Ultra-stable heavy hydrocarbon hydroprocessing catalyst and methods of making and use thereof
An ultra-stable catalyst composition for hydroprocessing hydrocarbon feedstocks and a method of making and use of the ultra-stable catalyst composition. The catalyst composition of the invention comprises a calcined mixture made by calcining a formed particle of a mixture comprising an inorganic oxide material, molybdenum trioxide, and a nickel compound; wherein the calcined mixture is further overlaid with a cobalt component and a molybdenum component to thereby provide the catalyst composition.
1. A catalyst comprising:
(a) a calcined particle comprising an inorganic oxide material and underbedded metals, wherein the underbedded metals comprise molybdenum and nickel; and
(b) an overlayer on top of the calcined particle, the overlayer comprising cobalt and molybdenum, and absent a nickel concentration in the form of a nickel overlayer.
2. The catalyst according to claim 1 , wherein the calcined particle further comprises a phosphorus compound.
3. The catalyst according to claim 1 ,
wherein the catalyst has a phosphorous content ranging from 0.5 wt. % to 4 wt. %, by weight of the calcined catalyst particle, and
wherein the calcined particle has a phosphorous content ranging from 0.05 wt. % to 2 wt. %, by weight of the calcined particle.
4. The catalyst according to claim 3 , wherein the overlayer further comprises a phosphorus component.
5. The catalyst according to claim 4 , wherein the catalyst has a phosphorous content ranging from 1 wt. % to 3 wt. %, and wherein the calcined particle has a phosphorous content ranging from 0.2 wt. % to 1 wt. %.
6. The catalyst according to claim 1 , wherein a molybdenum content of the calcined particle is in the range of from 2 wt. % to 10 wt. % of the total weight of the calcined particle, and a nickel content of the calcined particle is in the range of from about 0.5 wt. % to about 4 wt. % of the total weight of said calcined particle.
7. The catalyst according to claim 6 ,
wherein the molybdenum content of the catalyst is in the range of from 8 wt. % to 18 wt. % of the total weight of the catalyst, and
wherein the cobalt content of the catalyst is in the range of from 0.5 to 6 wt. % of the total weight of the catalyst.
8. The catalyst according to claim 7 , wherein the catalyst has an absence of a concentration of underbedded cobalt.
9. The catalyst according to claim 8 , wherein the catalyst has an absence of a concentration of nickel that is in the form of a nickel overlayer.
10. The catalyst according to claim 1 , wherein the calcined particle is made by calcining a particle formed of a mixture comprising an inorganic oxide, a molybdenum trioxide, and a nickel compound.
11. The catalyst according to claim 10 , wherein the mixture further comprises phosphorus as both underbedded phosphorus and an overlayer of phosphorus.
12. The catalyst according to claim 11 ,
wherein the catalyst has a phosphorous content ranging from 0.5 wt. % to 4 wt. %, by weight of the calcined catalyst particle, and
wherein the calcined particle has a phosphorous content ranging from 0.05 wt. % to 2 wt. %, by weight of the calcined particle.
13. The catalyst according to claim 1 , wherein less than 5% of a total pore volume of the catalyst has a pore diameter of greater than 1,000 angstroms.
14. The catalyst according to claim 1 , wherein at least 40% of a total pore volume of the catalyst has a pore in the range of from 100 angstroms to 150 angstroms.