WO2000069993A1 - Dual catalyst system - Google Patents
Dual catalyst system Download PDFInfo
- Publication number
- WO2000069993A1 WO2000069993A1 PCT/US2000/013060 US0013060W WO0069993A1 WO 2000069993 A1 WO2000069993 A1 WO 2000069993A1 US 0013060 W US0013060 W US 0013060W WO 0069993 A1 WO0069993 A1 WO 0069993A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- catalyst
- hydrocracking
- aromatics saturation
- noble metal
- range
- Prior art date
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Classifications
-
- 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
- C10G65/12—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only including cracking steps and other hydrotreatment steps
Definitions
- This application is related to a process for hydrocracking of heavy naphtha feeds, more particularly to a process in which aromatics saturation occurs in a separate stage from hydrocracking, by the placement of a low activity aromatics saturation catalyst prior to a high activity conversion catalyst.
- U.S. Pat. No 5,690,810 discloses a single step process to upgrade naphthas to an improved gasoline blending stock. It is an alternative to catalytic reforming, employing milder conditions. Simultaneous saturation of aromatics. paraffin isomerization, and selective cracking of heavier hydrocarbons occurs.
- the catalyst comprises a solid acid support, and at least one zeolite, such as zeolite beta or ZSM-5.
- the catalyst further comprises a Group VIII metal.
- a high activity catalyst is employed, which encourages cracking at the expense of isomerization.
- U.S. Pat. No. 4,906,353 discloses a dual- mode hydrocarbon conversion process which comprises reforming a sulfur-, nitrogen- and/or olefm-containing hydrocarbon feedstock, e.g., an FCC gasoline, in a conversion unit which is operated under reforming conditions.
- a noble metal-containing crystalline silicate having a Constraint Index of not greater than about 2 and a framework SiO 2 /Al 2 O 3 ratio of at least about 50 is employed as a catalyst to provide a relatively high yield of high octane reformate and a relatively low yield of C 3 . 4 hydrocarbons prior to or following hydrocracking the feedstock in the unit.
- the conversion unit is alternately operated under hydrocracking conditions in the presence of the aforesaid catalyst to provide a relatively low yield of high octane hydrocrackate and a relatively high yield of C 3 . 4 hydrocarbons.
- the latter can be separated from the liquid product and processed in a gas plant to provide LPG products.
- U.S. Pat. No. 5,831,139 discloses a process combination to selectively upgrade heavy naphtha to more aliphatic gasolines. Such gasolines contain lower concentrations of aromatics and have lower end points with concomitant reduced harmful automotive emissions. This process combination converts the higher-boiling portion of the naphtha, yields isobutane and other isoparaffins which are particularly suitable for upgrading or blending, and reduces cyclics in intermediate processing steps.
- the heavy naphtha fraction is treated with a solid acid isomerization catalyst.
- Isobutanes are removed with a separation step, and the remainder of the heavy naphtha feed is treated with a ring cleavage catalyst such as an L-zeolite.
- a ring cleavage catalyst such as an L-zeolite.
- the instant invention does not require a separation step, and hydrocracking with a high activity zeolite is employed for upgrading purposes, rather than isomerization with a solid acid catalyst.
- a portion of the hydrocracked product is passed to an aromatics saturation zone, and is subsequently passed from the hydrocracking zone and the aromatics saturation zone to one or more fractionating zones wherein the products are separated into a top fraction and a bottoms fraction, with the tops fraction being separated into light gasoline, naphtha, jet fuel and diesel fuel products, and a portion or all of the bottoms fraction being recycled to the hydrocracking zone and/or the aromatics saturation zone following the optional removal of heavies and polynuclear aromatics.
- There are numerous separation steps in this procedure which are not employed in the instant invention.
- saturation in Sanborn occurs following hydrocracking, rather than prior to it, as in the instant invention.
- Utilization of the dual catalyst system provides an improvement in yields when either noble metal or base metal hydrocracking catalysts are employed.
