Abstract: The specification discloses a highly macroporous catalyst for hydroprocessing and hydroconversion of heavy hydrocarbon feedstocks. The high macroporosity catalyst incudes an inorganic oxide, molybdenum, and nickel components. It has a pore structure such that at least 18% of its total pore volume is in pores of a diameter greater than 5,000 angstroms and at least 25% of its total pore volume is in pores of a diameter greater than 1,000 angstroms. Preferably, the pore structure is bimodal. The catalyst is made by co-mulling the catalytic components with a high molecular weight polyacrylamide followed by forming the co-mulled mixture into a particle or an extrudate. The particle or extrudate is dried and calcined under controlled calcination temperature conditions to yield a calcined particle or extrudate of the high macroporosity catalyst composition.

Abstract: The specification discloses a highly macroporous catalyst for hydroprocessing and hydroconversion of heavy hydrocarbon feedstocks. The high macroporosity catalyst incudes an inorganic oxide, molybdenum, and nickel components. It has a pore structure such that at least 18% of its total pore volume is in pores of a diameter greater than 5,000 angstroms and at least 25% of its total pore volume is in pores of a diameter greater than 1,000 angstroms. Preferably, the pore structure is bimodal. The catalyst is made by co-mulling the catalytic components with a high molecular weight polyacrylamide followed by forming the co-mulled mixture into a particle or an extrudate. The particle or extrudate is dried and calcined under controlled calcination temperature conditions to yield a calcined particle or extrudate of the high macroporosity catalyst composition.

Abstract: 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.

Abstract: A catalyst and process for the deoxygenation and conversion of bio-derived feedstocks. The catalyst comprises a silica-alumina support having specifically defined physical properties and a molybdenum component but a material absence of nickel. The process involves the processing of a bio-derived feedstock having an oxygen content to yield a conversion product having an exceptional distillation profile and physical properties and a substantially reduced oxygen content.

Abstract: A catalyst and process for the deoxygenation and conversion of bio-derived feedstocks. The catalyst comprises a silica-alumina support having specifically defined physical properties and a molybdenum component but a material absence of nickel. The process involves the processing of a bio-derived feedstock having an oxygen content to yield a conversion product having an exceptional distillation profile and physical properties and a substantially reduced oxygen content.

Abstract: The specification discloses a highly macroporous catalyst for hydroprocessing and hydroconversion of heavy hydrocarbon feedstocks. The high macroporosity catalyst includes an inorganic oxide, molybdenum, and nickel components. It has a pore structure such that at least 18% of its total pore volume is in pores of a diameter greater than 5,000 angstroms and at least 25% of its total pore volume is in pores of a diameter greater than 1,000 angstroms. Preferably, the pore structure is bimodal. The catalyst is made by co-mulling the catalytic components with a high molecular weight polyacrylamide followed by forming the co-mulled mixture into a particle or an extrudate. The particle or extrudate is dried and calcined under controlled calcination temperature conditions to yield a calcined particle or extrudate of the high macroporosity catalyst composition.

Abstract: A self-activating catalyst for treating heavy hydrocarbon feedstocks that comprises a calcined particle treated with a sulfoxide compound in the presence of hydrogen. The calcined particle comprises a co-mulled mixture made by co-mulling inorganic oxide powder, molybdenum trioxide powder, and a nickel compound and then forming the co-mulled mixture into a particle that is calcined to thereby provide the calcined particle. The calcined particle comprises from 1 to 10 weight percent molybdenum and nickel that is present in an amount such that the weight ratio of said nickel-to-molybdenum is less than 0.4. The calcined particle has a pore size distribution that contributes to the unique properties of the catalyst. The enhanced self-activating catalyst is used in the hydroprocessing of heavy residue feedstocks that have high nickel, vanadium and sulfur concentrations.

Abstract: 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.

Abstract: Disclosed is a method of hydrotreating a heavy hydrocarbon feedstock using a hydrotreating catalyst having specific properties that make it effective in converting nitrogen, sulfur and micro-carbon residue of a heavy hydrocarbon feedstock. The catalyst comprises a calcined support particle impregnated with a Group 6 metal component (e.g., molybdenum), a nickel component, and a phosphorus component present at concentrations in the catalyst such that the atomic ratio of the Group 6 metal-to nickel metal are within a specified range. The nickel metal acid extractability property of the catalyst is at least 50 percent.

Abstract: A self-activating catalyst for treating heavy hydrocarbon feedstocks that comprises a calcined particle treated with a sulfoxide compound in the presence of hydrogen. The calcined particle comprises a co-mulled mixture made by co-mulling inorganic oxide powder, molybdenum trioxide powder, and a nickel compound and then forming the co-mulled mixture into a particle that is calcined to thereby provide the calcined particle. The calcined particle comprises from 1 to 10 weight percent molybdenum and nickel that is present in an amount such that the weight ratio of said nickel-to-molybdenum is less than 0.4. The calcined particle has a pore size distribution that contributes to the unique properties of the catalyst. The enhanced self-activating catalyst is used in the hydroprocessing of heavy residue feedstocks that have high nickel, vanadium and sulfur concentrations.

Abstract: 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.

