US20050109679A1 - Process for making lube oil basestocks - Google Patents

Process for making lube oil basestocks Download PDF

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US20050109679A1
US20050109679A1 US10/949,483 US94948304A US2005109679A1 US 20050109679 A1 US20050109679 A1 US 20050109679A1 US 94948304 A US94948304 A US 94948304A US 2005109679 A1 US2005109679 A1 US 2005109679A1
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catalyst
process according
hydrotreating
metal
hydrotreating catalyst
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US10/949,483
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Gary Schleicher
Kenneth Riley
Randolph Smiley
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ExxonMobil Technology and Engineering Co
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Assigned to EXXONMOBIL RESEARCH & ENGINEERING CO. reassignment EXXONMOBIL RESEARCH & ENGINEERING CO. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: RILEY, KENNETH L., SCHLEICHER, GARY P., SMILEY, RANDOLPH J.
Publication of US20050109679A1 publication Critical patent/US20050109679A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/19—Catalysts containing parts with different compositions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
    • B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
    • B01J23/76—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
    • B01J23/84—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36 with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
    • B01J23/85—Chromium, molybdenum or tungsten
    • 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
    • C10G45/06—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 containing nickel or cobalt metal, or compounds thereof
    • C10G45/08—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 containing nickel or cobalt metal, or compounds thereof in combination with chromium, molybdenum, or tungsten metals, or compounds thereof
    • 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
    • C10G65/00—Treatment of hydrocarbon oils by two or more hydrotreatment processes only
    • C10G65/02—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only
    • C10G65/04—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only including only refining steps
    • 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
    • C10G65/00—Treatment of hydrocarbon oils by two or more hydrotreatment processes only
    • C10G65/02—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only
    • C10G65/04—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only including only refining steps
    • C10G65/08—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only including only refining steps at least one step being a hydrogenation of the aromatic hydrocarbons
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J35/00—Catalysts, in general, characterised by their form or physical properties
    • B01J35/60—Catalysts, in general, characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J35/64—Pore diameter
    • B01J35/647—2-50 nm
    • 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
    • C10G2300/1022—Fischer-Tropsch products
    • 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
    • C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
    • C10G2400/10—Lubricating oil

