U.S. patent application number 11/532640 was filed with the patent office on 2007-02-08 for hydrocracking catalyst and process for producing liquid hydrocarbon.
This patent application is currently assigned to NIPPON OIL CORPORATION. Invention is credited to Nobuo AOKI, Masahiro HIGASHI, Masakazu IKEDA, Hiroyuki SEKI, Toshio WAKU.
Application Number | 20070029228 11/532640 |
Document ID | / |
Family ID | 35056028 |
Filed Date | 2007-02-08 |
United States Patent
Application |
20070029228 |
Kind Code |
A1 |
AOKI; Nobuo ; et
al. |
February 8, 2007 |
HYDROCRACKING CATALYST AND PROCESS FOR PRODUCING LIQUID
HYDROCARBON
Abstract
Provided is a catalyst for hydrocracking paraffinic hydrocarbons
which provides satisfactorily high cracking activity and middle
distillate yield as well as the low pour point of the resulting gas
oil all together. The catalyst of the present invention comprises a
crystalline aluminosilicate, alumina-boria and a noble metal of
Group VIII of the Periodic Table.
Inventors: |
AOKI; Nobuo; (Yokohama-shi,
Kanagawa, JP) ; SEKI; Hiroyuki; (Yokohama-shi,
Kanagawa, JP) ; HIGASHI; Masahiro; (Yokohama-shi,
Kanagawa, JP) ; IKEDA; Masakazu; (Yokohama-shi,
Kanagawa, JP) ; WAKU; Toshio; (Yokohama-shi,
Kanagawa, JP) |
Correspondence
Address: |
AKIN GUMP STRAUSS HAUER & FELD L.L.P.
ONE COMMERCE SQUARE
2005 MARKET STREET, SUITE 2200
PHILADELPHIA
PA
19103
US
|
Assignee: |
NIPPON OIL CORPORATION
3-12, Nishi-shimbashi 1-chome
Tokyo
JP
|
Family ID: |
35056028 |
Appl. No.: |
11/532640 |
Filed: |
September 18, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
PCT/JP05/04728 |
Mar 10, 2005 |
|
|
|
11532640 |
Sep 18, 2006 |
|
|
|
Current U.S.
Class: |
208/113 ; 502/60;
502/63; 502/64; 502/66 |
Current CPC
Class: |
B01J 29/126 20130101;
B01J 37/0009 20130101; B01J 29/068 20130101; B01J 29/22 20130101;
B01J 2229/20 20130101; B01J 2229/42 20130101; B01J 29/44 20130101;
C10G 2400/06 20130101; B01J 21/02 20130101; B01J 29/7415
20130101 |
Class at
Publication: |
208/113 ;
502/060; 502/063; 502/064; 502/066 |
International
Class: |
C10G 11/00 20060101
C10G011/00; B01J 29/04 20060101 B01J029/04; B01J 29/06 20060101
B01J029/06 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 29, 2004 |
JP |
2004-094817 |
Claims
1. A catalyst for hydrocracking a paraffinic hydrocarbon comprising
a crystalline aluminosilicate, alumina-boria and a noble metal of
Group VIII of the Periodic Table.
2. The catalyst for hydrocracking a paraffinic hydrocarbon
according to claim 1 wherein the average particle diameter of the
crystalline aluminosilicate is 0.5 .mu.m or smaller.
3. A process for producing a liquid hydrocarbon wherein a
paraffinic hydrocarbon is hydrocracked using the catalyst according
to claim 1.
4. A process for producing a liquid hydrocarbon wherein a
paraffinic hydrocarbon is hydrocracked using the catalyst according
to claim 2.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation of International
Application No. PCT/JP2005/004728, filed Mar. 10, 2005, which was
published in the Japanese language on Oct. 6, 2005, under
International Publication No. WO 2005/092500 A1 and the disclosure
of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a catalyst for producing
liquid hydrocarbons from paraffinic hydrocarbons in the presence of
hydrogen and a process for producing liquid hydrocarbons using such
a catalyst.
[0003] In recent years, demands have been escalating rapidly toward
a clean liquid fuel which is low in contents of sulfur and aromatic
hydrocarbons. In response to such demands, fuel oil manufacturers
have already been studying various processes for producing clean
fuel. Among these, a process has been considered to be the most
prospective in which process paraffinic hydrocarbons such as waxes
are hydrocracked in the presence of a catalyst.
[0004] In a process of hydrocracking of a paraffinic hydrocarbon,
it is important to produce useful middle distillates at higher
yields in order to improve the economical efficiency of the
process. In addition, the resulting gas oil is necessarily low in
pour point. That is, development of a highly efficient
hydrocracking catalyst which can enhance the cracking activity and
middle distillate yield of the hydrocracking process and can render
the process possible to produce a gas oil with low pour point holds
the key to an improvement of economical efficiency of the
process.
