US3023159A - Controlled hydrocracking process - Google Patents

Controlled hydrocracking process Download PDF

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US3023159A
US3023159A US570440A US57044056A US3023159A US 3023159 A US3023159 A US 3023159A US 570440 A US570440 A US 570440A US 57044056 A US57044056 A US 57044056A US 3023159 A US3023159 A US 3023159A
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fraction
percent
conversion
hydrogen
boiling
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Frank G Ciapetta
Harry L Coonradt
William E Garwood
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ExxonMobil Oil Corp
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Socony Mobil Oil Co Inc
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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
    • C10G47/00—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions
    • C10G47/02—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions characterised by the catalyst used
    • C10G47/10—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions characterised by the catalyst used with catalysts deposited on a carrier
    • C10G47/12—Inorganic carriers
    • C10G47/14—Inorganic carriers the catalyst containing platinum group metals or compounds thereof

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  • the nitrogen content of the charge must'be below about 0.1'percent, by weight, and preferably lower than about 0.08 percent, by Weight.
  • the process could be operated to produce gasoline and/or fuel oil in any ratio varying from substantially 100 percent yield of gasoline to substantially 100 percent yield of fuel oil.
  • the cetane index of the fuel oil produced is relatively high and varies dependent upon the degree of conversion in the process.
  • an object of this invention to provide an improved process for cracking in the presence of hydrogen and of catalyst comprising platinum or palladium' series metals supported upon refractory acidic oxide 2 carriers. Another object is to provide a process for controlling the cetane index in the fuel oils obtained in the cracking process. A further object is to provide a method for regulating the amount of hydrogen consumed in a cracking process carried out in the presence of hydrogen. A further object is to provide a method for producing fuel oils having substantially uniform quaiity regardless of the yield thereof.
  • a specific object is to provide a method for maintaining the uniformity and quality of fuel oil produced by cracking a relatively high boiling hydrocarbon fraction in the presence of platinum and palladium series metal containing catalysts that involves operating the process at substantially uniform temperature and controlling the amount of conversion in the process by regulating the nitrogen content of the charge.
  • FIGURE 1 presents the graphic relationship between the volume percent conversion into products boiling at temperatures lower than about 390 F. and the temperature obtained by cracking a typical gas oil in the presence of hydrogen and of aplatinum-containing catalyst;
  • FIG. 2 presents the graphic relationship between the yield of fuel oil and the cetane index thereof, obtained by cracking a typical gas oil in the presence of hydrogen and of a platinum-containing catalyst, both with and without the addition of a nitrogenous compound to the feed;
  • FIG. 3 presents the graphicrelationship between the volume percent conversion into products boiling at ternperatures lower than about 390 F. and the weight percent nitrogen in the charge stock obtained by cracking a typical gas oil in the presence of hydrogen and of a platinum-containing catalyst with varying amounts of nitrogen in the charge;
  • FIG. 4 presents the graphic relationship betweenthe volume percent conversion into products boiling at temperatures lower than about 390 F. and the hydrogen consumption when a typical gas oil is cracked in the presence of hydrogen and of a platinum-containing catalyst in a process wherein no nitrogen is added to the feed, and also in a process wherein varying amounts of nitrogen are added to the feed.
  • the present invention provides, in a process for converting a hydrocarbon fraction having an initial boiling point of at least about 400 F., a 50 percent point of at least about 500 F. and an end boiling point of at least about 600 F. and boiling substantially continuously between said initial boiling point and said end boiling polnt into gasoline and/or fuel oil that comprises contasting said hydrocarbon fraction with a catalyst comprising between about 0.05 percent and about 20 percent by weight of the catalyst of at least one metal of the platinum and palladium series deposited upon a synthetic composite of oxides of at least two metals of groups IIA, IIIB and IV of the periodic arrangement of elements having an activity index of at least 25 in'the Lpresence'of 1 hydrogen inamountsexpressed in molar ratio of hydrogen tohydrocarbon chargevarying between about 2 and about 80, at pressures varying betwe'enabout psig and about 2500 p.s.i.g., at a liquid hourly space velocity varying between about 0.1 and about 10, and at temperatures varying between about 600 F.
