U.S. patent application number 11/866929 was filed with the patent office on 2008-04-10 for methods for producing a crude product.
Invention is credited to Opinder Kishan BHAN, Scott Lee Wellington.
Application Number | 20080083650 11/866929 |
Document ID | / |
Family ID | 38996723 |
Filed Date | 2008-04-10 |
United States Patent
Application |
20080083650 |
Kind Code |
A1 |
BHAN; Opinder Kishan ; et
al. |
April 10, 2008 |
METHODS FOR PRODUCING A CRUDE PRODUCT
Abstract
Methods for conversion of a hydrocarbon feed to a total product
are described. Contact of the hydrocarbon feed with one or more
catalysts at controlled contacting conditions produces the total
product. The total product includes a crude product that is a
liquid mixture at 25.degree. C. and 0.101 MPa and has a basic
nitrogen content of at most 90% of the basic nitrogen content of
the hydrocarbon feed.
Inventors: |
BHAN; Opinder Kishan; (Katy,
TX) ; Wellington; Scott Lee; (Bellaire, TX) |
Correspondence
Address: |
Shell Oil Company
910 Louisiana
Houston
TX
77002
US
|
Family ID: |
38996723 |
Appl. No.: |
11/866929 |
Filed: |
October 3, 2007 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60850109 |
Oct 6, 2006 |
|
|
|
Current U.S.
Class: |
208/46 |
Current CPC
Class: |
B01J 23/22 20130101;
B01J 35/1042 20130101; B01J 21/04 20130101; C10G 45/08 20130101;
B01J 35/002 20130101; C10G 2300/4012 20130101; B01J 35/1061
20130101; B01J 23/882 20130101; B01J 37/0009 20130101; C10G
2300/208 20130101; B01J 37/0203 20130101; C10G 65/12 20130101; C10G
47/00 20130101; C10G 47/12 20130101; B01J 35/1019 20130101; C10G
49/04 20130101; C10G 2300/308 20130101; B01J 23/28 20130101; B01J
35/108 20130101; C10G 47/10 20130101; C10G 2300/4006 20130101; C10G
2300/4018 20130101; C10G 2300/302 20130101; B01J 23/883 20130101;
C10G 45/04 20130101; C10G 2300/206 20130101 |
Class at
Publication: |
208/046 |
International
Class: |
C10G 35/04 20060101
C10G035/04 |
Claims
1. A method of producing a crude product, comprising: contacting a
hydrocarbon feed with one or more catalysts to produce a total
product that includes the crude product, wherein the crude product
is a liquid mixture at 25.degree. C. and 0.101 MPa, the hydrocarbon
feed having a basic nitrogen content of at least 0.0001 grams per
gram of hydrocarbon feed, at least one of the catalysts has at
least 0.01 grams of one or more metals from Column 6 of the
Periodic Table and/or one or more compounds of one or more metals
from Column 6 of the Periodic Table per gram of catalyst, the
Column 6 metal catalyst having a pore size distribution with median
pore diameter of between 50 angstroms and 180 angstroms;
controlling contacting conditions at a pressure of at least 3 MPa
and a temperature of at least 300.degree. C. to produce the crude
product, the crude product having a basic nitrogen content of at
most 90% of the basic nitrogen content of the hydrocarbon feed and
wherein basic nitrogen is as determined by ASTM Method D2896.
2. The method of claim 1, wherein the Column 6 metal catalyst
comprises molybdenum.
3. The method of claim 1, wherein the Column 6 metal catalyst
comprises at most 0.1 grams of molybdenum per gram of catalyst.
4. The method of claim 1, wherein the Column 6 metal catalyst is a
supported catalyst, and wherein the support comprises alumina,
silica, silica-alumina, titanium oxide, zirconium oxide, magnesium
oxide, or mixtures thereof.
5. The method of claim 1, wherein the Column 6 metal catalyst has a
pore size distribution with a median pore diameter from 55
angstroms to 150 angstroms, from 60 angstroms to 135 angstroms, or
from 70 angstroms to 120 angstroms.
6. The method of claim 1, wherein the Column 6 metal catalyst has a
surface area of at least 200 m.sup.2/g.
7. The method of claim 1, wherein the Column 6 metal catalyst
comprises molybdenum, nickel, cobalt or mixtures thereof.
8. The method of claim 1, wherein the Column 6 metal catalyst
further comprises one or more elements from Column 15 of the
Periodic Table and/or one or more compounds of one or more elements
from Column 15 of the Periodic Table.
9. The method of claim 1, wherein the hydrocarbon feed has an API
gravity of at most 10.
10. The method of claim 1, wherein the crude product has an
increase in API gravity of at least 5 relative to the API gravity
of the hydrocarbon feed.
11. The method of claim 1, wherein the hydrocarbon feed has at
least 0.01 grams of C.sub.5 asphaltenes per gram of hydrocarbon
feed, and wherein the crude product has a C.sub.5 asphaltenes
content of at most 90% of the hydrocarbon feed C.sub.5 asphaltenes
content.
12. The method of claim 1, wherein the hydrocarbon feed has a MCR
content of at least 0.002 grams of MCR per gram of crude, and
wherein the crude product has an MCR content of at most 90% of the
MCR content of the hydrocarbon feed MCR content.
13. The method of claim 1, wherein the hydrocarbon feed has a
viscosity of at least 10 cSt at 37.8.degree. C., and wherein the
crude product has a viscosity at 37.8.degree. C. of at most 50% of
the viscosity of the hydrocarbon feed at 37.8.degree. C.
14. The method of claim 1, wherein the crude product has a residue
content of at most 80%, at most 70%, or at most 60% of the
hydrocarbon feed residue content.
15. The method of claim 1, wherein the hydrocarbon feed is
contacted with one or more catalysts in a fixed bed reactor.
16. The method of claim 1, further comprising heating the one or
more catalysts to a temperature of at least 400.degree. C. in a
time period of less than three weeks.
17. The method of claim 16, wherein the one or more catalysts are
heated prior to contacting the hydrocarbon feed with the one or
more catalysts.
18. The method of claim 1, wherein the method further comprises
fractionating the crude product into one or more distillate
fractions, and producing transportation fuel from at least one of
the distillate fractions.