Definitions

  • This invention relates to a process for preparing lubricating oil basestocks from lube oil boiling range feedstreams. More particularly, the present invention is directed at a process wherein a wax containing feedstock is hydrotreated over a stacked bed catalyst system thereby producing a lube oil boiling range basestock.
  • Hydrocracking has been combined with hydrotreating as a preliminary step. However, this combination also results in decreased yields of lubricating oils due to the conversion to distillates that typically accompany the hydrocracking process.
  • the FIGURE is a plot of the relative volume activity of various catalysts and catalyst systems versus the days the respective catalysts and catalyst systems were on stream.
  • the present invention is directed at a process to prepare lubricating oil basestocks from lube oil boiling range feedstocks.
  • the process comprises:
  • the stacked bed hydrotreating catalyst system comprises a first and second catalyst, the first catalyst comprising a conventional hydrotreating catalyst having an average pore diameter of greater than about 10 nm and said second catalyst comprises a bulk metal hydrotreating catalyst.
  • feedstock and “feedstream” as used herein are synonymous.
  • the present process involves hydrotreating a lubricating oil feedstock with a stacked bed hydrotreating catalyst system in a reaction stage operated under effective hydrotreating conditions to produce a hydrotreated effluent comprising at least a gaseous product and a hydrotreated lubricating oil feedstock.
  • the hydrotreated effluent is stripped to remove at least a portion of the gaseous product from the hydrotreated effluent thereby producing at least a lubricating oil basestock.
  • Lube oil basestocks having a saturates content of at least 90%, a sulfur content of 0.03 wt. % or less, and a viscosity index (VI) between 80 and 120 can readily be produced through the use of the instant invention.
  • Feedstocks suitable for use in the present invention are wax-containing feeds that boil in the lubricating oil range, typically having a 10% distillation point greater than 650° F. (343° C.) and an endpoint greater than 800° F. (426° C.), measured by ASTM D 86 or ASTM 2887. These feedstocks can be derived from mineral sources, synthetic sources, or a mixture of the two.
  • Non-limiting examples of suitable lubricating oil feedstocks include those derived from sources such as oils derived from solvent refining processes such as raffinates, partially solvent dewaxed oils, deasphalted oils, distillates, vacuum gas oils, coker gas oils, slack waxes, foots oils and the like, dewaxed oils, automatic transmission fluid feedstocks, and Fischer-Tropsch waxes.
  • Automatic transmission fluid (“ATF”) feedstocks are lube oil feedstocks having an initial boiling point between about 200° C. and 275° C., and a 10% distillation point greater than about 300° C.
  • ATF feedstocks are typically 75-110N feedstocks.
  • feedstocks may also have high contents of nitrogen- and sulfur-contaminants.
  • Feeds containing up to 0.2 wt. % of nitrogen, based on feed and up to 3.0 wt. % of sulfur can be processed in the present process.
  • Feeds having a high wax content typically have high viscosity indexes of up to 200 or more.
  • Sulfur and nitrogen contents may be measured by standard ASTM methods D5453 and D4629, respectively.
  • hydrotreating refers to processes wherein a hydrogen-containing treat gas is used in the presence of a suitable catalyst that is primarily active for the removal of heteroatoms, such as sulfur, and nitrogen, and saturation of aromatics.
  • the lubricating oil feedstock is hydrotreated with a stacked bed hydrotreating catalyst system in a reaction stage operated under effective hydrotreating conditions to produce a hydrotreated effluent comprising at least a gaseous product and a hydrotreated lubricating oil feedstock.
  • the catalyst system used herein comprises at least a first and second hydrotreating catalyst.
  • stacked bed it is meant that the first catalyst appears in a separate catalyst bed, reactor, or reaction zone, and the second hydrotreating catalyst appears in a separate catalyst bed, reactor, or reaction zone downstream, in relation to the flow of the lubricating oil feedstock, from the first catalyst.
  • the first hydrotreating catalyst is a supported catalyst.
  • Suitable hydrotreating catalysts for use as the first catalyst of the present catalyst system include any conventional hydrotreating catalyst.
  • Conventional hydrotreating catalyst as used herein is meant to refer to those which are comprised of at least one Group VIII metal, preferably Fe, Co and Ni, more preferably Co and/or Ni, and most preferably Ni; and at least one Group VI metal, preferably Mo and W, more preferably Mo, on a high surface area support material, preferably alumina.
  • the Group VIII metal is typically present in an amount ranging from about 2 to 20 wt. %, preferably from about 4 to 12%.
  • the Group VI metal will typically be present in an amount ranging from about 5 to 50 wt. %, preferably from about 10 to 40 wt.
