Patent ID: 8703641
Filing Date: 2014-04-22
Classification: B01J,C10G

Abstract:
1. A process for forming a hydroprocessing catalyst composition with minimal amount of metals to waste treatment, the method comprises: co-precipitating at reaction conditions at least a Group VIB metal precursor feed and at least a Promoter metal precursor feed selected from Group VIII, Group IIB, Group IIA, Group IVA and combinations thereof, to form a mixture comprising a catalyst precursor, wherein the reaction conditions comprise a temperature between 25-350° C. and at a pressure between 0 to 3000 psig and a pH of 0-12; isolating the catalyst precursor from the mixture, forming a supernatant containing at least a Promoter metal residual and at least a Group VIB metal residual in a total amount of at least 10 mole % of the metal precursor feeds; mixing the supernatant with at least a base or an acid for a sufficient amount of time to precipitate at least 50 mole % of metal ions in at least one of the metal residuals, wherein the precipitation is carried out at a pre-selected pH; isolating the precipitate to recover a first effluent containing less than 50 mole % of metal ions in at least one of the metal residuals in the supernatant; contacting the first effluent with a chelated ion exchange resin for a sufficient amount of time for at least 50 mole % of metal ions in at least one of the metal residuals in the first effluent to be bound onto the resin, forming a second effluent containing less than 1000 ppm of metal ions of at least one of the metal residuals; eluting the resin to produce an eluate containing the metal ions previously bound onto the resin; treating the second effluent stream or the eluate to recover at least 80 mol % of the metal ions in the second effluent stream to form at least a metal precursor feed; recycling the at least a metal precursor feed formed by treating the second effluent stream or the eluate to the co-precipitating step; and sulfiding the catalyst precursor forming the bulk catalyst; wherein an effluent stream from the process to waste treatment contains less than 50 ppm metal ions.