- an optimized dual catalyst system non-metal aromatics saturation/base metal hydrocracking combination
- Utilization of a dual catalyst system for either improved yields or operability is applicable to fuels and lubes hydrocracking. Fuels hydrocracking generally involves conversion levels greater than 30%, and lubes hydrocracking generally involves conversion levels below 30%.
- Figure 1 illustrates product yield v. conversion of feed for single and dual catalyst systems.
- Figure 2 illustrates hydrogen consumption v. conversion of feed for single and dual catalyst systems.
- Figure 3 illustrates hydrogen consumption v. catalyst system employed.
- Figure 4 illustrates the products yields provided v. catalyst system employed.
- Figure 5 illustrates volumetric product yield v. catalyst system employed.
- Figure 6 illustrates distribution of total liquid product component v. catalyst system employed.
- Figure 7 illustrates the aromatics content of the liquid recycle v. catalyst system employed.
- Figure 8 illustrates ratio of isoparaffins to normal paraffins v. catalyst system employed.
- Figure 9 illustrates the amount of hydrogen consumed v. the percent noble metal catalyst in the reactor.
- Figure 10 illustrates the relationship of light naphtha product yield to the percent noble metal catalyst in the reactor.
- Figure 11 illustrates the relationship of heavy naphtha product yield to the percent noble metal catalyst in the reactor.
- Figure 12 illustrates yields by volume of C 3 -C 5 products v. percent noble metal catalyst in reactor.
- Figure 13 illustrates yields by volume of C 6 + products v. percent noble metal catalyst in reactor.
- Figure 14 illustrates the composition of total liquid product v. percent noble metal catalyst in the reactor.
- Figure 15 illustrates the aromatics content of liquid recycle v. percent noble metal catalyst in the reactor.
- Figure 16 illustrates the ratio of iso to normal hydrocarbons v. percent noble metal catalyst in the reactor.
- FIG. 17 illustrates start of cycle activity for different catalyst systems. DETAILED DESCRIPTION OF THE INVENTION
- the feedstock for the process can be straight-run, thermal or catalytically cracked naphtha. Naphthas derived from shales, tar sands and coal may also be treated. Typically naphthas boil at 25° to 260°C. While the process can accept any naphtha in this boiling range, it generally shows its greatest advantage on feedstocks which boil between 50° and 260°C. Since one of the features of the invented process is saturation of aromatic hydrocarbons, the feedstock naphtha will contain aromatic hydrocarbons, generally from 1 to 40 volume per cent. In order to obtain full benefit from the isomerization and cracking functions of the process the feed will also contain from 5 to 40 per cent n-paraffins. Preferred feedstocks will boil between 70° and 250°C and will contain 5 to 25 percent aromatic hydrocarbons and 10 to 30 percent n-paraffins.
- This process converts naphthas to gasoline blending stock by saturating and thus removing benzene and other aromatics. Some paraffin isomerization occurs, also. Higher boiling hydrocarbon components are selectively cracked. The heavier hydrocarbons are converted to gasoline range and lighter components.
- Aromatics wt.% 20.94 17.13 17.30
- both a catalyst having a aromatics saturation component and a catalyst which comprises an acidic component for cracking are employed.
- the cracking component is frequently PtPd USY/Al 2 O 3 , in highly dealuminated form or a form in which the acid sites are exchanged with a counterion.
- the USY is of very low acidity.
- the aromatics saturation function is provided by a transition metal or combination of metals.
- Noble metals of Group VIIIA of the Periodic Table, especially platinum or palladium are preferred. Base metals of Groups IVA, VIA and VIIIA may be used at very high pressures, however.
- the preferred base metals for use as aromatics saturation components are chromium, molybdenum, tungsten, cobalt and nickel, as well as combinations of metals such as nickel-molybdenum, cobalt- molybdenum, cobalt-nickel, nickel-tungsten, cobalt-nickel-molybdenum and nickel-tungsten-titanium.