Description
RELATED APPLICATION
[0001] The present application claims the benefit of the filing
date of U.S. Provisional patent application Ser. No. 60/850,109
filed Oct. 6, 2006, the disclosure of which is incorporated herein
by reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to systems, methods,
and catalysts for treating hydrocarbon feeds, and to compositions
that can be produced using such systems, methods, and catalysts.
More particularly, certain embodiments described herein relate to
systems, methods, and catalysts for conversion of a hydrocarbon
feed to a total product, wherein the total product includes a crude
product that is a liquid mixture at 25.degree. C. and 0.101 MPa and
has one or more properties that are changed relative to the
respective property of the hydrocarbon feed.
DESCRIPTION OF RELATED ART
[0003] Crudes that have one or more unsuitable properties that do
not allow the crudes to be economically transported, or processed
using conventional facilities, are commonly referred to as
"disadvantaged crudes".
[0004] Disadvantaged crudes may include acidic components that
contribute to the total acid number ("TAN") of the crude feed.
Disadvantaged crudes with a relatively high TAN may contribute to
corrosion of metal components during transporting and/or processing
of the disadvantaged crudes. Removal of acidic components from
disadvantaged crudes may involve chemically neutralizing acidic
components with various bases. Alternately, corrosion-resistant
metals may be used in transportation equipment and/or processing
equipment. The use of corrosion-resistant metal often involves
significant expense, and thus, the use of corrosion-resistant metal
in existing equipment may not be desirable. Another method to
inhibit corrosion may involve addition of corrosion inhibitors to
disadvantaged crudes before transporting and/or processing of the
disadvantaged crudes. The use of corrosion inhibitors may
negatively affect equipment used to process the crudes and/or the
quality of products produced from the crudes.
[0005] Disadvantaged crudes often contain relatively high levels of
residue. Disadvantaged crudes having such high levels of residue
tend to be difficult and expensive to transport and/or process
using conventional facilities.
[0006] Disadvantaged crudes may include relatively high amounts of
metal contaminants, for example, nickel, vanadium, and/or iron.
During processing of such crudes, metal contaminants and/or
compounds of metal contaminants, may deposit on a surface of the
catalyst or in the void volume of the catalyst. Such deposits may
cause a decline in the activity of the catalyst.
[0007] Coke may form and/or deposit on catalyst surfaces at a rapid
rate during processing of disadvantaged crudes. It may be costly to
regenerate the catalytic activity of a catalyst contaminated with
coke. High temperatures used during regeneration may also diminish
the activity of the catalyst and/or cause the catalyst to
deteriorate.
[0008] Disadvantaged crudes may include metals in metal salts of
organic acids (for example, calcium, potassium and/or sodium).
Metals in metal salts of organic acids are not typically separated
from disadvantaged crudes by conventional processes, for example,
desalting and/or acid washing.
[0009] Processes are often encountered in conventional processes
when metals in metal salts of organic acids are present. In
contrast to nickel and vanadium, which typically deposit near the
external surface of the catalyst, metals in metal salts of organic
acids may deposit preferentially in void volumes between catalyst
particles, particularly at the top of the catalyst bed. The deposit
of contaminants, for example, metals in metal salts of organic
acids, at the top of the catalyst bed, generally results in an
increase in pressure drop through the bed and may effectively plug
the catalyst bed. Moreover, the metals in metal salts of organic
acids may cause rapid deactivation of catalysts.
[0010] Disadvantaged crudes often contain organically bound
heteroatoms (for example, sulfur, oxygen, and nitrogen).
Organically bound heteroatoms may, in some situations, have an
adverse effect on catalysts.
[0011] Disadvantaged crudes may include organic oxygen compounds.
Treatment facilities that process disadvantaged crudes with an
oxygen content of at least 0.002 grams of oxygen per gram of
disadvantaged crude may encounter problems during processing.
Organic oxygen compounds, when heated during processing, may form
higher oxidation compounds (for example, ketones and/or acids
formed by oxidation of alcohols, and/or acids formed by oxidation
of ethers) that are difficult to remove from the treated crude
and/or may corrode/contaminate equipment during processing and
cause plugging in transportation lines.
[0012] Disadvantaged crudes may include basic nitrogen compounds
(for example, pyridine, quinolines, isoquinolines, benzoquinolines,
pyrroles, carbazoles, benzocarbazoles, and homologs thereof. Basic
nitrogen compounds may have adverse effects on catalysts used in
cracking processes, thus reducing the efficiency of the cracking
operation. Basic nitrogen compounds, when heated during processing,
may form high molecular weight compounds that contribute to gum
formation in operating units.
[0013] Disadvantaged crudes may include hydrogen deficient
hydrocarbons. When processing of hydrogen deficient hydrocarbons,
consistent quantities of hydrogen generally need to be added,
particularly if unsaturated fragments resulting from cracking
processes are produced. Hydrogenation during processing, which
typically involves the use of an active hydrogenation catalyst, may
be needed to inhibit unsaturated fragments from forming coke.
Hydrogen is costly to produce and/or costly to transport to
treatment facilities.
[0014] Disadvantaged crudes also tend to exhibit instability during
processing in conventional facilities. Crude instability tends to
result in phase separation of components during processing and/or
formation of undesirable by-products (for example, hydrogen
sulfide, water, and carbon dioxide).
[0015] Conventional processes often lack the ability to change a
selected property in a disadvantaged crude without also
significantly changing other properties in the disadvantaged crude.
For example, conventional processes often lack the ability to
significantly reduce TAN in a disadvantaged crude while, at the
same time, only changing by a desired amount the content of certain
components (such as sulfur or metal contaminants) in the
disadvantaged crude.
[0016] Some processes for improving the quality of crude include
adding a diluent to disadvantaged crudes to lower the weight
percent of components contributing to the disadvantaged properties.
Adding diluent, however, generally increases costs of treating
disadvantaged crudes due to the costs of diluent and/or increased
costs to handle the disadvantaged crudes. Addition of diluent to a
disadvantaged crude may, in some situations, decrease stability of
such crude.