  • the method of operation'that comprises operating said process at substantially constant temperature and controlling-"the amount of conversion intofproducts boilingv at temperatures lower than about 390 F. by regulating the nitrogen content of said hydrocarbon fraction within the range varying between about 0.01 percent, by weight, and about 1.0 percent, by weight;
  • Patented Feb, 27, 1962 conversion is intended to be a generic term for the amount of products boiling at temperatures lower than about 390 F. (l-recycle), of gasoline, or of fuel oil obtained in the process. It is expressed in terms of the volume percent of the initial charge which is transformed in the process.
  • the amount of product boiling at temperatures lower than about 390 F. is obtained by subtracting the volume percent of cycle stock (fuel oil) from 100 percent, i.e., from the initial volume of the charge.
  • the expression IOU-recycle is an abbreviation for 100 percent minus the volume percent recycle.
  • cycle stock i.e., the effiuent boiling at temperatures higher than about 390 F.
  • conversion into fuel oil is the volume percent of product which boils at temperatures higher than about 390 F.
  • the volume percent of conversion into products boiling at temperatures lower than about 390 F. (100-recycle) and the volume percent of conversion into fuel oil totals to 100 volume percent, based upon the initial charge.
  • Dry gas refers to the methane, ethane, propane, and ethylene and propylene produced in a cracking process, expressed in terms of weight percent of the initial charge.
  • Light naphtha is the product that boils between about 125 F. and about 170 F.
  • the heavy naphtha is the product that boils between about 170 and about 390 F.
  • the cetane index is a measure of ignition quality of a fuel, as described in ASTM test D975-53T, appendix II.
  • the cracking activity of a carrier is expressed in terms of the percent, by volume, of a standard hydrocarbon charge which is cracked, under specific operating conditions, in the Cat. A test. This test is described by Alexander and Shimp in National Petroleum News, 36, page R-537 (August 2, 1944).
  • the unit for rating the cracking activity of a material is called the activity index (Al).
  • catalysts utilizable herein are those described in copending application Serial Number 351,151, filed on April 27, 1953, now abandoned; and in the continuationin-part thereof Serial Number 418,166, filed on March 23, 1954-, now abandoned; and in continuation-in-part thereof, Patent No. 2,945,806, filed on July 6, 1959.
  • these catalysts comprise between about 0.05 percent, by Weight, and about 20 percent, by weight of the final catalyst, preferably between about 0.1 percent and about 5 percent, by weight, of the metals of the platinum and palladium series, i.e., those having atomic numbers of 44-46, inclusive, 76-78, inclusive, supported upon synthetic composites of two or more refractory oxides.
  • the carrier is a synthetic composite of two or more oxides of the metals of groups HA, IIIB and IVA and B of the periodic arrangement of elements [1. Chem. Ed., 16, 409 (1939)]. These synthetic composites of refractory oxides must have an activity index of at least about 25. They can also contain halogens and other materials which are known in the art as promoters for cracking catalysts, or small amounts of alkali metals that are added for the purpose of controlling the activity index of the carrier.
  • Non-limiting examples of the composites contemplated herein include silica-alumina, silica-zirconia, silica-alumina-zirconia, alumina-boria, silica-alumina-fluorine, and the like.
  • the preferred support is a synthetic composite of silica and alumina containing between about 1 percent, by weight, and about 90 percent, by weight, of alumina.
  • These synthetic composites of two or more refractory oxides can be made by any of the usual methods known to those skilled in the art of catalyst manufacture. Examples of methods of preparing them are set forth in abandoned applications Serial Nos. 351,151 and 418,166 and Patent No. 2,945,806.
  • a synthetic silica-alumina carrier or support containing 10 percent by weight alumina was prepared by mixing an aqueous solution of sodium silicate (containing 158 g. per liter of silica) with an equal amount of an aqueous acid solution of aluminum sulfate containing 39.4 g. A1 (S0 and 28.6 g. concentrated H 80 per liter. This mixture of solutions was dropped through a column of oil, wherein gelation of the hydrogel was effected in head form. The head hydrogel was soaked in hot water (about 120 F.) for about 3 hours.
