Hydroprocessing catalysts and methods for making thereof

摘要

A method to prepare an improved catalyst feed to a system to upgrade heavy oil. The method comprises: providing a spent catalyst that has been used in a hydroprocessing operation has with a solid content ranging from 5 to 50 wt. % in soluble hydrocarbons and having less than 80% but more than 10% of original catalytic activity; removing at least 50% of the soluble hydrocarbons removed in a deoiling step; treating the deoiled spent catalyst with a treating solution containing at least one of plain water, a mineral acid, an oxidizing agent, and combinations thereof to reduce the concentration of at least one metal contaminant in the deoiled spent catalyst by at least 40%. After treatment, the treated deoiled spent catalyst is slurried in a hydrocarbon medium, and fed to the heavy oil upgrade system as part of the catalyst feed system with a fresh slurry catalyst.

主权项

1. A method to prepare a catalyst feed for a system to upgrade a heavy oil feedstock, comprising:
providing a first slurry catalyst that has been used in a hydroprocessing operation with a solid content ranging from 5 to 50 wt. % in soluble hydrocarbons and having less than 80% but more than 10% of original catalytic activity; removing at least 50% of the soluble hydrocarbon in a deoiling step, generating a deoiled spent catalyst comprising at least 1 wt. % of at least one or more metal contaminants; treating the deoiled spent catalyst with a treating solution containing at least one of water, a mineral acid, an oxidizing agent, and combinations thereof at a volume ratio of treating solution to deoiled spent catalyst ranging from 2:1 to 100:1 for a treated deoiled spent catalyst having a reduced concentration of the at least one or more metal contaminants; mixing the treated deoiled spent catalyst with a hydrocarbon diluent, generating a treated deoiled spent catalyst slurry; providing a fresh slurry catalyst comprising a plurality of dispersed particles in a hydrocarbon diluent as a slurry; and feeding the fresh slurry catalyst and the treated deoiled spent catalyst slurry to the heavy oil upgrade system as a catalyst feed.