[0017] U.S. Pat. Nos. 6,554,994 to Reynolds et al.; 6,547,957 to
Sudhakar et al.; 6,436,280 to Harle et al.; 6,277,269 to Meyers et
al.; 6,162,350 to Soled et al.; 6,063,266 to Grande et al.;
5,928,502 to Bearden et al.; 5,928,501 to Sudhakar et al.;
5,914,030 to Bearden et al.; 5,897,769 to Trachte et al.; 5,871,636
to Trachte et al.; and 5,851,381 to Tanaka et al.; 5,322,617 to de
Bruijn et al.; 4,992,163 to Aldridge et al.; 4,937,222 to Angevine
et al.; 4,886,594 to Miller; 4,746,419 to Peck et al.; 4,548,710 to
Simpson; 4,525,472 to Morales et al.; 4,457,836 to Seiver et al.;
4,499,203 to Toulhoat et al.; 4,389,301 to Dahlberg et al.;
4,191,636 to Fukui et al.; U.S. Published Patent Application Nos.
20050133414 through 20050133418 to Bhan et al.; 20050139518 through
20050139522 to Bhan et al.; 20050145543 to Bhan et al.; 20050150818
to Bhan et al.; 20050155908 to Bhan et al.; 20050167320 to Bhan et
al.; 20050167324 through 20050167332 to Bhan et al.; 20050173301
through 20050173303 to Bhan et al., 20060060510 to Bhan; and U.S.
patent application Ser. Nos. 11/400,542; 11/400,294; 11/399,843;
11/400,628; and 11/400,295, all entitled "Systems, Methods, and
Catalysts for Producing a Crude Product" and all filed Apr. 7,
2006; 11/425,979; 11/425,983; 11/425,985 to Bhan all entitled
"Systems, Methods, and Catalysts for Producing a Crude Product" and
all filed Jun. 6, 2006 describe various processes, systems, and
catalysts for processing crudes.
[0018] In sum, disadvantaged crudes generally have undesirable
properties (for example, relatively high residue content, a
tendency to become unstable during treatment, and/or a tendency to
consume relatively large amounts of hydrogen during treatment).
Other undesirable properties include relatively high amounts of
undesirable components (for example, residue, organically bound
heteroatoms, metal contaminants, metals in metal salts of organic
acids, and/or organic oxygen compounds). Such properties tend to
cause problems in conventional transportation and/or treatment
facilities, including increased corrosion, decreased catalyst life,
process plugging, and/or increased usage of hydrogen during
treatment. Thus, there is a significant economic and technical need
for improved systems, methods, and/or catalysts for conversion of
disadvantaged crudes into crude products with more desirable
properties. There is also a significant economic and technical need
for systems, methods, and/or catalysts that can change selected
properties in a disadvantaged crude while only selectively changing
other properties in the disadvantaged crude.
SUMMARY OF THE INVENTION
[0019] Inventions described herein generally relate to systems,
methods, and catalyst for conversion of a hydrocarbon feed to a
total product comprising a crude product and, in some embodiments,
non-condensable gas. Inventions described herein also generally
relate to compositions that have novel combinations of components
therein. Such compositions can be obtained by using the systems and
methods described herein.
[0020] In some embodiments, the invention describes a method of
producing a crude product, that includes contacting a hydrocarbon
feed with one or more catalysts to produce a total product that
includes the crude product, wherein the crude product is a liquid
mixture at 25.degree. C. and 0.101 MPa, the hydrocarbon feed having
a molybdenum content of at least 0.1 wtppm of molybdenum, the
hydrocarbon feed having a Ni/V/Fe content of at least 10 wtppm, at
least one of the catalysts comprising one or more metals from
Columns 6-10 of the Periodic Table and/or one or more compounds of
one or more metals from Columns 6-10 of the Periodic Table, and the
Columns 6-10 metals catalyst having a pore size distribution with a
median pore diameter of up to 150 angstroms; and controlling
contacting conditions at a temperature of at least 300.degree. C.,
a partial pressure of hydrogen of at most 7 MPa, and a LHSV of at
least 0.1 h.sup.-1 to produce the crude product, the crude product
having a molybdenum content of at most 90% of the molybdenum
content of the hydrocarbon feed and a Ni/V/Fe content between 80%
and 120% of the Ni/V/Fe content of the hydrocarbon feed, wherein
molybdenum and Ni/V/Fe contents are as determined by ASTM Method
D5708 and median pore diameter is as determined by ASTM Method
D4284.
[0021] In some embodiments, the invention describes a method of
producing a crude product that includes contacting a hydrocarbon
feed with one or more catalysts to produce a total product that
includes the crude product, wherein the crude product is a liquid
mixture at 25.degree. C. and 0.101 MPa, the hydrocarbon feed
having, per gram of hydrocarbon feed, a total Ni/V/Fe content of at
least 0.00002 grams, and a total C.sub.5 and C.sub.7 asphaltene
content of at least 0.01 grams, and at least one of the catalysts
comprising one or more metals from Columns 6-10 of the Periodic
Table, and/or one or more compounds of one or more metals from
Columns 6-10 of the Periodic Table; and controlling contacting
conditions at a temperature of at least 300.degree. C., a partial
pressure of hydrogen of at most 7 MPa, and a LHSV of at least 0.1
h.sup.-1 to produce the crude product, the crude product having a
Ni/V/Fe content between 80% and 120% of the Ni/V/Fe content of the
hydrocarbon feed and a total C.sub.5 and C.sub.7 asphaltene content
of at most 90% of the hydrocarbon feed C.sub.5 and C.sub.7
asphaltene content, wherein the C.sub.5 and C.sub.7 asphaltenes
content is a sum of the C.sub.5 asphaltenes as determined by ASTM
Method D2007 and C.sub.7 asphaltenes as determined by ASTM Method
D3279.
[0022] In some embodiments, the invention describes a method of
producing a crude product that includes contacting a hydrocarbon
feed with one or more catalysts to produce a total product that
includes the crude product, wherein the crude product is a liquid
mixture at 25.degree. C. and 0.101 MPa, the hydrocarbon feed
having, per gram of hydrocarbon feed, a total Ni/V/Fe content of at
least 0.00002 grams, and viscosity of at least 10 cSt at
37.8.degree. C. and at least one of the catalysts comprising one or
more metals from Column 6 of the Periodic Table, and/or one or more
compounds of one or more metals from Column 6 of the Periodic
Table; and controlling contacting conditions at a temperature of at
least 300.degree. C., a partial pressure of hydrogen of at most 7
MPa, and a LHSV of at least 0.1 h.sup.-1 to produce the crude
product, the crude product having a Ni/V/Fe content between 80% and
120% of the Ni/V/Fe content of the hydrocarbon feed and a viscosity
at 37.8.degree. C. of at most 50% of the viscosity of the
hydrocarbon feed at 37.8.degree. C., wherein viscosity is as
determined by ASTM Method D445.