- the acidic component comprises zeolite beta, which is described in U.S. Pat. Nos. 3,303,069 and Re.28,341 and reference is made to these patents for details of this zeolite and its preparation.
- the high pour point in the unconverted fraction has generally meant that the middle distillates from conventional hydrocracking processes are pour point limited rather than end point limited.
- the specification for products such as light fiiel oil (LFO), jet fuel and diesel fuel generally specify a minimum initial boiling point (IBP) for safety reasons but end point limitations usually arise from the necessity of ensuring adequate product fluidity rather than from any actual need for an end point limitation in itself.
- the pour point requirements which are imposed effectively impose an end point limitation of about 345°C (about 650°F) with conventional processing techniques because inclusion of higher boiling fractions including significant quantities of paraffins will raise the pour point above the limit set by the specification.
- Zeolite Beta When Zeolite Beta is used as the hydrocracking catalyst, however, the lower pour point of the unconverted fraction enables the end point for the middle distillates to be extended so that the volume of the distillate pool can be increased. Thus, the use of Zeolite Beta as the acidic component of the hydrocracking catalyst effectively increases the yield of the more valuable components by reason of its paraffin selective catalytic properties.
- the processing is carried out under conditions similar to those used for conventional hydrocracking.
- Process temperatures of 230°C to 500°C may conveniently be used although temperatures above 425°C (800°F) will normally not be employed as the thermodynamics of the hydrocracking reactions become unfavorable at temperatures above this point.
- temperatures of 300°C to 425°C 570°F to 800°F will be employed.
- Total pressure is usually in the range of 500 to 20,000 kPa (58 to 2886 psig). The preferred range is from 2514 to 8375 kPa(350 to 1200 psig).
- the process is operated in the presence of hydrogen and hydrogen partial pressures will normally be from 600 to 6000 kPa (72 to 2305 psig).
- the ratio of hydrogen to the hydrocarbon feedstock (hydrogen circulation rate) will normally be from 10 to 3500 n.1.1 (56 to 19,660 SCF/bbl).
- the space velocity of the feedstock will normally be from 0.1 to 20 LHSV, preferably 0.1 to 10 LHSV.
- the n-paraffins in the feedstock will be converted in preference to the iso-paraffins but at higher conversions under more severe conditions the iso- paraffins will also be converted.
- the product is low in fractions boiling below 150°C (about 300°F) and in most cases the product will have a boiling range of 150° to 340°C (about 300° to 650°F).
- the conversion may be conducted by contacting the feedstock with a fixed stationary bed of catalyst, a fixed fluidized bed or with a transport bed.
- a simple configuration is a trickle-bed operation in which the feed is allowed to trickle through a stationary fixed bed. With such a configuration, it is desirable to initiate the reaction with fresh catalyst at a moderate temperature which is raised as the catalyst ages, in order to maintain catalytic activity.
- the catalyst may be regenerated by contact at elevated temperature with hydrogen gas, for example, or by burning in air or other oxygen-containing gas.
- a preliminary hydrotreating step to remove nitrogen and sulfur and to saturate aromatics to naphthenes without substantial boiling range conversion will usually improve catalyst performance and permit lower temperatures, higher space velocities, lower pressures or combinations of these conditions to be employed.
- the initial hydrotreating step is operated at a lower temperature range (200-500°F) than the hydrocracking steps which follow it.
- the temperature of the aromatics saturation catalyst would be dependent on the aromatic content of the feed (heat release achieved) as well as the temperature required to initiate the saturation reactions.
- the bed of aromatics saturation catalyst would be at a lower temperature than the beds of hydrocracking catalyst.
- the hydrocracking may be operated either in a naphtha directing mode under conditions of moderate to high severity or under conditions of low to moderate severity to produce a relatively higher proportion of product boiling in the middle distillate range.
