Hydrocracking catalysts for vacuum gas oil & de-metalized oil blend

Abstract

This invention relates to a catalyst and a process for treating heavy hydrocarbons using the catalyst. The catalyst is useful for treating heavy hydrocarbons, de-metallize oil (DMO) and is particularly useful in VGO/DMO hydrocarbon blend. It is also useful for DAO. The catalyst acts to catalytically convert the VGO/DMO blend to shorter-chain valuable hydrocarbon products. The catalyst includes a catalytic support material, a catalytic metal impregnated upon the catalytic support material, and a promoter metal on the catalytic support material to enhance catalytic conversion. The combination of the catalytic support material with catalytic metal and promoter metal is operable to catalytically convert VGO/DMO into hydrocarbon products having shorter carbon chains.

1 . A catalyst for treating VGO/DMO hydrocarbon blend to catalytically convert the VGO/DMO blend to shorter-chain valuable hydrocarbon products, the catalyst comprising: 
 a catalytic support material comprising MCM-41 mesoporous material,    a catalytic metal impregnated upon the catalytic support material, and,    a promoter metal on the catalytic support material to enhance catalytic conversion,    the catalytic support material with catalytic metal and promoter metal operable to catalytically convert VGO/DMO into hydrocarbon products having shorter carbon chains.    
   
   
       2 . The catalyst of  claim 1  wherein the catalytic metal component is molybdenum and the promoter metal is nickel.  
   
   
       3 . The catalyst of  claim 2  wherein the catalytic support material is solely MCM-41 mesoporous material.  
   
   
       4 . The catalyst of  claim 2  wherein substantially all of the nickel is in the form of nickel sulfide.  
   
   
       5 . The catalyst of  claim 1  wherein the catalytic metal component is selected from the group consisting of molybdenum, tungsten and combinations thereof, and wherein the promoter metal is selected from a group consisting of nickel, cobalt and combinations thereof.  
   
   
       6 . The catalyst of  claim 1  wherein the VGO/DMO hydrocarbon blend contains at least 10% DMO by volume.  
   
   
       7 . The catalyst of  claim 1  wherein the VGO/DMO hydrocarbon blend contains at least 15% DMO by volume.  
   
   
       8 . The catalyst of  claim 1  wherein the catalytic metal and the promoter metal are impregnated upon the catalytic support through co-impregnation.  
   
   
       9 . The catalyst of  claim 1  wherein the catalytic metal and the promoter metal are impregnated upon the catalytic support through successive impregnation.  
   
   
       10 . The process of catalytically converting a heavy hydrocarbon containing de-metallized oil comprising the steps of: 
 introducing the heavy hydrocarbon containing de-metallized oil into a reactor stage,    introducing the catalyst into the reactor stage, the catalyst comprising:    a catalytic support material comprising MCM-41 mesoporous material,    a catalytic metal impregnated upon the catalytic support material, and,    a promoter metal on the catalytic support material to enhance catalytic conversion,    the catalytic support material with catalytic metal and promoter metal operable to catalytically convert at least a portion of the de-metallized oil into hydrocarbon products having shorter carbon chains.    
   
   
       11 . The process of  claim 10  wherein the catalytic metal component is molybdenum and the promoter metal is nickel.  
   
   
       12 . The catalyst of  claim 11  wherein the catalytic support material includes ultra stable Y zeolite.  
   
   
       13 . The process of  claim 11  wherein the catalytic support material is solely MCM-41 mesoporous material.  
   
   
       14 . The process of  claim 11  wherein the catalytic support material includes β-zeolite.  
   
   
       15 . The process of  claim 11  wherein the catalytic support material includes amorphous silica alumina.  
   
   
       16 . The process of  claim 11  wherein the catalytic support material is selected from the group consisting of ultra stable Y zeolite, MCM-41 mesoporous material, β-zeolite, amorphous silica alumina, and combinations thereof.  
   
   
       17 . The process of  claim 11  wherein at least a portion of the nickel is in the form of nickel sulfide.  
   
   
       18 . The process of  claim 11  wherein the catalytic metal component is selected from the group consisting of nickel, cobalt and combinations thereof, and wherein the promoter metal is selected from a group consisting of molybdenum, tungsten and combinations thereof.  
   
   
       19 . The process of  claim 11  wherein the VGO/DMO hydrocarbon blend contains at least 10% DMO by volume.  
   
   
       20 . The process of  claim 11  wherein the VGO/DMO hydrocarbon blend contains at least 15% DMO by volume.  
   
   
       21 . The process of  claim 18  wherein at least a portion of the nickel is in the form of nickel sulfide.  
   
   
       22 . The process of  claim 18  wherein at least a portion of the cobalt is in the form of cobalt sulfide.  
   
   
       23 . The process of  claim 10  wherein the catalytic metal and the promoter metal are impregnated upon the catalytic support through co-impregnation.  
   
   
       24 . The process of  claim 10  wherein the catalytic metal and the promoter metal are impregnated upon the catalytic support through successive impregnation.  
   
   
       25 . The process of  claim 10  further comprising the step of maintaining a pre-defined temperature in the reactor.  
   
   
       26 . The process of  claim 25  wherein the pre-defined temperature is at least 390 degrees C.  
   
   
       27 . The process of  claim 25  wherein the pre-defined temperature is at least 400 degrees C.