[0023] In some embodiments, the invention describes a method of
producing a crude product that includes contacting a hydrocarbon
feed with one or more catalysts to produce a total product that
includes the crude product, wherein the crude product is a liquid
mixture at 25.degree. C. and 0.101 MPa, the hydrocarbon feed
having, per gram of hydrocarbon feed, a total Ni/V/Fe content of at
least 0.00002 grams, and a total residue content of at least 0.1
grams, and at least one of the catalysts comprising one or more
metals from Columns 6-10 of the Periodic Table, and/or one or more
compounds of one or more metals from Columns 6-10 of the Periodic
Table; and controlling contacting conditions at a temperature of at
least 300.degree. C., a partial pressure of hydrogen of at most 7
MPa, and a LHSV of at least 0.1 h.sup.-1 to produce the crude
product, the crude product having a Ni/V/Fe content between 80% to
120% of the Ni/V/Fe content of the hydrocarbon feed and a residue
content of at most 90% of the hydrocarbon feed residue content,
wherein Ni/V/Fe content is as determined by ASTM Method D5708 and
residue content is as determined by ASTM Method D5307.
[0024] In some embodiments, the invention describes a method of
producing a crude product that includes contacting a hydrocarbon
feed with one or more catalysts positioned in one or more
contacting zones of a fixed bed reactor to produce a total product
that includes the crude product, wherein the crude product is a
liquid mixture at 25.degree. C. and 0.101 MPa, the hydrocarbon feed
having, per gram of hydrocarbon feed, a total residue content of at
least 0.1 grams, and at least one of the catalysts comprising one
or more metals from Column 6 of the Periodic Table, and/or one or
more compounds of one or more metals from Column 6 of the Periodic
Table; and controlling contacting conditions at a temperature of at
least 300.degree. C., a partial pressure of hydrogen of at most 7
MPa, and a LHSV of at least 0.1 h.sup.-1 to produce the crude
product, the crude product a residue content of at most 90% of the
hydrocarbon feed residue content.
[0025] In some embodiments, the invention provides a hydrocarbon
composition that includes per gram of hydrocarbon composition: at
least 0.001 grams of hydrocarbons with a boiling range distribution
between 38.degree. C. and 200.degree. C. at 0.101 MPa; at least
0.001 grams of hydrocarbons with a boiling range distribution
between 204.degree. C. and 343.degree. C. at 0.101 MPa; at least
0.001 grams of hydrocarbons with a boiling range distribution
between 343.degree. C. and 650.degree. C. at 0.101 MPa; at least
0.001 grams of hydrocarbons with an initial boiling point of at
least 650.degree. C. at 0.101 MPa; at least 0.000150 grams of
Ni/V/Fe; and at most 0.01 grams of C.sub.5 asphaltenes.
[0026] In some embodiments, the invention describes a method of
producing a crude product that includes contacting a hydrocarbon
feed with one or more catalysts to produce a total product that
includes the crude product, wherein the crude product is a liquid
mixture at 25.degree. C. and 0.101 MPa, the hydrocarbon feed having
a viscosity of at least 10 cSt at 37.8.degree. C.; at least one of
the catalysts comprises one or more metals from Columns 6-10 of the
Periodic Table and/or one or more compounds of one or more metals
from Columns 6-10 of the Periodic Table; and controlling contacting
conditions at a temperature from 370.degree. C. to 450.degree. C.,
a partial pressure of hydrogen of at most 7 MPa, and an liquid
hourly space velocity (LHSV) of at least 0.1 h.sup.-1 to produce
the crude product, the crude product having a viscosity at
37.8.degree. C. of at most 50% of the viscosity of the hydrocarbon
feed at 37.8.degree. C., and wherein a P-value of a hydrocarbon
feed/total product mixture is at least 1.0 during contacting,
wherein viscosity is as determined by ASTM Method D445 and P-Value
is as determined by ASTM Method D7060.
[0027] In some embodiments, the invention describes a method of
treating a hydrocarbon feed that includes contacting a hydrocarbon
feed with hydrogen in the presence of one or more catalysts to
produce a total product that includes the crude product, wherein
the crude product is a liquid mixture at 25.degree. C. and 0.101
MPa and the hydrocarbon feed has a viscosity of at least 10 cSt at
37.8.degree. C.; and controlling contacting conditions at a partial
pressure of hydrogen of at most 7 MPa and a temperature of at most
450.degree. C. such that a P-value of a hydrocarbon feed/total
product mixture remains at least 1.0, a total consumption of
hydrogen is at most 80 Nm.sup.3/m.sup.3, and the crude product has
a viscosity of at most 50% at 37.8.degree. C. of the hydrocarbon
feed viscosity, wherein viscosity is as determined by ASTM Method
D445 and P-Value is as determined by ASTM Method D7060.
[0028] In some embodiments, the invention describes a system for
treating a hydrocarbon feed that includes an upstream contacting
system comprising one or more catalysts, at least one of the
catalysts comprising one or more metals from Column 6-10 of the
Periodic Table, and/or one or more compounds of one or more metals
from Column 6-10 of the Periodic Table; wherein contacting a first
feed having a viscosity of at least 100 cSt at 37.8.degree. C.,
with one or more of the catalysts in the upstream contacting system
at a temperature of at least 300.degree. C., a partial pressure of
hydrogen of at most 7 MPa, and a LHSV of at least 0.1 h.sup.-1
produces a crude product having a viscosity at 37.8.degree. C. of
at most 50% of the viscosity of the first feed at 37.8.degree. C.;
and a downstream contacting system coupled to the upstream
contacting system and configured to receive and process a feed
exiting the upstream contacting system, wherein the downstream
contacting system is configured to subject the feed exciting the
upstream contacting system to a cracking process.