[0005] Hydrocracking of a vacuum gas oil has already been
commercialized and is a technology which has been established for
more than decades. However, since the difference between the
reactivity of a paraffinic hydrocarbon and that of a vacuum gas oil
is so significant that it is difficult to use the catalyst for the
latter as it is for hydrocracking a paraffinic hydrocarbon, the
research and development have been continued vigorously to aim
development of a highly efficient catalyst for paraffinic
hydrocarbons. There are a few but some patents and reports
concerning such a catalyst. For example, Patent Document 1 below
discloses a catalyst comprising platinum loaded into a support
containing silica alumina. There is an example of a study in
Non-Patent Document 1 wherein the hydrocracking of a paraffinic
hydrocarbon was carried out using a catalyst comprising platinum
loaded into a crystalline aluminosilicate (zeolite).
[0006] However, the crystalline aluminosilicate catalyst is at a
satisfactorily higher level of the cracking activity but has
disadvantages that the middle distillate yield is low and the
resulting gas oil fails to obtain a sufficient pour point. On the
other hand, amorphous solid acid catalysts a typical example of
which is silica alumina are at satisfactorily higher level in
middle distillate yield and the pour point of the resulting gas oil
but low in cracking activity. That is, there has not been developed
a catalyst which satisfies high cracking activity and middle
distillate yield as well as the low pour point of the resulting gas
oil all together, resulting in a serious hindrance to an
improvement of economical efficiency of the hydrocracking process
of paraffinic hydrocarbons.
[0007] (1) Patent Document 1: Japanese Patent Laid-Open Publication
No. 6-41549
[0008] (2) Non-Patent Document 2: "Zeolite" (Volume 6, page 334 to
348, 1986)
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention has an object to provide a novel
catalyst for hydrocracking paraffinic hydrocarbons which can
satisfy higher cracking activity and middle distillate yield and
the lower pour point of the resulting gas oil all together thereby
improving the productivity of the hydrocracking process.
[0010] As a result of an extensive research made by the present
inventors, they completed the present invention based on the
finding that the above-described problems can be solved with a
catalyst comprising a crystalline aluminosilicate and alumina-boria
in combination.
[0011] That is, the present invention relates to a catalyst for
hydrocracking paraffinic hydrocarbons which comprises a crystalline
aluminosilicate, alumina-boria and a noble metal of Group VIII of
the Periodic Table.
[0012] The present invention also relates to the above-described
catalyst wherein the average particle diameter of the crystalline
aluminosilicate is 0.5 .mu.m or smaller.
[0013] The present invention also relates a process for producing
liquid hydrocarbons wherein paraffinic hydrocarbons are
hydrocracked using the foregoing catalyst.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The present invention will be described in more detail
below.
[0015] The term "aluminosilicate" used herein denotes a metal oxide
constituted by three elements, i.e., aluminum, silicon, and oxygen.
Although another metal element may coexist to an extent that the
present invention is not prohibited from achieving the advantageous
effects, the amount of such a metal element is 5 percent by mass or
less and preferably 3 percent by mass or less of the total amount
of alumina and silica in the form of an oxide. Examples of the
metal element which may coexist are titanium, lanthanum, manganese,
gallium and zinc. Preferred are titanium and lanthanum.
[0016] The crystallinity of aluminosilicate can be estimated with
the proportion of tetrahedrally coordinated Al atoms in all the Al
atoms which proportion can be measured by a solid .sup.27Al NMR
spectrum. The term "crystalline aluminosilicate" used in the
present invention denotes that whose proportion of tetrahedrally
coordinated Al atoms is 50 percent or more. Any crystalline
aluminosilicate can be used in the present invention as long as the
proportion of tetrahedrally coordinated Al atoms is 50 percent or
more. However, it is preferred to use those containing 70 percent
or more of the tetrahedrally coordinated Al atoms, and it is more
preferred to use those containing 80 percent or more of the
tetrahedrally coordinated Al atoms.
[0017] Crystalline aluminosilicates eligible for the present
invention are so-called zeolites. Preferred are Y- or USY-type
zeolites, beta-type zeolites, mordenite, and ZSM-5, and most
preferred is USY-type zeolite. If necessary, two or more types of
crystalline aluminosilicates may be used.
[0018] No particular limitation is imposed on the average particle
diameter of the crystalline aluminosilicate to be used in the
present invention. However, the average particle diameter is
preferably 1.0 .mu.m or smaller and particularly preferably 0.5
.mu.m or smaller.