  • the sodium in the hydrogel was then removed by exchanging the gel with an aqueous solution of aluminum sulfate [1.5% Al (SO.,) by weight] containing a small amount (0.2 percent by weight) of ammonium sulfate.
  • the thus-exchanged hydrogel head was water-washed. Then, it was dried in superheated steam (about 280-340 F.) for about 3 hours and, finally,
  • the silica-alumina beads were then crushed to pass through a l4-mesh screen and the material retained on a ZS-mesh screen (US. Standard Screen Series) was used for catalyst preparation. Portions of the crushed, calcined carrier were then barely covered with aqueous solutions of chloroplatinic acid, of concentrations suflicient to produce the desired amount of metal in the finished catalyst. The excess solution was removed by centrifuging. The thus-impregnated carrier was then aged in a lightly covered vessel at 230 F. for 24 hours. The catalyst was treated with hydrogen for 2 hours at 450 P. Then, it was activated in hydrogen for 2 hours at 900 F. before it was used. The catalyst thus prepared contained 0.47 percent platinum, by weight of the catalyst, and the silica-alumina carrier had an activity index of 46.
  • the charge stocks ntilizable herein are hydrocarbon fractions having an initial boiling point of at least about 400 F., a 50 percent-point of at least about 500 F. and an end-boiling point of at least about 600 F. and boiling substantially continuously between said initial boiling point and said end-boiling point.
  • Such charge stocks include gas oils, residual stocks, refractory cycle stocks from conventional cracking, whole topped crudes, and heavy hydrocarbon fractions derived by the destructive hydrogenation of coal, tars, pitches, asphalts, etc., such as, for example, middle 0'
  • the distillation of higher-boiling petroleum fractions must be carried out under vacuum, in order to avoid thermal cracking.
  • the boiling temperatures are expressed in terms of the boiling point at atmospheric pressure. In other words, in all instances, the boiling points of fractions distilled under vacuum have been corrected to the boiling points at atmospheric pressure.
  • gas oil is a broad, general term that covers a variety of stocks.
  • the term unless further modified, includes any fraction distilled from petroleum which has an initial boiling point of at least about 400 F., a 50 percent-point of at least about 500 R, and an end-boiling point of at least about 600 F., and boiling substantially continuously between the initial boiling point and the end-boiling point.
  • the portion which is not distilled is considered residual stock.
  • the exact boiling range of a gas oil therefore, will be determined by the initial distillation temperature (initial boiling point) the 50 percent-point, and by the temperature at which distillation is cut oif (end-boiling point).
  • a gas oil is a petroleum fraction which boils substantially continuously between two temperatures that establish a range falling within from about 400 F. to about 1100-1200" F., the 50 percent-point being at least about 500 F.
  • a gas oil could boil over the entire range 400-1200 F. or it could boil over a narrower range, e.g., 500-900" F.
  • the gas oils can be further roughly subdivided by overlapping boiling ranges.
  • a light gas oil boils between about 400 F. and about 600-650 F.
  • a medium gas oil distills between about 600-650" F. and about 700-750 F.
  • a heavy gas oil will boil between about 600-650 F. and about 800-900" F.
  • a gas oil boiling between about 800-850" F. and about 1100-1200 F. is sometimes designated as a vacuum gas oil. It must be understood, however, that a gas oil can overlap the foregoing ranges. It can even span several ranges, i.e., include, for example, light and medium gas oils.
  • a residual stock is any fraction which is not distilled. Therefore, any fraction, regardless of its initial boiling point, which includes all the heavy bottoms, such as tars, asphalts, etc., is a residual fraction. Accordingly, a residual stock can be the portion of the crude remaining undistilled at llO0-l200 F., or it can be made up of a gas oil fraction plus the portion undistillecl at 1100-1200 F. A whole topped crude, as the name implies, is the entire portion of the crude remaining after the light ends (the portion boiling up to about 400 F.) have been removed by distillation. Therefore, such a fraction includes the entire gas oil fraction (400 F.