[0029] In some embodiments, the invention describes a system for
treating a hydrocarbon feed comprising: an upstream contacting
system comprising one or more catalysts, at least one of the
catalysts comprising one or more metals from Column 6 of the
Periodic Table, and/or one or more compounds of one or more metals
from Column 6 of the Periodic Table; wherein contacting a first
feed having a viscosity of at least 100 cSt at 37.8.degree. C.,
with one or more of the catalysts in the upstream contacting system
at a temperature of at least 300.degree. C., a partial pressure of
hydrogen of at most 7 MPa, and a LHSV of at least 0.1 h.sup.-1
produces a crude product having a viscosity at 37.8.degree. C. of
at most 50% of the viscosity of the first feed at 37.8.degree. C.;
and a downstream contacting system coupled to the upstream
contacting system and configured to receive and process a feed
exiting the upstream contacting system, wherein the downstream
contacting system comprises a deasphalting unit.
[0030] In some embodiments, the invention describes a system
producing a crude product that comprising. an upstream contacting
system comprising one or more catalysts, at least one of the
upstream catalysts comprising, per gram of catalyst, 0.0001 grams
to 0.1 grams of one or more metals from Column 6 of the Periodic
Table and/or one or more compounds of one or more metals from
Column 6 of the Periodic Table, wherein contact of a hydrocarbon
feed having a molybdenum content of at least 0.1 wtppm of
molybdenum and at least 0.1 grams of residue per gram of
hydrocarbon feed, with one or more of the catalysts in the upstream
contacting system at a temperature of at most 450.degree. C. and 7
MPa produces a hydrocarbon feed/total product mixture, the
hydrocarbon feed/total product mixture having a molybdenum content
of at most 90% of the molybdenum of the hydrocarbon feed; and a
downstream contacting zone coupled to the upstream contacting zone,
the downstream contacting zone configured to receive the
hydrocarbon feed/total product mixture, the downstream contacting
system comprising one or more catalysts, at least one of the
downstream catalysts comprising, per gram of catalyst, at least 0.1
grams of one or more metals from Columns 6-10 of the Periodic Table
and/or one or more compounds of one or more metals from Columns
6-10 of the Periodic Table, the Columns 6-10 catalyst having a pore
size distribution with a median pore diameter of between 50
angstrom and 150 angstrom, wherein contact of the hydrocarbon
feed/total product mixture at a temperature of at most 450.degree.
C. and 7 MPa produces a total product that includes a crude
product, wherein the crude product is a liquid mixture at
25.degree. C. and 0.101 MPa and the crude product has a molybdenum
content of at most 90% of the molybdenum content of the hydrocarbon
feed and at most 90% of the residue content of the hydrocarbon
feed. The invention also provides a method of producing a crude
product with molybdenum reduction using said system.
[0031] In some embodiments, the invention produces a hydrocarbon
composition that includes at least 0.1 wtppm of molybdenum; at
least 0.01 grams of hydrocarbons having a boiling range
distribution between 38.degree. C. and 200.degree. C. per gram of
hydrocarbon composition; and at least 0.1 grams of hydrocarbons
having a boiling range distribution between 343.degree. C. and
650.degree. C. per gram of hydrocarbon composition.
[0032] In some embodiments, the invention provides a method of
producing a crude product, that includes contacting a hydrocarbon
feed with one or more catalysts to produce a total product that
includes the crude product, wherein the crude product is a liquid
mixture at 25.degree. C. and 0.101 MPa, the hydrocarbon feed having
a basic nitrogen content of at least 0.0001 grams per gram of
hydrocarbon feed, at least one of the catalysts has at least 0.01
grams of one or more metals from Column 6 of the Periodic Table
and/or one or more compounds of one or more metals from Column 6 of
the Periodic Table per gram of catalyst, the Column 6 metal
catalyst having a pore size distribution with median pore diameter
of between 50 angstroms and 180 angstroms; controlling contacting
conditions at a pressure of at least 3 MPa and a temperature of at
least 300.degree. C. to produce the crude product, the crude
product having a basic nitrogen content of at most 90% of the basic
nitrogen content of the hydrocarbon feed.
[0033] In some embodiments, the invention provides a method of
producing a crude product, that includes contacting a hydrocarbon
feed with one or more catalysts to produce a total product that
includes the crude product, wherein the crude product is a liquid
mixture at 25.degree. C. and 0.101 MPa; the hydrocarbon feed has a
residue content of at least 0.1 grams per gram of hydrocarbon feed;
and at least one of the catalysts is obtainable by combining: a
supported catalyst; one or more metals from Column 6 of the
Periodic Table and/or one or more compounds of one or more metals
from Column 6 of the Periodic Table; and a support; and controlling
contacting conditions at a partial pressure of hydrogen of least 3
MPa and a temperature of least 200.degree. C. to produce the crude
product; the crude product having a residue content of at most 90%
of the residue content of the hydrocarbon feed.
[0034] In some embodiments, the invention provides a method of
producing a crude product that includes contacting a hydrocarbon
feed with one or more catalysts to produce a total product that
includes the crude product, wherein the crude product is a liquid
mixture at 25.degree. C. and 0.101 MPa; the hydrocarbon feed has a
micro-carbon residue (MCR) content of at least 0.0001 grams per
gram of hydrocarbon feed; and at least one of the catalysts has:
one or more metals from Column 6 of the Periodic Table and/or one
or more compounds of one or more metals from Column 6 of the
Periodic Table; and one or more metals from Columns 9-10 of the
Periodic Table and/or one or more compounds of one or more metals
from Columns 9-10 of the Periodic Table; and controlling contacting
conditions at a partial pressure of hydrogen of at least 3 MPa and
a temperature of at least 200.degree. C. to produce the crude
product, the crude product having a MCR content of at most 90% of
the MCR content of the hydrocarbon feed, wherein MCR content is as
determined by ASTM Method D4530.
[0035] In some embodiments, the invention provides a method of
producing a crude product that includes providing one or more
catalysts to a contacting zone, wherein at least one of the
catalysts is a Column 6 metal catalyst, wherein the Column 6 metal
catalyst is produced by the method comprising: combining one or
more metals from Column 6 of the Periodic Table and/or one or more
compounds of one or more metals from Column 6 of the Periodic Table
with a support to form a mixture; and heating the mixture to a
temperature of at most 200.degree. C. to form a dried Column 6
metal catalyst; contacting a hydrocarbon feed with the dried Column
6 metal catalyst to produce a total product that includes the crude
product, wherein the crude product is a liquid mixture at
25.degree. C. and 0.101 MPa; wherein the hydrocarbon feed has a
residue content of at least 0.1 grams per gram of hydrocarbon feed,
and wherein contact of the hydrocarbon feed with the dried catalyst
at least partially sulfides the catalyst; and controlling
contacting conditions at a partial pressure of hydrogen of at least
3 MPa and a temperature of at least 200.degree. C. such that the
crude product has a residue content of at most 90% of the residue
content of the hydrocarbon feed.
