초록 ▼

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 t

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.

대표청구항 ▼

The invention claimed is: 1. A process for preparing a catalyst composition suitable for the hydroconversion of heavy oils, comprising:(a) mixing a group VIB metal compound and aqueous ammonia to form a group VIB metal mixture in solution;(b) sulfiding the aqueous mixture of step (a) with a gas com

The invention claimed is: 1. A process for preparing a catalyst composition suitable for the hydroconversion of heavy oils, comprising:(a) mixing a group VIB metal compound and aqueous ammonia to form a group VIB metal mixture in solution;(b) sulfiding the aqueous mixture of step (a) with a gas comprising hydrogen sulfide to form a slurry;(c) promoting the slurry with a Group VIII metal compound;(d) mixing under turbulent mixing conditions the slurry of step (c) with at least a hydrocarbon oil having a viscosity of at least 2 cSt @ 212° F. to form a homogenous slurry, and under sufficient temperature and pressure to maintain at least a portion of water in the slurry in a liquid phase, thereby forming an active catalyst composition admixed with a liquid hydrocarbon comprising slurry catalyst having an average particle size in the range of 1-20 microns. 2. The process of claim 1, wherein the sulfiding is with a gas comprising hydrogen sulfide and hydrogen. 3. The process of claim 1, wherein less than 90% of the water in the slurry is maintained in the liquid phase. 4. The process of claim 1, wherein less than 70% of the water in the slurry is maintained in the liquid phase. 5. The process of claim 1, wherein at least 50% of the water in the slurry is maintained in the liquid phase. 6. The process of claim 1, wherein the slurry of step (c) is mixed under turbulent mixing condition with at least a hydrocarbon oil and hydrogen gas. 7. The process of claim 1, wherein the slurry of step (c) is mixed under sufficient turbulent mixing condition for a Reynolds number of at least 2000. 8. The process of claim 7, wherein the slurry of step (c) is mixed under sufficient turbulent mixing condition for a Reynolds number of at least 3000. 9. The process of claim 1, further comprising the step of removing water from the catalyst composition in a separator. 10. The process of claim 1, wherein the forming of the active catalyst composition admixed with a liquid hydrocarbon is under a temperature of 300° F. to 600° F. and a pressure ranging from about 100 psig to about 3000 psig. 11. The process of claim 1, wherein the forming of the active catalyst composition occurs in two reaction zones, wherein the slurry of step (c) is first mixed with the at least a hydrocarbon oil in a first reaction zone to form and maintain a homogenous slurry; and the homogenous slurry is subsequently mixed with hydrogen gas in a second reaction zone to form the active catalyst composition. 12. The process of claim 11, 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. 13. The process of claim 12, 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. 14. The process 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 a pressure in the range from at least about 100 psig to about 3000 psig. 15. The process of claim 14, 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. 16. The process of claim 1, wherein the hydrocarbon oil viscosity ranges from at least about 2 cSt @ 212° F. to about 15 cSt @ 212° F. 17. The process of claim 1, wherein the Group VIII metal compound of step (c) is selected from the group consisting of nickel sulfates and cobalt sulfates. 18. The process of claim 1, wherein the group VIB metal compound is molybdenum oxide. 19. The process of claim 1, wherein the group VIB metal compound is molybdenum oxide, the Group VIII metal compound is a nickel compound, and the weight ratio of nickel to molybdenum ranges from 1:100 to about 1:2. 20. The process of claim 1, wherein the group VIB metal compound and the group VIII metal compound are present in an amount ranging from 9:1-1:9 molar ratio of Group VI metal to Group VIII metal. 21. The process of claim 1, wherein the at least a hydrocarbon oil is a vacuum gas oil. 22. The process of claim 21, which is continuously mixed in a storage tank to maintain homogenous slurry. 23. The process of claim 1, wherein the steps (a) to (d) are carried out sequentially in a plurality of tanks. 24. The process of claim 1, wherein steps (a) to (d) are carried out sequentially in one single tank. 25. The process of claim 1, wherein some of the steps from (a) to (d) are carried out concurrently in one single tank. 26. The process of claim 1, wherein the catalyst has an HDN conversion rate of at least 90%. 27. The process of claim 1, wherein the catalyst has an HDS conversion rate of at least 90%. 28. A process for preparing a catalyst composition suitable for the hydroconversion of heavy oils, comprising: (a) mixing a group VIB metal compound with aqueous ammonia,(b) sulfiding the mixture of (a) with hydrogen and hydrogen sulfide to form a group VIB metal catalyst precursor in an aqueous slurry;(c) promoting the slurry with a Group VIII metal compound;(c) mixing under turbulent mixing conditions the slurry of step (c) with hydrogen gas and at least a hydrocarbon oil having a viscosity of at least 2 cSt @ 212° F. to form a homogenous slurry, and under sufficient temperature and pressure to maintain at least a portion of water in the slurry in a liquid phase, thereby forming an active catalyst composition admixed with a liquid hydrocarbon comprising slurry catalyst having an average particle size in the range of 1-20 microns. 29. A process for preparing a catalyst composition suitable for the hydroconversion of heavy oils, comprising:(a) mixing a group VIII metal compound with aqueous ammonia,(b) adding hydrogen, hydrogen sulfide and a Group VIII metal compound to the mixture of step (a), forming a catalyst precursor in slurry;(c) mixing under turbulent mixing conditions the slurry of step (b) with hydrogen gas and at least a hydrocarbon oil having a viscosity of at least 2 cSt @ 212° F. to form a homogenous slurry, and under sufficient temperature and pressure to maintain at least a portion of water in the slurry in a liquid phase, thereby forming an active catalyst composition admixed with a liquid hydrocarbon comprising slurry catalyst having an average particle size in the range of 1-20 microns. 30. The process of claim 29, wherein the group VIB metal compound is molybdenum oxide. 31. The process of claim 29, wherein the Group VIII metal compound is a nickel compound. 32. The process of claim 29, wherein the group VIB metal compound and the group VIII metal compound are present in an amount ranging from 9:1-1:9 molar ratio of Group VI metal to Group VIII metal.