- the evaluation of this catalyst strategy in low pressure heavy naphtha hydrocracking required comparing data collected using an adiabatic pilot plant with data collected using an isothermal pilot plant.
- the heavy naphtha feedstock used in this evaluation is described in Table 1, above.
- the catalysts employed in the adiabatic pilot plant include a low cracking activity aromatic saturation catalyst which comprises Pt/Pd USY/Al 2 O 3 and a catalyst for heavy naphtha conversion which comprises Pt/zeolite beta/Al 2 O 3 .
- the process conditions for the adiabatic pilot plant evaluation of the dual catalyst system were 335 psig, 1.5 WHSV (total catalyst), and 4100 SCF/bbl.
- the isothermal pilot plant employed a single catalyst system.
- the conversion catalyst was nominally 0.6 wt.% Pt, 65 wt.% zeolite beta and 35 wt.% alumina.
- the alpha prior to metals addition was 350 and the SiO 2 /Al 2 O 3 ratio was approximately 50.
- the process conditions for the isothermal pilot plant evaluation of the single catalyst system were 350 psig, 2 WHSV, and 3100 SCF/bbl.
- Figure 1 shows that the yields with the dual catalyst system relative to the single catalyst system are shown in Figure 1 and the hydrogen consumption is shown in Figure 2.
- Figure 1 shows that the light gas ( -C ) production with the dual catalyst system is decreased relative to the single catalyst system, thereby resulting in an increase in C 5 -300°F product.
- Figure 2 shows that the hydrogen consumption of the dual catalyst system is decreased relative to the single catalyst system at the same 300°F + conversion.
- the dual catalyst system, System 2 exhibits increased hydrogen consumption relative to the base metal catalyst system (Figure 3) as expected due to the incorporation of 20% noble metal aromatics saturation catalyst.
- the increased hydrogen consumption of the dual catalyst system is greater than if it is assumed that the hydrogen consumption is linear between 0 and 100% noble metal aromatics saturation component ( Figure 9). This suggests that with optimization of the ratio of aromatics saturation to conversion catalyst, complete aromatic saturation could be obtained with a dual catalyst system having an aromatics saturation catalyst which contains a smaller percentage of noble metal than is found on a commercial noble metal hydrocracking catalyst. It would therefore be less expensive to employ a dual catalyst system in a hydrocracking process than a single hydrocracking catalyst which is loaded with noble metals.
- the iso/normal (i/n) ratio of the C 4 and C 5 hydrocarbons produced with the various catalyst systems was evaluated. Surprisingly, the greatest C and C 5 i/n ratio was observed for System 2. The increased iso/n ratio of the C 4 and C 5 hydrocarbons increases the value of these products to the refinery. Based on the severity of the process with the various catalysts, the largest iso/n ratios had been expected for the noble metal hydrocracking catalyst employed in System 3. As shown in Figure 16, the iso/n ratio of the C and C 5 hydrocarbons is significantly greater than would have been predicted by use of a aromatics saturation catalyst comprising 20% noble metal.
- Figure 17 shows the normalized average reactor temperature required for 60% per pass conversion in recycle-to-extinction operation with Systems 1, 2, and 3. Utilization of 20% aromatic saturation catalyst resulted in a 40% increase in conversion activity (System 2) relative to the base metal hydrocracking catalyst used alone (System 1). This increased activity may be of value to the refiner due to increased cycle length and decreased energy costs.