  • the refractory cycle stocks are cuts of conventionmly cracked stocks which boil above the gasoline boiling range, usually, between about 400 F. and about 850 F.
  • the refractory cycle stocks can be charged to the process of this invention in conjunction with a fresh petroleum charge stock, or they can be charged alone to the process.
  • the process of this invention is particularly adaptable to the cracking of sulfur-containing charge stocks.
  • the catalysts utilizable in the process of this invention are not deactivated by sulfur compounds, under the conditions of the process.
  • the hydrogen pressure used varies between about 100 pounds per square inch gauge and about 2500 pounds per square inch gauge, preferably, however, between about 350 and about 2000 pounds per square inch gauge.
  • the liquid hourly space velocity, i.e., the liquid volume of hydrocarbon per hour per volume of catalyst varies be- EXAMPLE 2
  • The-charge stock used in this example was obtained by coking a Mid-Continent residual fraction. This coker gas oil had the following properties:
  • Table 1 39g flonversion into products boiling .at temperatures lower than about
  • the curve in FIG. 1 is basedupon'the data set forth in a Table I. This curve shows the relationship between the volume percent conversion into products boiling at temperatures lower than about-390 E. and the. temperature, when a typical gas oil is cracked in the presence of the platinum-containing catalyst It. willbe noted that. the amount of conversion is.a-direct functionof the temperature, other variables beingconstant. -.This,..of course, represents one method of controlling the. outputof the cracking process.
  • the curvein FIG; 1, however, must be cousideredin conjunction .with curve A in FIG. 2.
  • AMPLE The charge "stock used in thisexample was a gas' oil obtained by-co-king a-coastalresidual w-hichgas oilhad been subjected to a hydro finishing-operation to -reduce its nitrogen-content to 0.04-weight percent.
  • This material had the following properties:
  • I.B.P. F 290 50% I F 520' E1.
  • This gas oil was subjected to cracking in the presenceof ydrogen. and of the equilib um .ca lvstfie b din Example 1..
  • the operation was carried out at a pressure of 1000 p.s.i.g. using a hydrogenetoroil molar ratio of 40 and z -liquid hourly space velocity of 0.5.
  • catalyst temperature was 760 E -Under these conditions there was effected 76 volume percent conversion into products boiling at temperaturelower. than about 390 F. Pertinent results are set forth in Table II.
  • EXAMPLE 4 The charge stock used in this example was another portionof the coastal poker gas oil that hadbeen. subjected to hydro-finishing operation to reduce the nitrogen content thereof to 0.1 weight percent. This material had the following properties:
  • EXAMPLE The charge stock used in this run is another portion of the coastal coker gas oil that had been subjected to hydro-finishing operation to lower the nitrogen content to 0.12. This material had the following properties:
  • the charge stock used in this run was still another portion of the coastal coker gas oil that had been subjected to a hydro-finishing operation to reduce the nitrogen content thereof to 0.24 weight percent. It had the following properties:
  • This curve presents the graphic relationship between the volume percent conversion into products boiling at temperatures lower than about 390 F. and the nitrogen content of the charge, when a hydrocarbon charge is cracked using the same catalyst temperature but varying the nitrogen content. It will he noted that as the nitrogen content of the charge is varied between about 0 weight percent and about 0.3 weight percent, the charge stock can be cracked at virtually any conversion level While operating at the same temperature throughout. In other words, as com-pared with the data presented in FIG. 1, the control of the cracking level was achieved by controlling the nitrogen content of the charge, instead of by varying the reaction temperature.
  • This control of the nitrogen content generally can be effected in several ways or by a combination thereof.
  • One method involves the addition of nitrogenous compounds to the charge stock in amounts sufiicient to achieve the desired total nitrogen content that will efieot the desired degree of conversion at the operating temperature selected.
  • the added compounds can be inorganic nitrogen compounds or they can be organic nitrogen compounds, such as amines, cyclic nitrogen materials, hydrazines and the like.
