Integrated conversion of extra-heavy crude oil and petroleum residue with the recovery of vanadium, nickel, and molybdenum

Based on experimental and calculation studies, it was demonstrated that, after the hydroconversion of tars and other heavy petroleum residues in the presence of a nanosized catalyst based on MoS2 or MoS2 and NiS, V, Ni, and Mo were quantitatively transferred to high-boiling fractions (HBFs) with boiling temperatures of > 420-520A degrees C and coke. At coke yields of < 0.5%, V, Ni, and Mo were almost completely concentrated in the HBF removed from the process. A hydrometallurgical process based on the treatment of ash and slag wastes (ASWs) with an ammonia solution of ammonium carbonate was developed. The resulting aqueous solution contained Mo and Ni compounds (nanosized catalyst precursors) with Mo recovery to 80% and V and Ni recovery of > 10% (on a weight basis in a HBF or its mixture with coke). Vanadium was extracted as V2O5 from the aqueous solution. The extraction of V and Ni from the solid residue after hydrometallurgical processing into commercial products can be performed by currently available industrial processes.