[0036] In some embodiments, the invention provides a method of
producing a crude product that includes contacting a hydrocarbon
feed with one or more catalysts to produce a total product that
includes the crude product, wherein the crude product is a liquid
mixture at 25.degree. C. and 0.101 MPa; the hydrocarbon feed has a
residue content of at least 0.1 grams per gram of hydrocarbon feed;
and at least one of the catalysts has at most 0.1 grams, per gram
of catalyst, of: one or more metals from Column 6 of the Periodic
Table and/or one or more compounds of one or more metals from
Column 6 of the Periodic Table; and one or more metals from Columns
9-10 of the Periodic Table and/or one or more compounds of one or
more metals from Columns 9-10 of the Periodic Table, and a pore
size distribution with a median pore diameter between 50 .ANG. and
120 .ANG.; and controlling contacting conditions at a partial
pressure of hydrogen of at least 3 MPa and a temperature of at
least 200.degree. C. to produce the crude product, the crude
product having a residue content of at most 90% of the residue
content of the hydrocarbon feed.
[0037] In some embodiments, the invention provides a method of
producing a crude product that includes contacting a crude feed
with one or more catalysts to produce a total product that includes
the crude product, wherein the crude product is a liquid mixture at
25.degree. C. and 0.101 MPa; the crude feed having a residue
content of at least 0.1 grams per gram of crude feed; and wherein
at least one of the catalysts has, per gram of catalyst, at least
0.3 grams of: one or more metals from Columns 6-10 of the Periodic
Table and/or one or more compounds of one or more metals from
Columns 6-10 of the Periodic Table; and a binder; and controlling
contacting conditions at a partial pressure of hydrogen of at least
3 MPa and a temperature of at least 200.degree. C. such that the
crude product has a residue content of at most 90% of the residue
content of the hydrocarbon feed.
[0038] In some embodiments, the invention describes a method of
producing a crude product that includes contacting a hydrocarbon
feed with one or more catalysts to produce a total product that
includes the crude product, wherein the crude product is a liquid
mixture at 25.degree. C. and 0.101 MPa; the hydrocarbon feed has a
residue content of at least 0.1 grams per gram of hydrocarbon feed;
and at least one of the catalysts is obtainable by combining: a
mineral oxide having an average particle diameter of at most 500
micrometers; one or more metals from Column 6 of the Periodic Table
and/or one or more compounds of one or more metals from Column 6 of
the Periodic Table; and a support; and controlling contacting
conditions at a partial pressure of hydrogen of least 3 MPa and a
temperature of least 200.degree. C. to produce the crude product;
the crude product having a residue content of at most 90% of the
residue content of the hydrocarbon feed.
[0039] In some embodiments, the invention provides a method of
producing a crude product that includes contacting a hydrocarbon
feed with one or more catalysts to produce a total product that
includes the crude product, wherein the crude product is a liquid
mixture at 25.degree. C. and 0.101 MPa; the hydrocarbon feed has a
viscosity of at least 10 cSt at 37.8.degree. C.; and at least one
of the catalysts is obtainable by combining: a mineral oxide fines;
one or more metals from Column 6 of the Periodic Table and/or one
or more compounds of one or more metals from Column 6 of the
Periodic Table; and a support; and controlling contacting
conditions at a partial pressure of hydrogen of at most 7 MPa and a
temperature of at most 500.degree. C. to produce the crude product;
the crude product having a viscosity content of at most 50% of the
hydrocarbon feed viscosity.
[0040] In some embodiments, the invention provides a catalyst that
includes a support, mineral oxides, and one or more metals from
Column 6 of the Periodic Table and/or one or more compounds of one
or more metals from Column 6 of the Periodic Table, wherein the
catalyst has a pore size distribution with a median pore diameter
of at least 80 .ANG. and the catalyst is obtainable by combining: a
mineral oxide fines; the one or more of metals from Column 6 of the
Periodic Table and/or the one or more compounds of one or more
metals from Column 6 of the Periodic Table; and a support.
[0041] In further embodiments, features from specific embodiments
may be combined with features from other embodiments. For example,
features from one embodiment may be combined with features from any
of the other embodiments.
[0042] In further embodiments, crude products are obtainable by any
of the methods and systems described herein.
[0043] In further embodiments, additional features may be added to
the specific embodiments described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] Advantages of the present invention will become apparent to
those skilled in the art with the benefit of the following detailed
description and upon reference to the accompanying drawings in
which:
[0045] FIG. 1 is a schematic of an embodiment of a contacting
system.
[0046] FIGS. 2A and 2B are schematics of embodiments of contacting
systems that include two contacting zones.
[0047] FIGS. 3A and 3B are schematics of embodiments of contacting
systems that include three contacting zones.
[0048] FIG. 4 is a schematic of an embodiment of a separation zone
in combination with a contacting system.
[0049] FIG. 5 is a schematic of an embodiment of a blending zone in
combination with a contacting system.
[0050] FIG. 6 is a schematic of an embodiment of a combination of a
separation zone, a contacting system, and a blending zone.
[0051] FIG. 7 depicts a Raman spectrum of a vanadium catalyst and
various molybdenum catalysts.
[0052] FIG. 8 is a tabulation of representative properties of crude
feed and crude product for an embodiment of contacting the crude
feed with three catalysts.
[0053] FIG. 9 is a graphical representation of weighted average bed
temperature versus length of run for an embodiment of contacting
the crude feed with one or more catalysts.
[0054] FIG. 10 is a tabulation of representative properties of
crude feed and crude product for an embodiment of contacting the
crude feed with two catalysts.
[0055] FIG. 11 is another tabulation of representative properties
of crude feed and crude product for an embodiment of contacting the
crude feed with two catalysts.
[0056] FIG. 12 is a tabulation of crude feed and crude products for
embodiments of contacting crude feeds with four different catalyst
systems.
[0057] FIG. 13 is a graphical representation of P-value of crude
products versus run time for embodiments of contacting crude feeds
with four different catalyst systems.