Abstract: A catalyst and its use for selectively desulfurizing sulfur compounds present in an olefin-containing hydrocarbon feedstock to very low levels with minimal hydrogenation of olefins. The catalyst comprises an inorganic oxide substrate containing a nickel compound, a molybdenum compound and optionally a phosphorus compound, that is overlaid with a molybdenum compound and a cobalt compound. The catalyst is further characterized as having a bimodal pore size distribution with a large portion of its total pore volume contained in pores having a diameter less than 250 angstroms and in pores having a diameter greater than 1000 angstroms.

Abstract: A catalyst and its use for selectively desulfurizing sulfur compounds present in an olefin-containing hydrocarbon feedstock to very low levels with minimal hydrogenation of olefins. The catalyst comprises an inorganic oxide substrate containing a nickel compound, a molybdenum compound and optionally a phosphorus compound, that is overlaid with a molybdenum compound and a cobalt compound. The catalyst is further characterized as having a bimodal pore size distribution with a large portion of its total pore volume contained in pores having a diameter less than 250 angstroms and in pores having a diameter greater than 1000 angstroms.

Abstract: A catalyst and its use for selectively desulfurizing sulfur compounds present in an olefin-containing hydrocarbon feedstock to very low levels with minimal hydrogenation of olefins. The catalyst comprises an inorganic oxide substrate containing a nickel compound, a molybdenum compound and optionally a phosphorus compound, that is overlaid with a molybdenum compound and a cobalt compound. The catalyst is further characterized as having a bimodal pore size distribution with a large portion of its total pore volume contained in pores having a diameter less than 250 angstroms and in pores having a diameter greater than 1000 angstroms.

Abstract: A self-activating hydroprocessing catalyst for treating heavy hydrocarbon feedstocks is further activated by contacting the self-activating catalyst with steam. The steam may be added to the heavy hydrocarbon feedstock prior to contacting with the self-activating catalyst or may be added to a reactor vessel containing the self-activating catalyst.

Abstract: Disclosed is a method of hydrotreating a heavy hydrocarbon feedstock using a hydrotreating catalyst having specific properties that make it effective in converting nitrogen, sulfur and micro-carbon residue of a heavy hydrocarbon feedstock. The catalyst comprises a calcined support particle impregnated with a Group 6 metal component (e.g., molybdenum), a nickel component, and a phosphorus component present at concentrations in the catalyst such that the atomic ratio of the Group 6 metal-to nickel metal are within a specified range. The nickel metal acid extractability property of the catalyst is at least 50 percent.

Abstract: Disclosed is a method of hydrotreating a heavy hydrocarbon feedstock using a hydrotreating catalyst having specific properties that make it effective in converting nitrogen, sulfur and micro-carbon residue of a heavy hydrocarbon feedstock. The catalyst comprises a calcined support particle impregnated with a Group 6 metal component (e.g., molybdenum), a nickel component, and a phosphorus component present at concentrations in the catalyst such that the atomic ratio of the Group 6 metal-to nickel metal are within a specified range. The nickel metal acid extractability property of the catalyst is at least 50 percent.

Abstract: A catalyst for treating heavy hydrocarbon feedstocks. The catalyst comprises a calcined particle comprising a co-mulled mixture made by co-mulling inorganic oxide powder, molybdenum trioxide powder, and a nickel compound or cobalt compound, or both compounds, and then forming the co-mulled mixture into a particle that is calcined to provide the calcined particle. The calcination is conducted at a temperature such that at least 20% of the pore volume of the calcined particle is in pores of greater than 5,000 ? and less than 70% of the pore volume of the calcined particle is in the pores having a pore size in the range of from 70 to 250 ?.

Abstract: A method of making a high activity catalyst composition suitable for use in the hydrodesulfurization of a middle distillate feed, such as diesel fuel, having a high concentration of sulfur, to thereby provide a low sulfur middle distillate product. The method comprises heat treating aluminum hydroxide under controlled temperature conditions thereby converting the aluminum hydroxide to gamma-alumina to give a converted aluminum hydroxide, and controlling the fraction of converted aluminum hydroxide that is gamma-alumina. A catalytic component is incorporated into the converted aluminum hydroxide to provide an intermediate, which is heat treated to provide the high activity catalyst composition. The high activity catalyst composition can suitably be used in the hydrodesulfurization of a middle distillate feed containing a high sulfur concentration.

Abstract: A self-activating catalyst for treating heavy hydrocarbon feedstocks that comprises a calcined particle treated with a sulfoxide compound in the presence of hydrogen. The calcined particle comprises a co-mulled mixture made by co-mulling inorganic oxide powder, molybdenum trioxide powder, and a nickel compound and then forming the co-mulled mixture into a particle that is calcined to thereby provide the calcined particle. The calcined particle comprises from 1 to 10 weight percent molybdenum and nickel that is present in an amount such that the weight ratio of said nickel-to-molybdenum is less than 0.4. The calcined particle has a pore size distribution that contributes to the unique properties of the catalyst. The enhanced self-activating catalyst is used in the hydroprocessing of heavy residue feedstocks that have high nickel, vanadium and sulfur concentrations.