Patent ID: 8586500
Filing Date: 2013-11-19
Classification: B01J,C10G

Abstract:
1. A process for forming a bulk hydroprocessing catalyst with minimal amount of metals to waste treatment, the method comprising: co-precipitating at reaction conditions at least one of 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 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 an amount of at least 10 mole % of the metal precursor feeds; treating the supernatant by any of chemical precipitation, ion exchange, electro-coagulation, and combinations thereof to generate at least a metal precursor feed and a first effluent stream containing less than 50 mole % of metal ions in at least one of the metal residuals; treating the first effluent stream to recover at least 80 mol % of the metal ions in the first effluent stream to form at least a metal precursor feed; recycling the at least a metal precursor feed formed by treating the first effluent stream 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.