  • Nonlimiting examples of the nitrogen containing compounds utilizable herein are ammonia, Z-methylpyridine, 2-rnethylpiperidine, pyrrole, pyrrolidine, quinoline, acridine, and carbazole.
  • Another source of-added nitrogen is a gas oil, or other hydrocarbon fraction, that has a high nitrogen content, e.g., a California thermally cracked gas oil. It will be appreciated that the regulation of nitrogen content by means of added nitrogen compounds is more generally applicable to charge stocks that have a relatively low nitrogen content. In such a case, the amount of nitrogen compound added will be suflicient to bring the total nitrogen content up to the desired level.
  • Another method of controlling the nitrogen content is by means of controlled reduction of the total nitrogen content of the charge.
  • This reduction of nitrogen content can be effected by any of the several means well known to those skilled in the art.
  • a particularly eiiective method is nondestructive hydrogenation to a degree just suflicient to efiect the desired amount of nitrogen removal without materially affecting the other properties of the charge stock.
  • a still further method of regulating the amount of nitrogen in the feed stock is by controlling the ammonia content of the hydrogen-containing recycle gas.
  • the amount of nitrogen compound ultimately in the charge stock will ordinarily vary between about 0.01 weight percent and about 1.0 weight percent, preferably between about 0.01 weight percent and about 0.5 weight percent.
  • the major factor that will efiect the desired nitrogen content for any given degree of conversion is the temperature at which cracking is carried out.
  • the curve in FIG. 3 represents the relationship between the nitrogen content and conversion when operating at a temperature of 760 F. throughout. It will be recognized, of course, that at other operating temperatures a dilferent range of nitrogen content will be used. This range, however, can
  • the process for the present invention is particularly applicable in refinery processes in which the cetane index does not have to be relatively high but in which it is highly desirable that fuel oil quality expressed in terms of cetane index should remain substantially constant regardless of the conversion level. That this is achieved in the present process will be apparent from curve B in FIG. 2.
  • This curve based upon the data set forth in Table II represents the relationship between rhe volume per cent conversion into fuel oil and the cetane index of the fuel oil.
  • the cetane index of the fuel oil remains substantially constant regardless of the conversion level.
  • curve A when cracking is carried out by means of controlling the conversion level by means of the temperature (curve A), the cetane index varies considerably with the conversion level.
  • cetane index is relatively higher than that expressed by curve B. Yet, a cetane index of such magnitude may not be generally desirable. Indeed, in cases where product uniformity is more desirable, the operation illustrated by curve B is much more desirable on a commercial basis.
  • Curve C represents the graphic relationship between the volume percent conversion into I products boiling at temperatures lower than about 390 F. and the amount of hydrogen consumed when the gas oil is cracked in the presence of hydrogen and of the platinum catalyst and by controlling the degree of conversion by varying the temperature.
  • Curve D presents a similar relationship in the case in which the gas oil charge is cracked at a constant temperature, varying the amount of conversion by controlling the nitrogen content of the charge, in accordance with the process of this invention. Particularly at conversion levels lower than about 50 volume percent, considerably more hydrogen is consumed at any given conversion level when the amount of conversion is controlled by means of the temperature.
  • the improved method of operation which comprises: adding nitrogenous compounds to said fraction to increase its nitrogen content and periodically adjusting the quantity of nitrogenous compounds added to effect at least a part of the control over the extent to which said hydrocarbon fraction is converted to lower boiling products, the nitrogen content of the fraction varying from time to time but at all times being within'the range about 0.01 to 1 percent by weight of the fraction, and at any given time an increase in added nitrogenous compounds being used to decrease the extent of conversion of the fraction to lower boiling products and a decrease in added nitrogenous compounds being used to increase the extent of conversion of the fraction to lower boiling products, whereby the hydrogen consumed during conversion to lower boiling products is lower than when the same control over the extent of conversion is effected by variation of reaction temperature alone.

