A hydroprocessing catalyst has been developed. The catalyst is a unique crystalline ammonia transition metal molybdate material. The hydroprocessing using the crystalline ammonia transition metal molybdate material may include hydrodenitrification, hydrodesulfurization, hydrodemetallation, hydrodesilication, hydrodearomatization, hydroisomerization, hydrotreating, hydrofining, and hydrocracking.

Catalyst particles comprising one or more active metal components and methods for manufacturing such catalyst particles are provided. The particles are a composite of a granulating agent or binder material such as an inorganic oxide, and an ultra-stable Y (hereafter USY) zeolite in which some of the aluminum atoms in the framework are substituted with zirconium atoms and/or titanium atoms and/or hafnium atoms. The one or more active phase components are incorporated prior to mixing the binder with the post-framework modified USY zeolite, extruding the resulting composite mixture, and forming the catalyst particles. The one or more active phase components are incorporated in the post-framework modified USY zeolite prior to forming the catalyst particles.

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.

Provided herein are compositions and methods for use of an organosilica material comprising a copolymer of at least one monomer of Formula [R.sup.1R.sup.2SiCH.sub.2].sub.3 (I), wherein, R.sup.1 represents a C.sub.1-C.sub.4 alkoxy group; and R.sup.2 is a C.sub.1-C.sub.4 alkoxy group or a C.sub.1-C.sub.4 alkyl group; and at least one other monomer of Formula [(Z.sup.1O).sub.xZ.sup.2.sub.3-xSiZ.sup.3SZ.sup.4] (II), wherein, Z.sup.1 represents a hydrolysable functional group; Z.sup.2 represents a C.sub.1-C.sub.10 alkyl or aryl group; Z.sup.3 represents a C.sub.2-C.sub.11 cyclic or linear hydrocarbon; Z.sup.4 is either H or O.sub.3H; and x represents any one of integers 1, 2, and 3. The composition may be used as a support material to covalently attach transition metal cations, as a sorbent for olefin/paraffin separations, as a catalyst support for hydrogenation reactions, as a precursor for highly dispersed metal nanoparticles, or as a polar sorbent for crude feeds.

This invention provides a catalyst formed by bringing together, in an aqueous medium, at least one phosphorus compound, at least one Group VI metal compound, at least one Group VIII metal compound, and an additive which is a) tetraethylene glycol, b) polyethylene glycol having an average molecular weight in the range of about 200 to about 400, c) a mixture of tetraethylene glycol and polyethylene glycol having an average molecular weight in the range of about 200 to about 400, or d) a mixture of (1) tetraethylene glycol and/or polyethylene glycol having an average molecular weight in the range of about 200 to about 400 and (2) one or more of monoethylene glycol, diethylene glycol, and triethylene glycol, forming an impregnated carrier; and
drying the impregnated carrier. The molar ratio of additive to the total moles of Group VI metal and Group VIII metal is about 0.36:1 to about 0.6:1.

This invention provides a catalyst formed by bringing together, in an aqueous medium, at least one phosphorus compound, at least one Group VI metal compound, at least one Group VIII metal compound, and an additive which is a) tetraethylene glycol, b) polyethylene glycol having an average molecular weight in the range of about 200 to about 400, c) a mixture of tetraethylene glycol and polyethylene glycol having an average molecular weight in the range of about 200 to about 400, or d) a mixture of (1) tetraethylene glycol and/or polyethylene glycol having an average molecular weight in the range of about 200 to about 400 and (2) one or more of monoethylene glycol, diethylene glycol, and triethylene glycol, forming an impregnated carrier; and
drying the impregnated carrier. The molar ratio of additive to the total moles of Group VI metal and Group VIII metal is about 0.36:1 to about 0.6:1.

A process to treat a heavy hydrocarbon feed in a liquid-full hydroprocessing reactor is disclosed. The heavy feed has a high asphaltenes content, high viscosity, high density and high end boiling point. Hydrogen is fed in an equivalent amount of at least 160 liters of hydrogen, per liter of feed, l/l (900 scf/bbl). The feed is contacted with hydrogen and a diluent, which comprises, consists essentially of, or consists of recycle product stream. The hydroprocessed product has increased value for refineries, such as a feed for an fluid catalytic cracking (FCC) unit.

A process to treat a heavy hydrocarbon feed in a liquid-full hydroprocessing reactor is disclosed. The heavy feed has a high asphaltenes content, high viscosity, high density and high end boiling point. Hydrogen is fed in an equivalent amount of at least 160 liters of hydrogen, per liter of feed, l/l (900 scf/bbl). The feed is contacted with hydrogen and a diluent, which comprises, consists essentially of, or consists of recycle product stream. The hydroprocessed product has increased value for refineries, such as a feed for an fluid catalytic cracking (FCC) unit.

A hydroconversion catalyst comprising a Group VIB metal component, a Group VIII metal component and a carrier material is disclosed wherein the catalyst has a total pore volume of 0.5 to 0.9 cc/g; and a pore volume distribution such that greater than 60% of pore volume are in pores present as micropores of diameter between 55 and 115 ?, less than 0.12 cc/g of pore volume are in pores present at pores of diameter greater than 160 ? and greater than 5% of the total pore volume is in pores of diameter greater than 210 ?.

A hydroconversion catalyst comprising a Group VIB metal component, a Group VIII metal component and a carrier material is disclosed wherein the catalyst has a total pore volume of 0.5 to 0.9 cc/g; and a pore volume distribution such that greater than 60% of pore volume are in pores present as micropores of diameter between 55 and 115 ?, less than 0.12 cc/g of pore volume are in pores present at pores of diameter greater than 160 ? and greater than 5% of the total pore volume is in pores of diameter greater than 210 ?.