EP0112667A1 - Wasserstoffumwandlungskatalysator und -verfahren - Google Patents

Wasserstoffumwandlungskatalysator und -verfahren Download PDF

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EP0112667A1
EP0112667A1 EP83307379A EP83307379A EP0112667A1 EP 0112667 A1 EP0112667 A1 EP 0112667A1 EP 83307379 A EP83307379 A EP 83307379A EP 83307379 A EP83307379 A EP 83307379A EP 0112667 A1 EP0112667 A1 EP 0112667A1
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Prior art keywords
catalyst
range
component
pore volume
metal
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EP0112667B1 (de
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Jeffrey Templeton Miller
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BP Corp North America Inc
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BP Corp North America Inc
Standard Oil Co
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    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G45/00—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
    • C10G45/02—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing
    • C10G45/04—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
    • C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
    • C10G2300/10—Feedstock materials
    • C10G2300/107—Atmospheric residues having a boiling point of at least about 538 °C

Definitions

  • This invention relates to hydrotreating catalysts having a desirable combination of activity and high temperature stability and to processes for preparation and use thereof.
  • Catalytic hydrotreating involves contacting a feed with hydrogen at elevated temperature and pressure in the presence of catalysts having hydrogenation activity.
  • sulfur and nitrogen in the feed are converted largely to hydrogen sulfide and ammonia which are easily removed.
  • Aromatics saturation and, to a lesser extent, cracking of larger molecules often take place to convert high boiling feed components to lower boiling components.
  • Metals content of the feed decreases as a result of deposition of metals on the surface of the hydrotreating catalyst.
  • Hydrotreating of low quality hydrocarbon feeds often is conducted under conditions more severe than those used in conventional hydrotreating of lighter hydrocarbon feeds in order to achieve suitable levels of nitrogen, sulfur and/or metals removal and/or conversion of high boiling components to lower boiling materials.
  • removal of nitrogen from'high nitrogen feeds such as whole shale oils or fractions thereof, typically requires higher temperatures and pressures and lower space velocities than those used in catalytic hydrotreating of low nitrogen feeds.
  • hydrotreating heavy petroleum crude oil fractions such as vacuum or atmospheric resids and particularly those containing significant quantities of sulfur, metal and/or asphaltenes, usually requires operation under conditions more severe than those employed in hydrotreating lighter feeds.
  • the second stage of the process comprises contacting the effluent from the first reaction zone with a catalyst consisting essentially of hydrogenation metal selected from Group VIB deposed on a relatively small pore, catalytically active support comprising alumina.
  • the second stage catalyst has a surface area within the range of about 150 m 2 /gm to about 300 m 2 /gm, a pore volume within the range of about 0.4 cc/gm to about 0.9 cc/gm, an average pore 0 0 diameter within the range of about 90A to about 160A, and a majority of its pore volume in pore diameters within the range of about 80A to about 130A.
  • the pore volume distribution is such that less than 40% of its pore volume is in pores having diameters 0 0 within the range of about 50A to about 80A, about 45% to about 90% of its pore volume is in pores having diame-0 0 ters within the range of about 80A to about 130A, and less than about 15% of its pore volume is in pores having diameters larger than 130A.
  • the catalyst disclosed has a pore volume distribution summarized as follows: In terms of the surface area, the pores of the disclosed 0 catalyst having diameters within the range of about 80A to about 130A preferably contain about 90 to about 180 m 2 /gm, and more preferably contain about 120 to about 180 m 2 /gm, of surface area.
  • the invention comprises the preparation of stabilized aqueous solutions which comprise an aqueous solvent having dissolved therein catalytically active compounds containing at least one element from Group VI of the periodic table and one element from Group VIII.”
  • Inorganic oxyacids of phosphorus are included among the disclosed stabilizers, and the examples of Pessimisis illustrate preparation of various cobalt-molybdenum, nickel-molybdenum, and nickel- tungsten catalysts using phosphorus and other acids as stabilizers. Hydrodesulfurization results with certain of the cobalt-molybdenum catalysts are presented, and the patentee suggests that the use of the stabilized solutions may lead to improved hydrodesulfurization activity in some instances.
  • Kerns et al., U.S. Patent No. 3,446,730 disclose hydrodenitrogenation catalysts comprising at least one of a nickel component and a Group VI metal component, supported on a specific alumina, such catalysts being promoted with 0.1 to 2.0 wt.% of a promoter selected from compounds of phosphorus, silicon and barium.
  • a promoter selected from compounds of phosphorus, silicon and barium.
  • the disclosed catalysts are more tolerant of nitrogen than catalysts prepared without an aluminosilicate component.
  • Examples 10-13 of both patents illustrate catalysts exhibiting improved hydrodenitrogenation activity as compared to catalysts prepared without an aluminosilicate component. Reported hydrodesulfurization activity is slightly worse.
  • 3,287,280 attribute to use of phosphoric acid in catalyst preparation, or to phosphoric acid residue content in finished catalysts, promotional effects in respect of hydrodesulfurization activity of cobalt-molybdenum and nickel-molybdenum catalysts, and while certain of the aforesaid Mickelson patents illustrate a similar influence on hydrodenitrogenation activity of Group VI and Group VIII metals-containing catalysts, the aforesaid Ripperger and Saum article teach that phosphoric acid use leads to improved hydrodenitrogenation activity for nickel-molybdenum catalysts but not for cobalt-molybdenum catalysts. Further, the aforesaid Kerns et al.
  • a further object of the invention is to provide a catalyst of improved stability and lifetime under high severity hydrotreating conditions.