[0058] FIG. 14 is a graphical representation of net hydrogen uptake
by crude feeds versus run time for embodiments of contacting crude
feeds with four different catalyst systems.
[0059] FIG. 15 is a graphical representation of residue content,
expressed in weight percentage, of crude products versus run time
for embodiments of contacting crude feeds with four different
catalyst systems.
[0060] FIG. 16 is a graphical representation of change in API
gravity of crude products versus run time for embodiments of
contacting the crude feed with four different catalyst systems.
[0061] FIG. 17 is a graphical representation of oxygen content,
expressed in weight percentage, of crude products versus run time
for embodiments of contacting crude feeds with four different
catalyst systems.
[0062] FIG. 18 is a tabulation of representative properties of
crude feed and crude products for embodiments of contacting the
crude feed with catalyst systems that include various amounts of a
molybdenum catalyst and a vanadium catalyst, with a catalyst system
that include a vanadium catalyst and a molybdenum/vanadium
catalyst, and with glass beads.
[0063] FIG. 19 is a tabulation of properties of crude feed and
crude products for embodiments of contacting crude feeds with one
or more catalysts at various liquid hourly space velocities.
[0064] FIG. 20 is a tabulation of properties of crude feeds and
crude products for embodiments of contacting the crude feeds at
various contacting temperatures.
[0065] FIG. 21 is a tabulation of crude feed and crude products for
embodiments of contacting the crude feed for greater than 500
hours.
[0066] FIG. 22 is a tabulation of crude feed and crude products for
embodiments of contacting the crude feed with a molybdenum
catalyst.
[0067] FIG. 23 is a tabulation of hydrocarbon feed and crude
product for embodiments of contacting the hydrocarbon feed with two
catalysts.
[0068] FIG. 24 is a tabulation of hydrocarbon feed and crude
product for embodiments of contacting the hydrocarbon feed with two
catalysts.
[0069] FIG. 25 is a tabulation of hydrocarbon feed and crud product
for an embodiment of contacting the hydrocarbon feed with a dried
catalyst.
[0070] While the invention is susceptible to various modifications
and alternative forms, specific embodiments thereof are shown by
way of example in the drawings. The drawings may not be to scale.
It should be understood that the drawings and detailed description
thereto are not intended to limit the invention to the particular
form disclosed, but on the contrary, the intention is to cover all
modifications, equivalents and alternatives falling within the
spirit and scope of the present invention as defined by the
appended claims.
DETAILED DESCRIPTION
[0071] Certain embodiments of the inventions are described herein
in more detail. Terms used herein are defined as follows.
[0072] "ASTM" refers to American Standard Testing and
Materials.
[0073] "API gravity" refers to API gravity at 15.5.degree. C.
(60.degree. F.). API gravity is as determined by ASTM Method
D6822.
[0074] Atomic hydrogen percentage and atomic carbon percentage of
the hydrocarbon feed and the crude product are as determined by
ASTM Method D5291.
[0075] Boiling range distributions for the hydrocarbon feed, the
total product, and/or the crude product are as determined by ASTM
Method D5307 unless otherwise mentioned.
[0076] "C.sub.5 asphaltenes" refers to asphaltenes that are
insoluble in n-pentane. C.sub.5 asphaltenes content is as
determined by ASTM Method D2007.
[0077] "C.sub.7 asphaltenes" refers to asphaltenes that are
insoluble in n-heptane. C.sub.7 asphaltenes content is as
determined by ASTM Method D3279.
[0078] "Column X metal(s)" refers to one or more metals of Column X
of the Periodic Table and/or one or more compounds of one or more
metals of Column X of the Periodic Table, in which X corresponds to
a column number (for example, 1-12) of the Periodic Table. For
example, "Column 6 metal(s)" refers to one or more metals from
Column 6 of the Periodic Table and/or one or more compounds of one
or more metals from Column 6 of the Periodic Table.
[0079] "Column X element(s)" refers to one or more elements of
Column X of the Periodic Table, and/or one or more compounds of one
or more elements of Column X of the Periodic Table, in which X
corresponds to a column number (for example, 13-18) of the Periodic
Table. For example, "Column 15 element(s)" refers to one or more
elements from Column 15 of the Periodic Table and/or one or more
compounds of one or more elements from Column 15 of the Periodic
Table.
[0080] In the scope of this application, weight of a metal from the
Periodic Table, weight of a compound of a metal from the Periodic
Table, weight of an element from the Periodic Table, or weight of a
compound of an element from the Periodic Table is calculated as the
weight of metal or the weight of element. For example, if 0.1 grams
of MoO.sub.3 is used per gram of catalyst, the calculated weight of
the molybdenum metal in the catalyst is 0.067 grams per gram of
catalyst.
[0081] "Content" refers to the weight of a component in a substrate
(for example, a hydrocarbon feed, a total product, or a crude
product) expressed as weight fraction or weight percentage based on
the total weight of the substrate. "Wtppm" refers to parts per
million by weight.
[0082] "Crude feed" refers to a crude and/or disadvantaged crude
that is to be treated herein.
[0083] "Crude feed/total product mixture" or "hydrocarbon
feed/total product" refers to the mixture that contacts the
catalyst during processing.
[0084] "Distillate" refers to hydrocarbons with a boiling range
distribution between 204.degree. C. (400.degree. F.) and
343.degree. C. (650.degree. F.) at 0.101 MPa. Distillate content is
as determined by ASTM Method D5307.
[0085] "Heteroatoms" refers to oxygen, nitrogen, and/or sulfur
contained in the molecular structure of a hydrocarbon. Heteroatoms
content is as determined by ASTM Methods E385 for oxygen, D5762 for
total nitrogen, and D4294 for sulfur. "Total basic nitrogen" refers
to nitrogen compounds that have a pKa of less than 40. Basic
nitrogen ("bn") is as determined by ASTM Method D2896.
[0086] "Hydrocarbon feed" refers to a feed that includes
hydrocarbons. Hydrocarbon feed may include, but is not limited to,
crudes, disadvantaged crudes, hydrocarbons obtained from refinery
processes, or mixtures thereof. Examples of hydrocarbon feed
obtained from refinery processes include, but are not limited to,
long residue, short residue, vacuum residue, hydrocarbons boiling
above 538.degree. C. (1000.degree. F.), or mixtures thereof.
