Regeneration and reactivation of deactivated hydrorefining catalyst

Claim 1

A method for regenerating a deactivated hydrorefining catalyst, said hydrorefining catalyst containing a refractory oxide and having sulfur-containing coke deposits on the surface thereof, said method comprising: (1) contacting a phosphorus component with said catalyst, said phosphorus component selected from the group consisting of elemental phosphorus and a nonmetallic phosphorus compound, said phosphorus component incorporated in an amount such that the catalyst from step (2) comprises at least one weight percent of phosphorus, calculated as P; and (2) combusting said coke deposits from said catalyst obtained from step (1) such that no significant sulfation of said refractory oxide occurs.

Claim 2

A method for regenerating a deactivated hydrorefining catalyst, said hydrorefining catalyst containing a refractory oxide and having sulfur-containing coke deposits on the surface thereof, said method comprising: (1) contacting a phosphorus component with said catalyst, said phosphorus component selected from the group consisting of elemental phosphorus and a nonmetallic phosphorus compound, said phosphorus component incorporated in an amount such that the catalyst from step (2) comprises at least one weight percent of phosphorus, calculated as P; and (2) combusting said coke deposits from said catalyst obtained from step (1) such that no significant sulfation of said refractory oxide occurs.

Claim 8

A method for regenerating a deactivated hydrorefining catalyst, said hydrorefining catalyst comprising a refractory oxide and having metal contaminants and sulfur-containing coke deposits on the surface thereof, which method comprises: (1) combusting part of said coke deposits from said deactivated catalyst; (2) incorporating a non-metallic phosphorus component with the catalyst obtained from step (1), said non-metallic phosphorus component incorporated in an amount such that the catalyst from step (3) comprises at least one weight percent of phosphorus, calculated as P; and (3) combusting a substantial proportion of the remaining coke deposits from said catalyst, said catalyst having no substantial loss of surface area as compared to said deactivated catalyst.

Claim 9

A method for regenerating a deactivated hydrorefining catalyst, said hydrorefining catalyst comprising a refractory oxide and having metal contaminants and sulfur-containing coke deposits on the surface thereof, which method comprises: (1) combusting part of said coke deposits from said deactivated catalyst; (2) incorporating a non-metallic phosphorus component with the catalyst obtained from step (1), said non-metallic phosphorus component incorporated in an amount such that the catalyst from step (3) comprises at least one weight percent of phosphorus, calculated as P; and (3) combusting a substantial proportion of the remaining coke deposits from said catalyst, said catalyst having no substantial loss of surface area as compared to said deactivated catalyst.

Claim 10

A method for regenerating a deactivated hydrorefining catalyst, said hydrorefining catalyst comprising hydrogenation metal components on a refractory oxide and having metal contaminants and sulfur-containing coke deposits on the surface thereof, which method comprises: (1) combusting part of said coke deposits from said deactivated catalyst; (2) incorporating a non-metallic phosphorus component with the catalyst obtained from step (1), said non-metallic phosphorus component incorporated in an amount such that the catalyst from step (3) comprises at least one weight percent of phosphorus, calculated as P; and (3) combusting a substantial proportion of the remaining coke deposits from said catalyst without substantial loss of average crushing strength as compared to said deactivated catalyst.

Claim 11

A method for regenerating a deactivated hydrorefining catalyst, said hydrorefining catalyst comprising hydrogenation metal components on a refractory oxide and having metal contaminants and sulfur-containing coke deposits on the surface thereof, which method comprises: (1) combusting part of said coke deposits from said deactivated catalyst; (2) incorporating a non-metallic phosphorus component with the catalyst obtained from step (1), said non-metallic phosphorus component incorporated in an amount such that the catalyst from step (3) comprises at least one weight percent of phosphorus, calculated as P; and (3) combusting a substantial proportion of the remaining coke deposits from said catalyst without substantial loss of average crushing strength as compared to said deactivated catalyst.

Claim 25

A method for regenerating a deactivated hydrorefining catalyst useful for hydrodesulfurization, said catalyst comprising cobalt and molybdenum components on a refractory oxide containing alumina, said catalyst further containing nickel and vanadium metal contaminants and sulfur-containing coke deposits on the surface thereof, which method comprises: (1) extracting vanadium and nickel components from said deactivated catalyst by contacting said deactivated catalyst with an extraction solution containing components selected from the group consisting of oxalic acid, aluminum nitrate, glycolic acid, and ammonium nitrate; (2) combusting part of said coke deposit from the catalyst obtained from step (1) by heating said catalyst to a temperature in the range from about 350° F. to about 550° F.; (3) incorporating cobalt, molybdenum, and phosphorus components with said catalyst obtained from step (2), said phosphorus component being incorporated in an amount sufficient to yield essentially no loss of surface area of said catalyst in step (4); (4) calcining said catalyst obtained from step (3) at a temperature in the range from about 700° F. to about 1300° F. such that a substantial proportion of said coke deposits are combusted from said catalyst without substantial loss in surface area thereof; (5) crushing said catalyst obtained from step (4) and mixing said crushed catalyst with alumina; and (6) forming said mixture obtained from step (5) into particulates and calcining.

Claim 26

A method for regenerating a deactivated hydrorefining catalyst useful for hydrodesulfurization, said catalyst comprising cobalt and molybdenum components on a refractory oxide containing alumina, said catalyst further containing nickel and vanadium metal contaminants and sulfur-containing coke deposits on the surface thereof, which method comprises: (1) extracting vanadium and nickel components from said deactivated catalyst by contacting said deactivated catalyst with an extraction solution containing components selected from the group consisting of oxalic acid, aluminum nitrate, glycolic acid, and ammonium nitrate; (2) combusting part of said coke deposit from the catalyst obtained from step (1) by heating said catalyst to a temperature in the range from about 350° F. to about 550° F.; (3) incorporating cobalt, molybdenum, and phosphorus components with said catalyst obtained from step (2), said phosphorus component being incorporated in an amount sufficient to yield essentially no loss of surface area of said catalyst in step (4); (4) calcining said catalyst obtained from step (3) at a temperature in the range from about 700° F. to about 1300° F. such that a substantial proportion of said coke deposits are combusted from said catalyst without substantial loss in surface area thereof; (5) crushing said catalyst obtained from step (4) and mixing said crushed catalyst with alumina; and (6) forming said mixture obtained from step (5) into particulates and calcining.