  • Another object of the invention is to provide for such improvements by simple and inexpensive methods for catalyst preparation and without the need for expensive reactants or complicated preparative techniques.
  • a more specific object of the invention is to provide a catalyst of improved activity and stability for hydrotreating high nitrogen hydrocarbon feeds under severe conditions as well as methods for the use of such catalyst.
  • the catalytic composition of the present invention comprising a hydrogenating component supported on the surface of a porous refractory inorganic oxide support, wherein the hydrogenating component consists essentially of (1) a metal component in which the metal is selected from Group VIB of the Periodic Table and (2) a phosphorus component and wherein the support is free of a zeolite component.
  • the present invention is also a method for hydrotreating a hydrocarbon feed in the presence of such catalyst.
  • the aforesaid catalyst has a pore volume within the range of about 0.4 cc/gm to about 0.9 cc/gm, a surface area within the range of about 130 m 2 /gm to about 300 m 2 /gm, an average pore diameter 0 0 within the range of about 90A to about 160A, and a pore volume distribution such that less than 40% of its pore volume is in pores having diameters within the range of 0 0 about 50A to about 80A, about 45% to about 90% of its pore volume is in pores having diameters within the range o 0 of about 80A to about 130A, and less than about 15% of its pore volume is in pores having diameters larger than o 130A.
  • the catalysts comprise from about 8 wt.% to about 22 wt.% product of the Group VIB metal component, calculated as the metal oxide, and from about 0.5 wt.% to about 3 wt.% of the phosphorus component, calculated as elemental phosphorus and based on the weight of the catalyst.
  • the aforesaid catalyst has a pore volume within the range of from about 0.3 cc/gm to about 1.2 cc/gm, a surface area within the range of from about 100 m2/gm to about 350 m 2 /gm, and an average pore diameter within the range of from about 0 0 70 A to about 120 A.
  • the catalyst comprises from about 15 wt.% to about 22 wt.% of the Group VIB metal component, calculated as the metal oxide and based on the weight of the catalyst, and from about 0.5 wt.% to about 3 wt.% of the phosphorus component, calculated as elemental phosphorus and based on the weight of the catalyst.
  • the aforesaid catalyst has a pore volume within the range of from about 0.7 cc/gm to about 1.7 cc/gm, a surface area within the range of from about 100 m2/gm to about 400 m2/gm, and an average pore diameter within the range of from about 0 0 125 A to about 350 A.
  • the hydrogenation component consists essentially of a Group VIB metal component, a phosphorus component, and optionally a Group VIII metal component.
  • the Group VIB metal component is at a concentration within the range of from about 1 wt.% to about 30 wt.% calculated as the metal oxide and based on the weight of the catalyst.
  • the phosphorus component is present at a concentration of from about 0.5 wt.% to about 3 wt.%, calculated as elemental phosphorus and based on the weight of the catalyst.
  • the Group VIII metal component is present at a concentration up to about 15 wt.%, calculated as the metal oxide and based on the weight of the catalyst.
  • Stability and activity maintenance of the catalysts of the present invention are comparable or superior to those of high stability catalysts, such as those of Hensley et al. '242, in which the original active hydrogenation metal is selected from Group VIB, as well as those of Quick et al. '602, '284 and '635 and Hensley et al. '144, '566 and '965, in which a stabilizing chromium component is incorporated into hydrogenating components comprising another metal of Group VIB or combinations thereof with a metal of Group VIII.
  • the catalysts of the present invention exhibit activities comparable or superior to those of conventional catalysts wherein the hydrogenating component contains a Group VIB metal component alone or promoted by a Group VIII metal component.
  • the invented catalysts are particularly well suited for hydrotreating feeds containing nitrogen, sulfur, metals and/or high boiling components under severe hydrotreating conditions.
  • the improved hydrotreating catalysts of this invention comprise a hydrogenating component consisting essentially of (1) a metal component in which the metal is selected from Group VIB and (2) a phosphorus component, such hydrogenating component being deposed on the surface of a support component comprising a porous refractory inorganic oxide and free of a zeolite component.
  • Preferred catalysts are those in which the phosphorus component is a phosphoric acid residue, the same most preferably being prepared by impregnation of a support component comprising a porous refractory inorganic oxide with an impregnating solution containing phosphoric acid and one or more precursors to the aforesaid metal component.
  • Such catalysts are used in hydrotreating hydrocarbon feeds containing nitrogen, sulfur, metals and/or high boiling components wherein the feed is contacted with hydrogen under hydrotreating conditions, particularly severe hydrotreating conditions, in the presence of the catalyst.
  • the hydrogenating component of the invented catalyst comprises (1) a metal component in which the metal is selected from Group VIB and (2) a phosphorus component.
  • the Group VIB metal can be molybdenum, chromium, tungsten or a binary or ternary combination thereof.
  • the Group VIB metal is present in the metal component in elemental form, as an oxide or sulfide, as an oxygenated phosphorus species or as a combination thereof.
  • the Group VIB metal of the metal component is molybdenum alone or in combination with chromium or tungsten, because molybdenum exhibits superior hydrogenation activity when promoted by a phosphorus component.
  • a molybdenum component is the sole Group VIB metal component in the metal component of the hydrogenation component.
  • the hydrogenating component also contains a phosphorus component which is present in a form effective to promote the activity of the Group VIB metal component.
  • a preferred phosphorus component is a phosphoric acid residue remaining in the hydrogenation component as a result of simultaneous or sequential impregnation of support component with a solution or solutions consisting essentially of a precursor to the metal component and phosphoric acid in a suitable solvent, for example, water.