  • All metals weight percents are on support.
  • On support we mean that the percents are based on the weight of the support. For example, if the support were to weigh 100 g. then 20 wt. % Group VIII metal would mean that 20 g. of Group VIII metal was on the support.
  • the average pore diameter of the first catalyst must have a specific size to be suitable for use herein.
  • a conventional catalyst as described above, but having an average pore diameter greater than 10 nm, as measured by water adsorption porosimetry, must be used as the first catalyst of the present stacked bed catalyst system. It is preferred that the average pore diameter of the first catalyst, i.e. the conventional hydrotreating catalyst, of the present stacked bed catalyst system be greater than 11 nm, more preferably greater than 12 nm.
  • the second hydrotreating catalyst is a bulk metal catalyst.
  • bulk metal it is meant that the catalysts are unsupported wherein the bulk catalyst particles comprise 30-100 wt. % of at least one Group VIII non-noble metal and at least one Group VIB metal, based on the total weight of the bulk catalyst particles, calculated as metal oxides and wherein the bulk catalyst particles have a surface area of at least 10 m 2 /g.
  • the bulk metal hydrotreating catalysts used herein comprise about 50 to about 100 wt. %, and even more preferably about 70 to about 100 wt. %, of at least one Group VIII non-noble metal and at least one Group VIB metal, based on the total weight of the particles, calculated as metal oxides.
  • the amount of Group VIB and Group VIII non-noble metals can easily be determined VIB TEM-EDX.
  • Bulk catalyst compositions comprising one Group VIII non-noble metal and two Group VIB metals are preferred. It has been found that in this case, the bulk catalyst particles are sintering-resistant. Thus the active surface area of the bulk catalyst particles is maintained during use.
  • the molar ratio of Group VIB to Group VIII non-noble metals ranges generally from 10:1-1:10 and preferably from 3:1-1:3. In the case of a core-shell structured particle, these ratios of course apply to the metals contained in the shell. If more than one Group VIB metal is contained in the bulk catalyst particles, the ratio of the different Group VIB metals is generally not critical. The same holds when more than one Group VIII non-noble metal is applied.
  • the molybenum:tungsten ratio preferably lies in the range of 9:1-1:9.
  • the Group VIII non-noble metal comprises nickel and/or cobalt.
  • the Group VIB metal comprises a combination of molybdenum and tungsten.
  • combinations of nickel/molybdenum/tungsten and cobalt/molybdenum/tungsten and nickel/cobalt/molybdenum/tungsten are used. These types of precipitates appear to be sinter-resistant. Thus, the active surface area of the precipitate is remained during use.
  • the metals are preferably present as oxidic compounds of the corresponding metals, or if the catalyst composition has been sulfided, sulfidic compounds of the corresponding metals.
  • the bulk metal hydrotreating catalysts used herein have a surface area of at least 50 m 2 /g and more preferably of at least 100 m 2 /g. It is also desired that the pore size distribution of the bulk metal hydrotreating catalysts be approximately the same as the one of conventional hydrotreating catalysts. More in particular, these bulk metal hydrotreating catalysts have preferably a pore volume of 0.05-5 ml/g, more preferably of 0.1-4 ml/g, still more preferably of 0.1-3 ml/g and most preferably 0.1-2 ml/g determined by nitrogen adsorption. Preferably, pores smaller than 1 nm are not present.
  • these bulk metal hydrotreating catalysts preferably have a median diameter of at least 50 nm, more preferably at least 100 nm, and preferably not more than 5000 ⁇ m and more preferably not more than 3000 ⁇ n. Even more preferably, the median particle diameter lies in the range of 0.1-50 ⁇ m and most preferably in the range of 0.5-50 ⁇ m.
  • the reaction stage containing the stacked bed hydrotreating catalyst system used in the present invention can be comprised of one or more fixed bed reactors or reaction zones each of which can comprise one or more catalyst beds of the same or different catalyst.
  • fixed beds are preferred.
  • Such other types of catalyst beds include fluidized beds, ebullating beds, slurry beds, and moving beds.
  • Interstage cooling or heating between reactors, reaction zones, or between catalyst beds in the same reactor can be employed since some olefin saturation can take place, and olefin saturation and the desulfurization reaction are generally exothermic.
  • a portion of the heat generated during hydrotreating can be recovered. Where this heat recovery option is not available, conventional cooling may be performed through cooling utilities such as cooling water or air, or through use of a hydrogen quench stream. In this manner, optimum reaction temperatures can be more easily maintained.
