Hydrocracking and hydrotreating catalytic compositions comprising a zeolite and regenerated, spent catalyst and uses thereof
The invention relates to a composition useful as a hydrotreating or hydrocracking catalyst, where fresh catalyst useful in hydrotreating or hydrocracking is combined with spent catalyst, and optionally with additional active metal. The resulting compositions can be used in hydrotreating or hydrocracking but not FCC processes.
1. A composition of matter comprising:
(i) a fresh hydrotreating or hydrocracking catalyst, said hydrotreating or hydrocracking catalyst comprises a zeolite, one or more of Mo, Ni, Co, and W, and a binder, wherein said binder comprises regenerated spent catalyst, wherein said regenerated catalyst has not been treated to recover any active metals contained therein.
2. The composition of matter of claim 1 , wherein said regenerated spent catalyst is a spent hydrotreating or hydrocracking catalyst.
3. The composition of matter of claim 1 , wherein said fresh and regenerated spent catalyst are the same.
4. The composition of matter of claim 1 , wherein said fresh and regenerated spent catalyst are different.
5. The composition of matter of claim 1 , wherein said regenerated spent catalyst is a powder with a mesh size of 30 or greater.
6. The composition of claim 1 , wherein said regenerated spent catalyst further comprises C, S, W, P, Ni, Mo, Co, W, Fe, or As.
7. The composition of claim 1 , further comprising an additional fresh binder.
8. The composition of claim 7 , wherein said fresh binder comprises USY-zeolite.
9. A method for hydrotreating or hydrocracking a hydrocarbon feedstock, comprising contacting the composition of matter of claim 1 to said hydrocarbon feedstock at a temperature of from 350-400° C., a pressure of 10-250 bars, a residence time of 450-36,000 seconds, a hydrogen/oil ratio of from 100-150 SLT/LT.
10. The method of claim 9 , said method comprising a two reactor system.
11. The method of claim 10 , wherein said two reactor system comprises a hydrogen feedstock liquid phase and a catalyst solid phase reactor.
12. The method of claim 9 , said method comprising a three reactor system.
13. The method of claim 9 , wherein said three reactor system comprises hydrogen-gas, feedstock-liquid, and catalyst-solid phase reactors.
14. The method of claim 9 , comprising a fixed bed, ebullated bed, moving bed, or slurry bed reactor.
15. The composition of matter of claim 1 , wherein said binder comprises USY hierarchical/mesoporous-zeolite substituted with Ti and Zr in its framework T atoms.