  • phosphoric acid residues present in the hydrogenating component are present in the form of one or more oxides, a phosphate anion, compounds of the Group VIB metal or metals of the hydrogenating component and/or polymeric species containing recurring phosphorus-oxygen units and/or phosphorus-oxygen-Group VIB metal groups.
  • Presently preferred catalysts according to the present invention comprise about 1 to about 50 weight percent hydrogenating component and about 50 to about 99 weight percent support.
  • the Group VIB metal content preferably ranges from about 1 to about 30 weight percent, calculated as the metal oxide, that is, Mo0 3' W0 3 , Cr 2 0 3 .
  • the phosphorus component is present in an amount effective to promote the activity, the amount preferably ranging from about 0.1 to about 5 weight percent, calculated as elemental phosphorus, in order to promote the activity without adversely affecting the strength and other important catalyst physical properties. It is to be understood that the weight percentages set forth herein are based upon total catalyst weight after calcination.
  • the support on which the aforesaid hydrogenating component is deposed comprises at least one porous refractory inorganic oxide, specific examples of which include silica, alumina, silica-alumina, zirconia, titania, magnesia, boria and the like.
  • porous refractory inorganic oxide specific examples of which include silica, alumina, silica-alumina, zirconia, titania, magnesia, boria and the like.
  • metal oxides also are contemplated.
  • Modified porous refractory inorganic oxides such as fluorided aluminas and chlorided silica-alumina also are contemplated.
  • Supports containing minor amounts of one or more oxides of phosphorus, for example, up to about 2 wt.%, calculated as phosphorus, in combination with one or more of the aforesaid porous refractory inorganic oxides also can be employed although the same are not preferred, because the presence of phosphorus oxide in the support can be detrimental to promotion of the hydrogenating metal component with phosphorus.
  • the presence of a zeolite component in the support of the cata - lyst of this invention changes the essential character of the catalyst and hence is not contemplated for the catalyst of this invention.
  • the support preferably is calcined prior to any impregnation in which phosphorus component precursor is to be present as hydroxyl groups of the support may react with the precursor and thereby hinder incorporation of sufficient phosphorus component into the hydrogenating component.
  • the support can be used in any suitable form, for example, as extrudates, spheres or powder. From the standpoint of attaining desirable hydrotreating performance, presently preferred supports are aluminas and silica-aluminas containing up to about 50 wt.% of silica. More preferably, the support is an alumina or a silica-alumina containing up to about 50 wt.% of silica.
  • the finished catalysts have a BET surface area of at least about 100 m 2 /gm, a pore volume of about 0.3 to about 1.7 cc/gm, both as determined by nitrogen desorption, and an average pore diameter within the range of from about 70 A to about 350 A.
  • the catalyst of this invention When the catalyst of this invention is used in a hydrotreating operation in which removal of sulfur is a major concern, for example, with a feed comprising a vacuum or atmospheric resid, it is highly preferred that the catalyst has a pore volume within the range of about 0.4 cc/gm to about 0.9 cc/gm, a surface area within the range of about 130 m 2 /gm to about 300 m 2 /gm, an average 0 pore diameter within the range of about 90A to about 160A, and a pore volume distribution such that less than 40% of its pore volume is in pores having diameters within the range of about 50A to about 80A, about 45% to about 90% of its pore volume is in pores having diame- ters within the range of about 80A to about 130A, and less than about 15% of its pore volume is in pores having diameters larger than 130A. More preferably, the catalyst of this invention has a pore volume distribution summarized as follows:
  • the catalyst of this invention has a pore volume within the range of about 0.5 cc/gm to about 0.7 cc/gm, a surface area within the range of about 140 m 2 /gm to about 250 m 2 /gm, an average pore diameter within 0 the range of about 110A to about 140A, and a pore volume distribution summarized as follows:
  • the catalyst pores having diameters within the range of about 80A to about 130A preferably contain about 90 m /gm to about 180 m 2 /gm, and more preferably contain about 120 m 2 /gm to about 180 m 2 /gm, of surface area in order to attain maximum desulfurization activity.
  • the catalyst of the present invention preferably comprises from about 8 wt.% to about 22 wt.% of the Group VIB metal component, calculated as the metal oxide and based on the weight of the catalyst, and from about 0.5 wt.% to about 3 wt.% of the phosphorus component, calculated as elemental phosphorus and based on the weight of the catalyst.
  • the catalyst of this invention When the catalyst of this invention is used in a hydrotreating operation in which removal of nitrogen is a major concern, for example, with a feed comprising a whole shale oil or shale oil fraction, it is highly preferred that the catalyst has a pore volume within the range of about 0.3 cc/gm to about 1.2 cc/gm, a surface area within the range of from about 100 m 2 /gm to about 350 m 2 /gm and an average pore diameter within the range o 0 of from about 70 A to about 120 A.
  • the catalyst comprise from about 15 wt.% to about 22 wt.% of the Group VIB metal component, calculated as the meta] oxide and based on the weight of the catalyst, and from about 0.5 wt.% to about 3 wt.% of the phosphorus component, calculated as elemental phosphorus and based on the weight of the catalyst.
  • the catalyst of this invention When the catalyst of this invention is used in a hydrotreating operation in which removal of metals is a major concern, for example, with a feed comprising a high metals resid, it is highly preferred that the catalyst has a pore volume within the range of from about 0.7 cc/gm to 1.7 cc/gm, a surface area within the range of from about 100 m 2 /gm to about 400 m2/gm, an average pore 0 diameter within the range of from about 125 A to about o 350 A, a Group VIB metal component concentration from about 1 wt.% to about 30 wt.%, preferably to about 20 wt.%, calculated as the metal oxide and based on the weight of the catalyst, a Group VIII metal component concentration of up to about 15 wt.%, preferably from about 0.5 wt.% to about 12 wt.%, calculated as the metal oxide and based on the weight of the catalyst, and a phosphorus component concentration of from about
  • the invented catalysts are prepared by impregnation of a support comprising at least one porous refractory inorganic oxide with a solution or solutions consisting essentially of precursors to the metal and phosphorus components of the final catalyst in a suitable solvent and calcination of impregnated support.
