Hydroprocessing catalyst and use thereof
The invention pertains to a hydroprocessing catalyst suitable for the conversion of heavy hydrocarbon oils, which comprises 7–20 wt. % of Group VI metal, calculated as trioxide, and about 0.5–6 wt. % of Group VIII metal, calculated as oxide, on a carrier comprising alumina, the catalyst having a surface area of about 100–180 m 2 /g, a total pore volume of about 0.55 ml/g or more, a % PV(>200 Å d) of at least about 50%, a % PV(>1,000 Å d) of at least about 5%, a % PV(100–1,200 Å d) of at least about 85%, a % PV(>4,000 Å d) of about 0–2%, and a % PV(>10,000 Å d) of about 0–1%. The catalyst of the present invention shows improved metals and asphaltene removal, combined with appropriate sulfur, nitrogen, and Conradson carbon removal. Additionally, the catalyst shows a decrease in sediment formation and an improved conversion in ebullating bed operations. In fixed bed operation, the catalyst produces product with an improved storage stability. The invention also pertains to a process for hydroprocessing heavy hydrocarbon feeds with the catalyst according to the invention in fixed bed or ebullating bed operation.
1. A hydroprocessing catalyst useful for the conversion of heavy hydrocarbon oils comprising about 7–20 wt. % of Group VI metal, calculated as trioxide, and about 0.5–6 wt. % of Group VIII metal, calculated as oxide, on a carrier comprising alumina, the catalyst having the following physical properties: a surface area of about 100–180 m 2 /g, a total pore volume of about 0.55 ml/g or more, a %PV(>200 Å d) of at least 50%, a %PV(>1,000 Å d) of at least about 5%, a %PV(100–1,200 Å d) of at least about 85%, a %PV(>4,000 Å d) of about 0–2%, and a %PV(>10,000 Å d) of about 0–1%.
2. The catalyst of claim 1 wherein the %PV(>200 Å d) is about 60–80%.
3. The catalyst of claim 1 wherein the %PV(>1,000 Å d) is about 8–30%.
4. The catalyst of claim 1 wherein the %PV(>1,000 Å d) is about 8–25%.
5. The catalyst of claim 1 wherein the carrier consists essentially of alumina with less than about 2.5 wt. % of silica.
6. The catalyst of claim 1 wherein the carrier consists essentially of alumina with less than about 1.5 wt. % of silica.
7. The catalyst of claim 1 wherein the carrier consists essentially of alumina with less than about 0.5 wt. % of silica.
8. The catalyst of claim 1 wherein the Group VI metal is molybdenum and the Group VIII metal is nickel.
9. A process for the hydroprocessing of heavy hydrocarbon feeds comprising contacting a heavy hydrocarbon feed with a hydroprocessing catalyst of claim 1 in the presence of hydrogen at a temperature of about 350–450° C. and a pressure of about 5–25 MPa.
10. The process of claim 9 wherein the temperature is about 400–450° C. and the pressure is about 14–19 MPa.
11. The process of claim 9 wherein the catalyst is in the form of an ebullating bed.
12. The process of claim 9 wherein the catalyst is in the form of a fixed bed.