iron, cobalt, and nickel, wherein the Group VI metal comprises molybdenum and tungsten, and wherein the zeolite base comprises alumina and silica. 
     
     
         16 . The process of  claim 12  wherein the reduced size spent hydroprocessing catalyst is present in an amount of about 30 wppm to about 100 wppm. 
     
     
         17 . The process of  claim 12  wherein the ground spent hydroprocessing catalyst has an average size of less than 500 μm. 
     
     
         18 . The process of  claim 12  wherein the ground spent hydroprocessing catalyst has an average size of less than 100 μm. 
     
     
         19 . The process of  claim 12  further comprising recovering the ground spent hydroprocessing catalyst from the slurry hydrocracking effluent. 
     
     
         20 . A slurry hydrocracking process using spent hydroprocessing catalyst comprising:
 obtaining the spent hydroprocessing catalyst from a hydroprocessing zone, wherein the spent hydroprocessing catalyst has at least one of:
 a metals content of at least about 10 wt %; 
 a crushing strength after regeneration of less than about 20 N; 
 a weight activity after regeneration of less than about 80% of a weight activity of an initial hydroprocessing catalyst or a volume activity after regeneration of less than about 80% of a volume activity of the initial hydroprocessing catalyst; or 
 a surface area after regeneration of less than about 80% of a surface area of the initial hydroprocessing catalyst; and 
   introducing a heavy hydrocarbon feed and a hydrogen stream into a slurry hydrocracking zone in the presence of the spent hydroprocessing catalyst under slurry hydrocracking conditions to form a slurry hydrocracking effluent.