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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)
- Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
- Catalysts (AREA)
Abstract
Description
Claims
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
BR0010212-1A BR0010212A (en) | 1999-05-13 | 2000-05-12 | Process for hydrocracking naphtha supplies |
CA002371209A CA2371209A1 (en) | 1999-05-13 | 2000-05-12 | Dual catalyst system |
AU48448/00A AU4844800A (en) | 1999-05-13 | 2000-05-12 | Dual catalyst system |
JP2000618401A JP2002544369A (en) | 1999-05-13 | 2000-05-12 | Improved selectivity and operability of binary catalyst systems |
EP00930667A EP1183320A1 (en) | 1999-05-13 | 2000-05-12 | Dual catalyst system |
NO20015525A NO20015525D0 (en) | 1999-05-13 | 2001-11-12 | Improved selectivity and operability of two-part catalyst system |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US31139799A | 1999-05-13 | 1999-05-13 | |
US09/311,397 | 1999-05-13 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2000069993A1 true WO2000069993A1 (en) | 2000-11-23 |
WO2000069993A9 WO2000069993A9 (en) | 2002-07-04 |
Family
ID=23206703
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2000/013060 WO2000069993A1 (en) | 1999-05-13 | 2000-05-12 | Dual catalyst system |
Country Status (7)
Country | Link |
---|---|
EP (1) | EP1183320A1 (en) |
JP (1) | JP2002544369A (en) |
AU (1) | AU4844800A (en) |
BR (1) | BR0010212A (en) |
CA (1) | CA2371209A1 (en) |
NO (1) | NO20015525D0 (en) |
WO (1) | WO2000069993A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7749373B2 (en) | 2004-12-17 | 2010-07-06 | Haldor Topsoe A/S | Hydrocracking process |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10301560B2 (en) | 2016-06-15 | 2019-05-28 | Uop Llc | Process and apparatus for hydrocracking a hydrocarbon stream in two stages with aromatic saturation |
Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
BE594884A (en) * | ||||
GB1109922A (en) * | 1965-08-26 | 1968-04-18 | Universal Oil Prod Co | Catalytic hydrocracking process |
US3923641A (en) * | 1974-02-20 | 1975-12-02 | Mobil Oil Corp | Hydrocracking naphthas using zeolite beta |
EP0552072A1 (en) * | 1992-01-15 | 1993-07-21 | Institut Français du Pétrole | Lowering of the benzene contact of gasolines |
-
2000
- 2000-05-12 BR BR0010212-1A patent/BR0010212A/en not_active Application Discontinuation
- 2000-05-12 WO PCT/US2000/013060 patent/WO2000069993A1/en not_active Application Discontinuation
- 2000-05-12 CA CA002371209A patent/CA2371209A1/en not_active Abandoned
- 2000-05-12 AU AU48448/00A patent/AU4844800A/en not_active Abandoned
- 2000-05-12 EP EP00930667A patent/EP1183320A1/en not_active Withdrawn
- 2000-05-12 JP JP2000618401A patent/JP2002544369A/en active Pending
-
2001
- 2001-11-12 NO NO20015525A patent/NO20015525D0/en not_active Application Discontinuation
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
BE594884A (en) * | ||||
GB1109922A (en) * | 1965-08-26 | 1968-04-18 | Universal Oil Prod Co | Catalytic hydrocracking process |
US3923641A (en) * | 1974-02-20 | 1975-12-02 | Mobil Oil Corp | Hydrocracking naphthas using zeolite beta |
EP0552072A1 (en) * | 1992-01-15 | 1993-07-21 | Institut Français du Pétrole | Lowering of the benzene contact of gasolines |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7749373B2 (en) | 2004-12-17 | 2010-07-06 | Haldor Topsoe A/S | Hydrocracking process |
KR101307226B1 (en) | 2004-12-17 | 2013-09-12 | 할도르 토프쉐 에이/에스 | Hydrocracking process |
Also Published As
Publication number | Publication date |
---|---|
WO2000069993A9 (en) | 2002-07-04 |
AU4844800A (en) | 2000-12-05 |
NO20015525L (en) | 2001-11-12 |
CA2371209A1 (en) | 2000-11-23 |
BR0010212A (en) | 2002-02-13 |
NO20015525D0 (en) | 2001-11-12 |
EP1183320A1 (en) | 2002-03-06 |
JP2002544369A (en) | 2002-12-24 |
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