Upgrading carbo-metallic oils with used catalyst

摘要

A process is disclosed for upgrading a hydrocarbon oil feed having a significant content of metals, especially vanadium, to provide a higher grade of oil products by contacting the feed under sorbing conditions in an upgrading zone with a high surface area, high pore volume sorbent material containing an added alkaline metal to neutralize acidic cracking sites. Upgrading conditions are such that coke and metals are deposited on the sorbent in the upgrading zone. Coked sorbent is regenerated by contact with an oxygen containing gas under regeneration conditions to remove the coke, and regenerated sorbent is recycled to the upgrading zone for contact with fresh feed. The added alkaline metal is present on the sorbent in an amount sufficient to neutralize substantially all of the acidic cracking sites and provide a sorbent material having a MAT relative activity in the range of about 0 to about 1 percent. A sorbent composition disclosed comprises a deactivation, spent or equilibrium catalyst withdrawn from an FCC or RCC cracking operation and treated with an alkaline metal additive during the upgrading process and/or prior to use in the upgrading process by impregnation techniques. The alkaline metal additives include water soluble inorganic salts and/or hydrocarbon soluble organo-metallic compounds of select alkaline metals.