  • a support comprising at least one porous refractory inorganic oxide with a solution or solutions consisting essentially of precursors to the metal and phosphorus components of the final catalyst in a suitable solvent and calcination of impregnated support.
  • simultaneous impregnation of a support with phosphorus and metal component precursors, followed by calcination of the impregnated support is conducted in order to maximize the promotional effect of the phosphorus component of the final catalyst.
  • sequential impregnation with phosphorus and metal component precursors also gives good results.
  • a preferred sequential impregnation involves impregnation of support with phosphorus component precursor followed by calcination, followed by impregnation with metal component precursor
  • the mechanics of impregnating a support are well known to persons skilled in the art.
  • a technique preferred for the sake of simplicity involves forming a solution or solutions of appropriate compounds in a suitable solvent and contacting a support with an amount or amounts of solution or solutions sufficient to fill the pores of the support.
  • Useful precursors to the metal component of the invented catalysts also are well known to persons skilled in the art. Specific examples include ammonium chromate, ammonium dichromate, chromium(III) nitrate, chromium acetate, ammonium heptamolybdate, ammonium paramolybdate, molybdic anhydride, phosphomolybdic acid and ammonium tungstate.
  • Phosphorus component precursors useful in preparation of the,invented catalysts include phosphoric acid, phosphorous acid, hypophosphorous acid and pyrophosphoric acid. Esters of such acids also can be used although they are not preferred. Phosphorus oxides, such as P 2 0 5 and P 4 0 6 , also can be used. Salts of the aforesaid acids and esters also are contemplated. Specific examples of these include ammonium phosphate, diammonium hydrogen phosphate and ammonium dihydrogen phosphate. As the preferred catalysts according to this invention are those in which a phosphoric acid residue is present, phosphoric acid is the preferred phosphorus component precursor.
  • dilute or concentrated aqueous phosphoric acid is used as an impregnating solvent for the Group VIB metal component precursor.
  • Other phosphorus component precursors can be employed in the form of a solution in a suitable solvent, such as water or alcohol, or the same can simply be dissolved in a solution or solutions containing one or more Group VIB metal component precursors.
  • Phosphorus compound concentrations vary depending on solubility, amount of phosphorus component desired in the ultimate catalyst and amount of solution that can be accommodated by the particular support to be used as can be appreciated by persons skilled in the art.
  • a Group VIII metal component precursor can be used in place of, or in addition to, the Group VIB metal component precursor in the impregnation process.
  • the impregnated support is calcined. Calcination preferably is conducted at temperatures of at least about 425°C and more preferably at least about 535°C for a period of at least about 1/2 hour. The calcination is conducted in the presence of a gas containing molecular oxygen, air being preferred from the standpoint of convenience and cost. While not required, it is desirable to dry the impregnated support at a temperature high enough to drive off excess solvent from the impregnation step prior to calcination. When water is used as the solvent in impregnation, preferred temperatures are at least about 120°C. Drying times of at least about 1/2 hour are preferred.
  • sulfiding can be conducted to sulfide and partially reduce the metal or metals of the hydrogenating component.
  • a sulfiding treatment that is preferred from the standpoint of convenience comprises heating the catalyst to from about 120°C to about 180°C and contacting the catalyst with a flowing gaseous mixture of hydrogen sulfide and hydrogen under pressure for from about 1/2 to about 2 hours, raising the temperature to from about 175°C to about 235°C with continued flow of the gaseous mixture for an additional 1/2 to about 2 hours, raising the temperature to from about 340°C to about 400°C, and contacting with additional hydrogen-hydrogen sulfide gas mixture for an additional period of time, preferably from about 1/2 to about 2 hours.
  • the gas should be employed in an amount effective to provide at least about 110 percent of the stoichiometric amount of hydrogen sulfide needed to sulfide the metal or metals of the hydrogenating component.
  • concentration of hydrogen sulfide in the gaseous mixture is not critical.
  • the catalyst can be contacted with carbon disulfide or a hydrocarbon oil containing sulfur can be passed over the catalyst for a time sufficient to convert the hydrogenating component to sulfide form.
  • sulfiding treatment is conducted while the catalyst is disposed in a hydrotreating reaction zone because on conclusion thereof, the flow of hydrogen sulfide or other source of sulfide can be discontinued and hydrogen partial pressure and temperature adjusted to operating levels. Once operating conditions are achieved, hydrocarbon feed is simply introduced into the reaction zone.
  • Hydrotreating according to the present invention can be conducted in either fixed bed or expanded bed operations.
  • Preferred catalysts for use in fixed bed processes are those having an average particle size of from about 0.8 millimeter to about 3.2 millimeters effective diameter. Pellets, spheres, and/or extrudate are contemplated for fixed bed use. In addition, more complicated shapes, such as clover leaf, cross-shaped or C-shaped catalyst are contemplated.
  • Preferred catalysts for expanded bed use are spheres or extrudates having diameters of from about 0.8 millimeter to about 1.6 millimeters.
  • Hydrocarbon feeds to be hydrotreated according to this invention are those containing sufficiently high levels of nitrogen, sulfur, metals or high boiling components as to hinder direct use in more conventional refining operations, such as catalytic cracking or hydrocracking.