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3117075A (en) * 1961-03-28 1964-01-07 California Research Corp Hydrocaracking process employing as a feed, a nitrogen containing distillate oil
US3166489A (en) * 1961-09-21 1965-01-19 California Research Corp Hydrocracking process
US3213013A (en) * 1962-07-25 1965-10-19 Exxon Research Engineering Co Regulating a hydrocracking process, with a crystalline zeolite catalyst, containing a platinum group metal, to obtain a constant octane gasoline
US3306839A (en) * 1963-03-18 1967-02-28 Union Oil Co Hydrocracking process in several stages and regulating the hydrocracking by varying the amount of hydrogen sulfide in the reaction zones
US5419830A (en) * 1985-07-26 1995-05-30 Mobil Oil Corporation Method for controlling hydrocracking and isomerization dewaxing

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2550531A (en) * 1949-12-29 1951-04-24 Atlantic Refining Co Reforming process and catalyst therefor
US2708180A (en) * 1951-04-17 1955-05-10 Basf Ag Carrying out catalytic reactions with hydrocarbons in the presence of hydrogen
US2717230A (en) * 1951-06-19 1955-09-06 Universal Oil Prod Co Catalytic reforming of hydrocarbon charge stocks high in nitrogen compounds
US2758064A (en) * 1951-05-26 1956-08-07 Universal Oil Prod Co Catalytic reforming of high nitrogen and sulfur content gasoline fractions
US2763623A (en) * 1951-05-26 1956-09-18 Universal Oil Prod Co Preparation of silica-alumina catalyst of reduced cracking activity
US2799626A (en) * 1952-06-07 1957-07-16 Kellogg M W Co Treatment of residual oils
US2849377A (en) * 1953-04-16 1958-08-26 Atlantic Refining Co Control of catalytic reforming process
US2911356A (en) * 1957-02-18 1959-11-03 Union Oil Co Hydrocracking of hydrocarbons with reaction conditions dependent on nitrogen contentof feed

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2550531A (en) * 1949-12-29 1951-04-24 Atlantic Refining Co Reforming process and catalyst therefor
US2708180A (en) * 1951-04-17 1955-05-10 Basf Ag Carrying out catalytic reactions with hydrocarbons in the presence of hydrogen
US2758064A (en) * 1951-05-26 1956-08-07 Universal Oil Prod Co Catalytic reforming of high nitrogen and sulfur content gasoline fractions
US2763623A (en) * 1951-05-26 1956-09-18 Universal Oil Prod Co Preparation of silica-alumina catalyst of reduced cracking activity
US2717230A (en) * 1951-06-19 1955-09-06 Universal Oil Prod Co Catalytic reforming of hydrocarbon charge stocks high in nitrogen compounds
US2799626A (en) * 1952-06-07 1957-07-16 Kellogg M W Co Treatment of residual oils
US2849377A (en) * 1953-04-16 1958-08-26 Atlantic Refining Co Control of catalytic reforming process
US2911356A (en) * 1957-02-18 1959-11-03 Union Oil Co Hydrocracking of hydrocarbons with reaction conditions dependent on nitrogen contentof feed

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3117075A (en) * 1961-03-28 1964-01-07 California Research Corp Hydrocaracking process employing as a feed, a nitrogen containing distillate oil
US3166489A (en) * 1961-09-21 1965-01-19 California Research Corp Hydrocracking process
US3213013A (en) * 1962-07-25 1965-10-19 Exxon Research Engineering Co Regulating a hydrocracking process, with a crystalline zeolite catalyst, containing a platinum group metal, to obtain a constant octane gasoline
US3306839A (en) * 1963-03-18 1967-02-28 Union Oil Co Hydrocracking process in several stages and regulating the hydrocracking by varying the amount of hydrogen sulfide in the reaction zones
US5419830A (en) * 1985-07-26 1995-05-30 Mobil Oil Corporation Method for controlling hydrocracking and isomerization dewaxing
US6416654B1 (en) * 1985-07-26 2002-07-09 Mobil Oil Corporation Method for controlling hydrocracking and isomerization dewaxing operations

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