The use of well dispersed catalytic particles for hydro-upgrading of heavy oils has been proposed since two decades already. Varied technical propositions during the period have progressively reduced the particle size of the catalysts employed. In this paper are presented the most significant variables that ensure particle size control in the preparation of ultradispersed catalysts for use in both hydroprocessing and steam processing (or aqua-processing) of bitumen heaviest fractions. A brief of results obtained using a mini pilot plant (0.05 bpd), designed and built at the “Catalysis for Bitumen Upgrading and Hydrogen Production” laboratory of Schulich School of Engineering-University of Calgary, will also be presented. The performance of different ultradispersed catalysts formulations suitable for the processes mentioned above was evaluated. The relevance of catalyst particle size for the performance of each of the processes will be addressed and discussed. In both types of processing Athabasca bitumen heavy fractions were used as feedstock. The results are compared with patented data from processes based on hydroprocessing and aqua-processing reported in the literature.

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