  • feeds that can be treated according to this invention include petroleum hydrocarbon streams, hydrocarbon streams derived from coal, hydrocarbon streams derived from tar sands and hydrocarbon streams derived from oil shale.
  • Typical examples of petroleum hydrocarbon streams include petroleum distillates, virgin gas oils, vacuum gas oils, coker gas oils and atmospheric and vacuum resids.
  • Hydrocarbon streams derived from oil shale, such as whole shale oil or a fraction thereof, are also particularly well suited.
  • Preferred feeds are those containing at least about 0.1 wt.% nitrogen or resids containing high concentrations of sulfur and/or metals.
  • the conditions employed in operation of the process of the present invention will vary with the particular hydrocarbon.stream being treated, with mild conditions being employed in the hydrotreating of light distillates, such as naphtha and kerosene, typically 232°C to 316°C and about 690 kPa to 4,137 kPa of hydrogen partial pressure.
  • Heavier materials can be treated under conditions of.about 3.45 MPa to 20.76 MPa of hydrogen partial pressure, an average catalyst bed temperature within the range of about 315°C to about 443°C, with an LHSV (liquid hourly space velocity) within the range of about 0.1 to about 5 volumes of hydrocarbon per hour per volume of catalyst, and a hydrogen recycle rate or hydrogen addition rate within the range of about 89 m 3 /m 3 to 3,560 m 3 /m 3.
  • LHSV liquid hourly space velocity
  • hydrodenitrogenation conditions are preferred for the removal of nitrogen from feeds containing at least 0.1 wt.% nitrogen. Best results in removing nitrogen from whole shale oil are obtained under hydrodenitrogenation conditions comprising about 8.3 MPa to about 17.3 MPa total pressure, average catalyst bed temperatures within the range of about 388°C to about 427°C, an LHSV of about 0.3 to about 2 volumes of hydrocarbon per hour per volume of catalyst, and a hydrogen recycle rate or hydrogen addition rate within the range of about 178 m 3 /m 3 to about 1780 m 3 /m 3 .
  • hydrodemetallation conditions are preferred and include a temperature of from about 371°C to about 454°C, a pressure of from about 7 MPa to about 21 MPa, a hydrogen addition rate of from about 178 m 3 /m 3 to about 1780 m3/m3 and a space velocity of from about 0.1 to about 5 volumes of feed per volume of catalyst per hour.
  • hydrodesulfurization conditions are preferred for the removal of sulfur from feeds containing at least about 0.1 wt.% sulfur. Best results in removing sulfur from a vacuum or atmospheric resid are hydrodesulfurization conditions comprising about 12.4 MPa to 20.7 MPa total pressure, about 399°C to 427°C average catalyst bed temperature, about 178 m3/m3 to 1780 m3/m3 hydrogen rate and about 0.1 to about 5 volumes feed per volume catalyst per hour LHSV.
  • resid includes a resid which has been subjected to a prior treatment such as a hydrodemetallation treatment.
  • a demetallation catalyst is employed in the first stage and provides demetallated effluent which is contacted in the second stage with a desulfurization catalyst.
  • a catalyst of the present invention having the aforesaid preferred pore volume, surface area, average pore diameter and pore size distribution is employed as the desulfurization catalyst in the aforesaid two-stage hydrotreatment process.
  • such preferred embodiment of the present invention comprises a two-stage process for the hydrodemetallation and hydrodesulfurization of a hydrocarbon feedstock containing asphaltenes and a substantial amount of metals.
  • feedstock generally contains asphaltenes, metals, nitrogen compounds and sulfur compounds.
  • the feedstocks that are to be treated by the preferred two-stage hydrotreatment process of the present invention contain from a small amount of nickel and vanadium, for example, about 40 ppm up to more than 1,000 ppm of the combined total amount of nickel and vanadium, up to about 25 wt.% of asphaltenes.
  • This preferred two-stage hydrotreatment process is particularly useful in treating feedstock with a substantial amount of metals, for example, one containing 150 ppm or more of nickel and vanadium, and with a sulfur content in the range of about 1 wt.% to about 10 wt.%.
  • Typical feedstocks that can be treated satisfactorily by the preferred two-stage hydrotreatment process of the present invention also contain a substantial amount of components that boil appreciably above 538°C.
  • Examples of typical feedstocks are crude oils, topped crude oils, petroleum hydrocarbon resids, both atmospheric and vacuum resids, oils obtained from tar sands and resids derived from tar sands oil, hydrocarbon streams derived from coal, and blends of any of the aforesaid resids with lower boiling materials.
  • Such hydrocarbon streams contain organometallic contaminants which create deleterious effects in various refining processes that employ catalysts in the conversion of the particular hydrocarbon stream being treated.
  • the metallic contaminants that are found in such feedstocks include, but are not limited to, iron, vanadium and nickel.
  • the first-stage catalyst and the second-stage catalyst can be employed in a single reactor as a dual bed or the two catalysts can be employed in separate, sequential reactors, and various combinations of these two basic reactor schemes can be employed to achieve flexibility of operation and product upgrade.
  • the feed is contacted with the demetallation catalyst first and then with the desulfurization catalyst.
  • either of the basic reactor schemes described can comprise multiple parallel beds of the catalyst.
  • the direction of flow of the feedstock can be upward or downward.
  • the volumetric ratio of first-stage catalyst to second-stage catalyst can be within a broad range, preferably within about 5:1 to about 1:10 and more preferably within about 2:1 to about 1:5.
  • the first-stage, demetallation catalyst in the method of the present invention comprises a hydrogenation component and a large-pore, high surface area inorganic oxide support.
