Hydroprocessing catalysts and their production

Abstract

The precursor of a hydroprocessing catalyst is made by impregnating a metal oxide component comprising at least one metal from Group 6 of the Periodic Table and at least one metal from Groups 8-10 of the Periodic Table with an amide formed from a first organic compound containing at least one amine group, and a second organic compound containing at least one carboxylic acid group. Following impregnation heat treatment follows to form in situ generated unsaturation additional to that in the two organic compounds. The catalyst precursor is sulfided to form an active, sulfide hydroprocessing catalyst.

1 . (canceled) 
     
     
         2 . A method for hydroprocessing a biocomponent feedstock, comprising:
 exposing a biocomponent feedstock comprising a bio-derived fraction and a mineral oil fraction to a bulk mixed metal catalyst, in the presence of hydrogen under effective deoxygenation conditions, the bulk mixed metal catalyst comprising at least one Group VI metal selected from Mo and W and at least one Group VIII metal selected from Co and Ni; and forming a deoxygenated effluent.   
     
     
         3 . The method of  claim 2 , wherein the bio-derived fraction makes up about 20 wt % of the biocomponent feedstock. 
     
     
         4 . The method of  claim 2 , wherein the bio-derived fraction includes a lipids fraction, wherein about 2 wt % to about 40 wt % of lipids in the lipids fraction, based on the weight of the bio-derived fraction, is sourced from algal sources. 
     
     
         5 . The method of  claim 2 , wherein the deoxygenated effluent is substantially oxygen free. 
     
     
         6 . The method of  claim 2 , wherein the dexoygenation conditions comprise a hydrogen partial pressure of from about 5 barg (0.5 MPag) to about 300 barg (30 MPag), a reaction temperature of from about 392° F. to about 842° F. (200° C. to 450° C.), a liquid hourly space velocity of from about 0.05 hr −1  to about 10 hr −1 , and a hydrogen treat gas rate from about 200 scf/B (34 Nm 3 /m 3 ) to about 10,000 scf/B (1685 Nm 3 /m 3 ). 
     
     
         7 . The method of  claim 2 , wherein the bio-derived fraction comprises at least one of a vegetable oil, an animal fat, and a algae oil. 
     
     
         8 . The method of  claim 2 , wherein the total amount of the Group VI metals and Group VIII metals comprise at least 80 wt % of the bulk mixed metal catalyst. 
     
     
         9 . The method of  claim 8 , wherein the bulk mixed metal catalyst contains less than 15 wt % carrier or support material. 
     
     
         10 . The method of  claim 2 , wherein the bulk mixed metal catalyst is further combined with a binder. 
     
     
         11 . The method of  claim 10 , wherein the binder is selected from silica, silica-alumina, alumina, titania, zirconia, and mixtures thereof. 
     
     
         12 . The method of  claim 11 , wherein the amount of binder is from about 40 wt % to about 95 wt % binder based on the total weight of the bulk mixed metal catalyst and the binder. 
     
     
         13 . The method of  claim 2 , wherein the bulk mixed metal catalyst is further comprised of at least one organic compound. 
     
     
         14 . The method of  claim 13 , wherein the bulk mixed metal catalyst is further sulfided prior to exposing the biocomponent feedstock to the bulk mixed metal catalyst, and the at least one organic compound is present on the bulk mixed metal catalyst at the time the catalyst is exposed to the sulfiding conditions. 
     
     
         15 . The method of  claim 14 , wherein the at least one organic compound is a condensation/decomposition reaction product derived from an amine, a carboxylic acid, or combinations thereof. 
     
     
         16 . The method of  claim 15 , wherein the amine, carboxylic acid, or combination thereof is subjected to a reaction temperature of from about 195° C. to about 250° C. (about 383° F. to about 482° F.) to form the condensation/decomposition reaction product. 
     
     
         17 . The method of  claim 2 , wherein the at least one Group VI metal is Mo and at least one Group VIII metal is Co. 
     
     
         18 . The method of  claim 2 , wherein the bulk mixed metal catalyst is comprised of Mo, W, and Ni.