[0019] The hydrocracking catalyst of the present invention is
characterized in that it comprises a crystalline aluminosilicate
and alumina-boria. No particular limitation is imposed on the
content ratio of alumina to boria in alumina-boria. However, in
general the ratio of alumina to boria is preferably 30 to 99
percent by mass: 70 to 1 percent by mass, more preferably 50 to 95
percent by mass: 50 to 5 percent by mass, and most preferably 70 to
90 percent by mass: 30 to 10 percent by mass.
[0020] No particular limitation is imposed on the mass ratio of the
crystalline aluminosilicate to alumina-boria in the catalyst.
However, in general the mass ratio is preferably from 0.001 to
2.000, more preferably 0.010 to 1.500 and most preferably 0.015 to
0.200.
[0021] The catalyst may be molded into a desired shape without
using a binder. However, a binder may be used if necessary. No
particular limitation is imposed on the binder. However, preferred
binders are alumina, silica, silica-alumina, titania and magnesia,
and most preferred is alumina. No particular limitation is imposed
on the percentage of binder in the whole molded catalyst. However,
it is usually from 5 to 99 percent by mass and preferably from 20
to 99 percent by mass.
[0022] The catalyst of the present invention necessarily contains a
noble metal of Group VIII of the Periodic Table as an active
component. When a metal other than that of Group VIII of the
Periodic Table is used as an active agent, the middle distillate
yield obtained by a hydrocracking process using a catalyst
containing such a metal is extremely reduced thereby failing to
achieve the purposes of the present invention.
[0023] Specific examples of the noble metal of Group VIII of the
Periodic Table include cobalt, nickel, rhodium, palladium, iridium,
and platinum. Most preferred are palladium and platinum. The
catalyst of the present invention can be produced by loading these
metals into the above-described molded catalyst by a well-known
method such as impregnation or ion-exchange.
[0024] If necessary, two or more noble metals may be loaded in
combination. For example, both platinum and palladium may be
loaded. No particular limitation is imposed on the loaded amount of
the noble metal. The amount is usually from 0.02 to 2 percent by
mass based on the total mass of the catalyst.
[0025] In the present invention, the term "paraffinic hydrocarbon"
used herein denotes hydrocarbons the paraffin molecule content of
which is 70 percent by mol or more. No particular limitation is
imposed on the carbon atom number of the hydrocarbon molecules.
However, those having from 10 to 100 carbon atoms are usually used.
The catalyst of the present invention is particularly effective for
hydrocracking paraffinic hydrocarbons having 20 or more carbon
atoms, so-called "wax".
[0026] No particular limitation is imposed on the process for
producing a paraffinic hydrocarbon which will be the feedstock of
the hydrocracking process. Therefore, the catalyst of the present
invention is applicable to various paraffinic hydrocarbons such as
petroleum-based or synthetic paraffinic hydrocarbons. However,
particularly preferred paraffinic hydrocarbons are so-called FT
waxes produced by Fischer-Tropsch synthesis.
[0027] The catalyst of the present invention may be used in a
conventional fixed bed reactor apparatus. The reaction conditions
are a reaction temperature of 200 to 500.degree. C., a hydrogen
pressure of 0.5 to 12 MPa, and an LHSV (liquid hourly space
velocity) of a paraffinic hydrocarbon feedstock of 0.1 to 10/h.
Preferred conditions are a reaction temperature of 250 to
400.degree. C., a hydrogen pressure of 2.0 to 8.0 MPa, and an LHSV
(liquid hourly space velocity) of a paraffinic hydrocarbon
feedstock of 0.3 to 5.0/h.
[0028] When the catalyst of the present invention comprising the
above-described aluminosilicate, alumina-boria and a noble metal of
Group VIII of the Periodic Table is used for hydrocracking
paraffinic hydrocarbons, it can achieve high cracking activity and
middle distillate yield and the low pour point of the resulting
liquid hydrocarbon all together.
[0029] The present invention will be described in more detail with
reference to the following examples and comparative examples but
are not limited thereto.
EXAMPLE 1
[0030] A column-like support with a size of 1/16 inch (about 1.6
mm) comprising 30 g of a USY zeolite with an average particle
diameter of about 0.4 .mu.m and 970 g of alumina-boria was
impregnated with an aqueous solution containing dichlorotetraammine
platinum (II) in such an amount that the amount of the platinum
element was 0.8 percent by mass of the support. The support was
dried at a temperature of 120.degree. C. for 3 hours and calcined
at a temperature of 500.degree. C. for one hour thereby preparing a
catalyst.
[0031] The catalyst thus prepared (200 ml) was filled into a fixed
bed flow reactor and used to hydrocrack a paraffinic hydrocarbon.