  • Suitable demetallation catalysts comprise catalytic amounts of a hydrogenation component typically including a,Group VIB metal, a Group VIII metal or a mixture of Group VIB and Group VIII metals deposed on a relatively large-pore, high surface area porous inorganic oxide support, suitably alumina, silica, magnesia, zirconia and similar materials.
  • This first-stage catalyst has a surface area of about 100 m2/gm to about 400 m2/gm, 0 0 an average pore diameter of about 125A to about 350A, and a pore volume of about 0.7 cc/gm to about 1.7 cc/gm.
  • the composition of the demetallation catalyst comprises from about 1 wt.% to about 30 wt.% of the Group VIB metal, calculated as the oxide, and/or from about 0.5 to about 12 wt.% of the Group VIII metal, calculated as the oxide, based upon the total weight of the composition.
  • the Group VIB and Group VIII classifications of the Periodic Table of Elements can be found on page 628 of Webster's Seventh New Collegiate Dictionary, G. & C. Merriam Company, Springfield, Massachusetts, U.S.A. (1965). While calculated as the oxide, the hydrogenation metal components of the catalyst can be present in the elemental form or as the sulfide or oxide thereof.
  • first-stage, demetallation catalyst Commercially available catalysts that are suitable for use as the first-stage, demetallation catalyst include American Cyanamid's 1442B and Amocat 1A@, both bimodal.
  • embodiment of the catalyst of the present invention which is described hereinabove as employed in a hydrotreatment operation in which demetallation is a major concern, can also be employed as the first-stage demetallation catalyst.
  • the first-stage catalyst used in the process of the present invention can be prepared by the typical commercial method of impregnating a large-pore, high surface area inorganic oxide support.
  • Appropriate commercially available alumina, preferably calcined at about 426°C. to 872°C, for about 0.5 to about 10 hours, can be impregnated to provide a suitable lead catalyst having an ° average pore diameter of about 125A to about 350A, a surface area ranging from about 100 m 2 /gm to about 400 m 2 /gm, and a pore volume within the range of about 0.7 cc/gm to about 1.7 cc/gm.
  • the alumina can be impregnated with a solution, usually aqueous, containing a heat-decomposable compound of the metal(s) to be placed on the catalyst, and the impregnated material is then dried and calcined.
  • the drying can be conducted in air at a temperature of about 65°C to about 204°C for a period of 1 to 16 hours.
  • the calcination can be carried out at a temperature of about 426°C to about 648°C for a period of from 0.5 to 8 hours.
  • the finished second-stage catalyst that is employed in the process of the present invention has a pore volume within the range of about 0.4 cc/gm to about 0.9 cc/gm, a surface area within the range of about 130 m 2 /gm to about 300 m 2 /gm, and an average pore diameter within the range 0 of about 90A to about 160A.
  • the catalyst possesses a pore volume within the range of about 0.5 cc/gm to about 0.7 ce/gm, a surface area within the range of about 140 m 2 /gm to about 250 m 2 /gm, and an average pore diameter within the range of about 110A to about 140A.
  • the second-stage catalyst should have less than 40% of its pore volume in pores having diameters within the range of about 50A to about 80A, about 45% to about 90% of its pore volume in pores having diameters within the range of about 80A to about 130A, and less than about 15% of its pore volume in pores having diameters that are larger than 130A. More preferably, the second-stage catalyst has a pore volume distribution summarized as follows:
  • the second-stage catalyst has a pore volume distribution summarized as follows:
  • the catalyst pores having diameters 80A to 130A preferably should contain from about 90 m2/gm to 180 m 2 /gm, and more preferably 120 m 2 /gm to 180 m 2 /gm, of surface area in order to attain maximum activity.
  • operating conditions for the hydrotreatment of heavy hydrocarbon streams comprise a pressure within the range of about 7 MPa to about 21 MPa, an average catalyst bed tempprature within the range of about 371 0 C to about 454°C, a LHSV within the range of about 0.1 volume of hydrocarbon per hour per volume of catalyst to about 5 volumes of hydrocarbon per hour per volume of catalyst, and a hydrogen recycle rate or hydrogen addition rate within the range of about 178 m 3 /m 3 to about 2,671 m 3 /m 3 .
  • the operating conditions comprise a total pressure within the range of about 10 MPa to about 18 MPa; an average catalyst bed temperature within the range of about 387°C to about 437°C; a LHSV within the range of about 0.1 to about 1.0; and a hydrogen recycle rate or hydrogen addition rate within the range of about 356 m 3 /m 3 to about 1,780 m 3 /m 3 .
  • a control catalyst identified hereinafter as Catalyst I and containing 15.0 wt.% MoO 3 supported on gamma-alumina, was prepared as follows.
  • 300 gm gamma-alumina obtained from Continental Oil Company and identified as Catapal
  • the calcined product having BET surface area of 230 m2/gm, pore volume of 0.65 cc/gm® as determined by nitrogen adsorption using a Digisorb 0 2500 instrument and average pore diameter of 113A calculated as (4V x 10 )/A was placed in a desiccator until used.
  • Catalyst II A catalyst according to the invention, identified hereinafter as Catalyst II and containing 15.0 wt.% Mo03 and 1.3 wt.% P, was prepared as follows.
  • Example II Following the procedure of Example I, 18.40 gm ammonium heptamolybdate and 4.83 gm 85% phosphoric acid dissolved in 46 ml water were added to 82.02 gm of the calcined gamma-alumina from Example I. After standing for one hour at ambient temperature, the impregnated support was dried, calcined and crushed and screened as in Example I. The resulting catalyst was tested for activity according to Example IV.