  • the catalyst system of the present invention comprises about 5-95 vol. % of the first catalyst with the second catalyst comprising the remainder, preferably about 40-60 vol. %, more preferably about 5 to about 50 vol. %.
  • the second catalyst will comprise 50 vol. % also.
  • Effective hydrotreating conditions include temperatures of from 150 to 400° C., a hydrogen partial pressure of from 1480 to 20786 kPa (200 to 3000 psig), a space velocity of from 0.1 to 10 liquid hourly space velocity (LHSV), and a hydrogen to feed ratio of from 89 to 1780 m 3 /m 3 (500 to 10000 scf/B).
  • the contacting of the lube oil boiling range feedstock with the stacked bed hydrotreating catalyst system produces a hydrotreated effluent comprising at least a gaseous product and a hydrotreated lubricating oil feedstock.
  • the hydrotreated effluent is stripped to remove at least a portion of the gaseous product from the hydrotreated effluent thereby producing at least a lubricating oil basestock.
  • the means used herein to strip the hydrotreated effluent is not critical to the present invention. Thus, any stripping method, process, or means known can be used.
  • suitable stripping methods, means, and processes include flash drums, fractionators, knock-out drums, steam stripping, etc.
  • a medium vacuum gas oil having the properties outlined in Table 1 was processed in an isothermal pilot plant over three catalysts systems at 1200 psig hydrogen partial pressure.
  • the catalyst systems and operating conditions are given in Table 2.
  • Catalyst B is a conventional hydrotreating catalyst having about 4.5 wt. % Group VI metal, about 23 wt. % Group VIII metal on an alumina support and has an average pore size of 14.0 nm.
  • the bulk metal hydrotreating catalyst was a commercial bulk metal hydrotreating catalyst marketed under the name Nebula by Akzo-Nobel.
  • the Nitrogen Removal Relative Volume Activity (“RVA”) for each catalyst system was calculated by simple first order kinetic modeling. As shown in Table 2, the 50/50 vol. % stacked bed catalyst system, with the large average pore size Catalyst B upstream of the bulk metal catalyst, showed higher nitrogen removal activity than either of the single catalyst systems demonstrated on their own.
  • the hydrotreating ability of different stacked beds of Catalyst B and Nebula were analyzed by hydrotreating different feedstreams over the stacked beds in the in two parallel reactor trains of the same isothermal pilot plant unit used in Example 1 above.
  • the feedstreams used were Medium Cycle Oils (“MCO”) from an FCC unit and blends of the MCO with a virgin feedstock were tested in two parallel reactor trains.
  • MCO Medium Cycle Oils
  • one reactor train consisted entirely of a conventional NiMo on Alumina hydrotreating catalyst, Catalyst C, with an average pore diameter of 7.5 nm.
  • the other reactor train contained a stacked bed system with 75-vol. % of Catalyst C followed by 25-vol. % of Catalyst A, a bulk multimetallic sulfide catalyst having an average pore diameter of 5.5 nm.
  • each of the two reactor trains was divided into two separate reactor vessels where the temperature of the first 75-volume % containing 75 vol. % of the catalyst loading of that reactor could be independently controlled from the last 25-volume % of catalyst.
  • the activity advantage for the stacked bed catalyst system containing begins to decrease from about 275% to about 225% and then was subsequently reduced over about 20 days to slightly less than 150%.
  • Example 2 was conducted in the same two reactor train pilot plant unit as described in Example 2 above. The operating conditions for the two trains were 1200 psig H 2 , liquid hourly space velocities of 2 vol./hr/vol., and 5000 SCF/B of hydrogen.
  • Example 5 As can be seen in Table 5, when a conventional catalyst having an average pore diameter of 14 nm was used in the first 75 vol. % of the reactor, the Nitrogen Removal Relative Volume Activity (“RVA”) for the catalyst system remained constant when the heavier feed was used. In comparing the results of Example 3 to those obtained in Example 2, one can see that when a catalyst having a pore volume of 7.5 nm preceded the bulk metal catalyst, the RVA of the catalyst system decreased. However, in Example 3, the heavier feed did not negatively impact the RVA of the catalyst system.
  • RVA Nitrogen Removal Relative Volume Activity

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  • Chemical & Material Sciences (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Engineering & Computer Science (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
  • Catalysts (AREA)
  • Lubricants (AREA)
US10/949,483 2003-11-10 2004-09-24 Process for making lube oil basestocks Abandoned US20050109679A1 (en)

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EP (1) EP1685213B1 (ja)
JP (1) JP2007510797A (ja)
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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2414098A1 (en) * 2009-03-31 2012-02-08 ExxonMobil Research and Engineering Company A hydrotreating catalyst system suitable for use in hydrotreating hydrocarbonaceous feedstreams

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