The feedstock used herein was an FT wax whose paraffin content was
95 percent and carbon number distribution was from 20 to 80. The
hydrogen pressure was 3 MPa, while the LHSV of the feedstock was
2.0/h. The fraction whose boiling point was 360.degree. C. or lower
was defined as "cracked product". The reaction temperature at which
the cracked product in an amount of 80 percent by mass based on the
feed stock was obtained was measured. Also measured were the yield
of the middle distillate whose boiling point was from 145.degree.
C. to 360.degree. C. and the pour point of the resulting gas oil
whose boiling point was from 260.degree. C. to 360.degree. C. The
results are set forth in Table 1 below.
EXAMPLE 2
[0032] 30 g of a USY zeolite with an average particle diameter of
about 0.4 .mu.m, 570 g of alumina-boria powder, and 400 g of
alumina used as a binder were molded thereby obtaining a
column-like support with a size of 1/16 inch (about 1.6 mm).
Platinum was loaded into the support such that the amount of the
platinum was 0.8 percent by mass of the support in the same manner
as Example 1. The support was dried at a temperature of 120.degree.
C. for 3 hours and calcined at a temperature of 500.degree. C. for
one hour thereby preparing a catalyst.
[0033] Hydrocracking was conducted using this catalyst in the same
manner as Example 1 so as to measure the reaction temperature at
which the cracked product in an amount of 80 percent by mass based
on the feed stock was obtained, the yield of the middle distillate
whose boiling point was from 145.degree. C. to 360.degree. C. and
the pour point of the resulting gas oil whose boiling point was
from 260.degree. C. to 360.degree. C. The results are set forth in
Table 1 below.
EXAMPLE 3
[0034] Preparation of a catalyst and hydrocracking were conducted
by the same procedures of Example 1 except that a USY-type zeolite
with an average particle diameter of 0.8 .mu.m was used so as to
measure the reaction temperature at which the cracked product in an
amount of 80 percent by mass based on the feed stock was obtained,
the yield of the middle distillate whose boiling point was from
145.degree. C. to 360.degree. C. and the pour point of the
resulting gas oil whose boiling point was from 260.degree. C. to
360.degree. C. The results are set forth in Table 1 below.
COMPARATIVE EXAMPLE 1
[0035] Preparation of a catalyst and hydrocracking were conducted
by the same procedures of Example 1 except that alumina was used
instead of alumina-boria so as to measure the reaction temperature
at which the cracked product in an amount of 80 percent by mass
based on the feed stock was obtained, the yield of the middle
distillate whose boiling point was from 145.degree. C. to
360.degree. C. and the pour point of the resulting gas oil whose
boiling point was from 260.degree. C. to 360.degree. C. The results
are set forth in Table 1 below.
COMPARATIVE EXAMPLE 2
[0036] Preparation of a catalyst and hydrocracking were conducted
by the same procedures of Example 1 except that a USY-type zeolite
was not used so as to measure the reaction temperature at which the
cracked product in an amount of 80 percent by mass based on the
feed stock was obtained, the yield of the middle distillate whose
boiling point was from 145.degree. C. to 360.degree. C. and the
pour point of the resulting gas oil whose boiling point was from
260.degree. C. to 360.degree. C. The results are set forth in Table
1 below.
COMPARATIVE EXAMPLE 3
[0037] Preparation of a catalyst and hydrocracking were conducted
by the same procedures of Example 1 except that the support loaded
with nickel in an amount of 5 percent by mass based on the support
and tungsten in an amount of 15 percent by mass based on the
support instead of platinum so as to measure the reaction
temperature at which the cracked product in an amount of 80 percent
by mass based on the feed stock was obtained, the yield of the
middle distillate whose boiling point was from 145.degree. C. to
360.degree. C. and the pour point of the resulting gas oil whose
boiling point was from 260.degree. C. to 360.degree. C. The results
are set forth in Table 1 below.
[0038] As apparent from the results set forth in Table 1, the
combination of a crystalline aluminosilicate and alumina-boria can
satisfy high cracking activity, high middle distillate yield and
the low pour point of the resulting gas oil all together.
Furthermore, it was also apparent that noble metals of the Group
VIII of the Periodic Table are effective as active metals.
TABLE-US-00001 TABLE 1 Middle Cracking Distillate Pour Point of
Temperature Yield Resulting Gas Oil .degree. C. mass % .degree. C.
Example 1 298 52.9 -37.5 Example 2 305 53.0 -37.5 Example 3 301
50.9 -37.5 Comparative Example 1 330 47.5 -30.0 Comparative Example
2 355 47.4 -37.5 Comparative Example 3 361 25.5 -35.0
[0039] It will be appreciated by those skilled in the art that
changes could be made to the embodiments described above without
departing from the broad inventive concept thereof. It is
understood, therefore, that this invention is not limited to the
particular embodiments disclosed, but it is intended to cover
modifications within the spirit and scope of the present invention
as defined by the appended claims.
* * * * *