  • a second control catalyst identified hereinafter as Catalyst III and again containing 15.0 wt.% Mo03, was prepared by a two-step impregnation as follows.
  • Example II To 85.00 gm of the calcined gamma-alumina from Example I were added 9.2 gm ammonium heptamolybdate dissolved in 52 ml water. After standing for an hour at ambient temperature, the impregnated support was dried and calcined as in Example I. To the result were added 9.20 gm ammonium heptamolybdate dissolved in 52 ml H 2 0 and the result again was allowed to stand, and then dried and calcined as in Example I. The calcined catalyst was crushed and screened to 14/20 mesh as in Example I and tested according to Example IV.
  • the catalysts from Examples I-III were tested in a 81 cm long, 0.95 cm inner diameter, vertical reactor equipped with automatic controls for monitoring temperature, feed rate and hydrogen partial pressure.
  • 15.00 cc catalyst were loaded into the reactor and sulfided by passing 8 Vol.% H 2 S in hydrogen over the catalyst at about 0.03 m 3 /hr and total pressure of about 2 MPa at 148 Q C for one hour, followed by 204°C for one hour, and then 375°C for one hour.
  • temperature was increased to 404°C
  • the feed was introduced via a positive displacement Ruska pump at a liquid hourly space velocity (LHSV) of 0.64 volume feed per volume catalyst per hour, and the reactor was charged with hydrogen to 12 MPa.
  • LHSV liquid hourly space velocity
  • the feed used in all tests was a whole shale oil generated in situ from oil shale and having properties as shown in Table 1. Also shown in the table are properties of samples of product taken on the last day of each test.
  • Catalyst II exhibited superior hydrodenitrogenation activity as measured by both total and basic product nitrogen. Based on first order hydrodenitrogenation kinetics observed for total nitrogen removal, Catalyst II had a hydrodenitrogenation activity about 1.5 times that of control Catalyst I and about 1.7 times that of control Catalyst III. It also can be seen from Table 1 that Catalyst II gave about 95% removal of product sulfur indicating high hydrodesulfurization activity.
  • Example IV A series of catalysts was prepared according to the general procedure of Examples I-III and tested as in Example IV. Composition of the catalysts and hydrodenitrogenation activity based upon both total and basic nitrogen relative to control Catalyst I (see Example I) are reported in Table 2. For completeness, relative activities of Catalyst II and control Catalyst III also are included in the table. Unless otherwise indicated, MoO 3 content of catalysts was 15 wt.% and phosphorus content, calculated as the element, was 1.3 wt.%.
  • Catalysts II, VI and VII according to the invention were significantly more active for hydrodenitrogenation than any of the other catalysts, with Catalysts II and VII, in which molybdenum and phosphorus component precursors were simultaneously impregnated, being superior to Catalyst VI, in which phosphorus and molybdenum component precursors were sequentially impregnated.
  • Direct comparison of results with Catalysts IV and V to results with the other catalysts is difficult because the pore structure of the alumina- and phosphorus oxide-containing support of the former was significantly different from that of the small-pore alumina used for the other catalysts.
  • comparison of results with Catalyst IV to those with Catalyst V indicates that the presence of phosphorus in the support was detrimental to attempted promotion of hydrogenating metal with phosphorus component.
  • the calcined alumina has the following surface area distribution: 58.9 m2/gm in pores having diameters of 50A to 80A, 137.4 m /gm in pores having diameters of 80A to 130A, 84.9 m /gm in pores having 80A to 100A, 525.5 m 2 /gm in pores having diame- ters of 100A to 130A, and 2.2 m /gm in pores having diameters greater than 130A.
  • the resulting product is designated Catalyst A, and its metals content, pore volume, pore volume distribution, surface area, surface area distribution and average pore diameter are presented in Table 3.
  • Catalysts A, B, C and D were employed in a two-reactor system for the demetallation and desulfurization of a resid feed.
  • Each of Catalysts B, C and D was a metal-impregnated gamma-alumina extrudate obtained from American Cyanamid and having a 0.079 centimeter average diameter.
  • the metals content, pore volume, pore volume distribution, surface area, surface area distribution and average pore diameter of each of Catalysts B, C and D are also presented in Table 3.
  • Catalyst D is marketed as Amocat lA.
  • Each reactor was 81 centimeters long and had an inside diameter of 0.95 centimeter.
  • the feed flowed upwardly through the first or upstream reactor and the effluent from the first reactor then flowed upwardly through the second or downstream reactor.
  • the upstream reactor was loaded with a uniform mixture of 10 cubic centimeters of Catalyst C and 10 cubic centimeters of 10/14 mesh porous alpha-alumina diluent
  • the downstream reactor was loaded with a uniform mixture of 20 cubic centimeters of Catalyst B and 20 cubic centimeters of 10/14 mesh porous alpha-alumina diluent.
  • Example 9 the upstream reactor was loaded with a uniform mixture of 10 cubic centimeters of Catalyst C and 10 cubic centimeters of 10/14 mesh alpha-alumina diluent, and the downstream reactor was loaded with a uniform mixture of 20 cubic centimeters of Catalyst A and 20 cubic centimeters of 10/14 mesh, alpha-alumina diluent.
  • Example 10 the upstream reactor was loaded with a uniform mixture of 10 cubic centimeters of Catalyst D and 20 cubic centimeters of 10/14 mesh vermiculite diluent, and the downstream reactor was loaded with a uniform mixture of 20 cubic centimeters of Catalyst A and 20 cubic centimeters of 10/14 mesh vermiculite diluent.
  • Example 11 the upstream reactor was loaded with a uniform mixture of 10 cubic centimeters of Catalyst D and 20 cubic centimeters of 10/14 mesh alpha-alumina diluent, and the downstream reactor was loaded with a uniform mixture of 20 cubic centimeters of Catalyst A and 20 cubic centimeters of 10/14 mesh alpha-alumina diluent.
  • the feed used in Examples VII-XI was a vacuum resid, an atmospheric resid or a blend of these resids.
  • the feed characteristics are presented in Table 4.
  • both upstream and downstream reactors were filled with gas oil and pressured to 13.8 MPa with hydrogen.
  • the temperature of each reactor was then raised to 149°C. for at least one hour and then was raised to the desired reaction temperature.
  • resid feed was then introduced to the upstream reactor, from which the effluent then passed into the downstream reactor.
  • the feed rate in each reactor was from about 0.2 to about 1.0 volume per hour per volume of catalyst, in terms of space velocity.
  • Each of Examples VII-XI was conducted for 14 to 61 days, with daily sampling and analysis of the liquid product recovered using a high pressure separator.
  • Example VII-XI The conditions employed in Examples VII-XI are shown in Table 5.
  • the reaction temperature, space velocity or identity of the feed employed in Examples IX-XI were varied during the course of the run. Consequently, in Table 5, the reaction temperature, space velocity and identity of the feed are listed for each stage of the runs where one of them is changed.
  • the feed rate presented in Table 5 is the overall space velocity based on combined volume of catalysts in the upstream and downstream reactors.
  • the higher metals content of Feed 2 was employed, and generally at higher space velocities, to accelerate the substantial deposition of metal contaminants on the catalyst, under which condition, prior art catalysts are known to deactivate.
  • Example IX the conversion to product boiling below 538°C was at substantially the same level in Example IX at the 9th day of the run and at a reaction temperature of only 405°C as in Example VII at the 23rd day of the run and at the higher reaction temperature of 416°C.

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  • Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Catalysts (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
EP19830307379 1982-12-06 1983-12-05 Wasserstoffumwandlungskatalysator und -verfahren Expired EP0112667B1 (de)

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0183283A2 (de) * 1984-11-30 1986-06-04 Shell Internationale Researchmaatschappij B.V. Einstufiges Hydrobehandlungsverfahren
EP0203228A1 (de) * 1985-05-21 1986-12-03 Shell Internationale Researchmaatschappij B.V. Einstufiges Raffinationsverfahren
US4738944A (en) * 1986-12-05 1988-04-19 Union Oil Company Of California Ni-P-Mo catalyst and hydroprocessing use thereof
US4846961A (en) * 1986-12-05 1989-07-11 Union Oil Company Of California Hydroprocessing catalyst with a Ni-P-Mo
EP0525259A1 (de) * 1988-05-13 1993-02-03 Texaco Development Corporation Katalysator und Verfahren zur Wasserstoffbehandlung von Erdöleinsätzen
US5246569A (en) * 1990-08-03 1993-09-21 Akzo N.V. Process for the hydrodesulfurization of light hydrocarbon feeds
CN111100698A (zh) * 2018-10-29 2020-05-05 中国石油化工股份有限公司 一种高干点高氮原料油的加氢裂化方法

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10144882B2 (en) 2010-10-28 2018-12-04 E I Du Pont De Nemours And Company Hydroprocessing of heavy hydrocarbon feeds in liquid-full reactors

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US4255282A (en) * 1979-05-11 1981-03-10 Union Oil Company Of California Hydrotreating catalyst and process for its preparation
GB2055602A (en) * 1979-08-03 1981-03-11 Katalco Corp Hydrotreating catalyst preparation and process

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DE1270007B (de) * 1963-06-14 1968-06-12 American Cyanamid Co Verfahren zur Herstellung eines Hydrierungskatalysators
US3446730A (en) * 1966-06-21 1969-05-27 Gulf Research Development Co Catalytic hydrodenitrogenation of petroleum fractions
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FR2281788A1 (fr) * 1974-08-12 1976-03-12 Chevron Res Compositions ameliorees pour catalyse et leur procede de preparation
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US4255282A (en) * 1979-05-11 1981-03-10 Union Oil Company Of California Hydrotreating catalyst and process for its preparation
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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0183283A2 (de) * 1984-11-30 1986-06-04 Shell Internationale Researchmaatschappij B.V. Einstufiges Hydrobehandlungsverfahren
EP0183283A3 (en) * 1984-11-30 1988-03-16 Shell Internationale Research Maatschappij B.V. Single-stage hydrotreating process
EP0203228A1 (de) * 1985-05-21 1986-12-03 Shell Internationale Researchmaatschappij B.V. Einstufiges Raffinationsverfahren
US4738944A (en) * 1986-12-05 1988-04-19 Union Oil Company Of California Ni-P-Mo catalyst and hydroprocessing use thereof
US4846961A (en) * 1986-12-05 1989-07-11 Union Oil Company Of California Hydroprocessing catalyst with a Ni-P-Mo
EP0525259A1 (de) * 1988-05-13 1993-02-03 Texaco Development Corporation Katalysator und Verfahren zur Wasserstoffbehandlung von Erdöleinsätzen
US5246569A (en) * 1990-08-03 1993-09-21 Akzo N.V. Process for the hydrodesulfurization of light hydrocarbon feeds
CN111100698A (zh) * 2018-10-29 2020-05-05 中国石油化工股份有限公司 一种高干点高氮原料油的加氢裂化方法

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AU2180583A (en) 1984-06-14
CA1243976A (en) 1988-11-01
EP0112667B1 (de) 1988-03-02
AU571189B2 (en) 1988-04-14

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