[0087] "Hydrogen source" refers to hydrogen, and/or a compound
and/or compounds that when in the presence of a hydrocarbon feed
and the catalyst react to provide hydrogen to compound(s) in the
hydrocarbon feed. A hydrogen source may include, but is not limited
to, hydrocarbons (for example, C.sub.1 to C.sub.4 hydrocarbons such
as methane, ethane, propane, and butane), water, or mixtures
thereof. A mass balance may be conducted to assess the net amount
of hydrogen provided to the compound(s) in the hydrocarbon
feed.
[0088] "Flat plate crush strength" refers to compressive force
needed to crush a catalyst. Flat plate crush strength is as
determined by ASTM Method D4179.
[0089] "LHSV" refers to a volumetric liquid feed rate per total
volume of catalyst and is expressed in hours (h.sup.-1). Total
volume of catalyst is calculated by summation of all catalyst
volumes in the contacting zones, as described herein.
[0090] "Liquid mixture" refers to a composition that includes one
or more compounds that are liquid at standard temperature and
pressure (25.degree. C., 0.101 MPa, hereinafter referred to as
"STP"), or a composition that includes a combination of one of more
compounds that are liquid at STP with one or more compounds that
are solids at STP.
[0091] "Periodic Table" refers to the Periodic Table as specified
by the International Union of Pure and Applied Chemistry (IUPAC),
November 2003.
[0092] "Metals in metal salts of organic acids" refer to alkali
metals, alkaline-earth metals, zinc, arsenic, chromium, or
combinations thereof. A content of metals in metal salts of organic
acids is as determined by ASTM Method D1318.
[0093] "Micro-Carbon Residue" ("MCR") content refers to a quantity
of carbon residue remaining after evaporation and pyrolysis of a
substrate. MCR content is as determined by ASTM Method D4530.
[0094] "Molybdenum content in the hydrocarbon feed" refers to the
content of molybdenum in the feed. The molybdenum content includes
the amount of inorganic molybdenum and organomolybdenum in the
feed. Molybdenum content in the hydrocarbon feed is as determined
by ASTM Method D5807.
[0095] "Naphtha" refers to hydrocarbon components with a boiling
range distribution between 38.degree. C. (100.degree. F.) and
200.degree. C. (392.degree. F.) at 0.101 MPa. Naphtha content is as
determined by ASTM Method D5307.
[0096] "Ni/V/Fe" refers to nickel, vanadium, iron, or combinations
thereof.
[0097] "Ni/V/Fe content" refers to the content of nickel, vanadium,
iron, or combinations thereof. The Ni/V/Fe content includes
inorganic nickel, vanadium and iron compounds and/or organonickel,
organovanadium, and organoiron compounds. The Ni/V/Fe content is as
determined by ASTM Method D5708.
[0098] "Nm.sup.3/m.sup.3" refers to normal cubic meters of gas per
cubic meter of hydrocarbon feed.
[0099] "Non-carboxylic containing organic oxygen compounds" refers
to organic oxygen compounds that do not have a carboxylic
(--CO.sub.2--) group. Non-carboxylic containing organic oxygen
compounds include, but are not limited to, ethers, cyclic ethers,
alcohols, aromatic alcohols, ketones, aldehydes, or combinations
thereof, which do not have a carboxylic group.
[0100] "Non-condensable gas" refers to components and/or mixtures
of components that are gases at STP.
[0101] "P (peptization) value" or "P-value" refers to a numeral
value, which represents the flocculation tendency of asphaltenes in
the hydrocarbon feed. P-Value is as determined by ASTM Method
D7060.
[0102] "Pore diameter", "median pore diameter", and "pore volume"
refer to pore diameter, median pore diameter, and pore volume, as
determined by ASTM Method D4284 (mercury porosimetry at a contact
angle equal to 140.degree.). A Micromeritics.RTM. A9220 instrument
(Micromeritics Inc., Norcross, Ga., U.S.A.) may be used to
determine these values.
[0103] "Organometallic" refers to compound that includes an organic
compound bonded or complexed with a metal of the Periodic Table.
"Organometallic content" refers to the total content of metal in
the organometallic compounds. Organometallic content is as
determined by ASTM Method D5807.
[0104] "Residue" refers to components that have a boiling range
distribution above 538.degree. C. (1000.degree. F.), as determined
by ASTM Method D5307.
[0105] "Sediment" refers to impurities and/or coke that are
insoluble in the hydrocarbon feed/total product mixture. Sediment
is as determined by ASTM Method D4807. Sediment may also be
determined by the Shell Hot Filtration Test ("SHFST") as described
by Van Kenoort et al. in the Jour. Inst. Pet., 1951, pages
596-604.
[0106] "SCFB" refers to standard cubic feet of gas per barrel of
hydrocarbon feed.
[0107] "Surface area" of a catalyst is as determined by ASTM Method
D3663.
[0108] "TAN" refers to a total acid number expressed as milligrams
("mg") of KOH per gram ("g") of sample. TAN is as determined by
ASTM Method D664.
[0109] "Used catalyst" refers to one or more catalysts that have
been contacted with a hydrocarbon feed. A used catalyst includes,
but is not limited to, a catalyst that has been contacted with a
hydrocarbon feed and which has undergone further treatment (for
example, regenerated catalysts).
[0110] "VGO" refers to hydrocarbons with a boiling range
distribution between 343.degree. C. (650.degree. F.) and
538.degree. C. (1000.degree. F.) at 0.101 MPa. VGO content is as
determined by ASTM Method D5307.
[0111] "Viscosity" refers to kinematic viscosity at 37.8.degree. C.
(100.degree. F.). Viscosity is as determined using ASTM Method
D445.
[0112] In the context of this application, it is to be understood
that if the value obtained for a property of the substrate tested
is outside of limits of the test method, the test method may be
modified and/or recalibrated to test for such property.
[0113] Crudes may be produced and/or retorted from hydrocarbon
containing formations and then stabilized. Crudes are generally
solid, semi-solid, and/or liquid. Crudes may include crude oil.
Stabilization may include, but is not limited to, removal of
non-condensable gases, water, salts, or combinations thereof from
the crude to form a stabilized crude. Such stabilization may often
occur at, or proximate to, the production and/or retorting
site.
[0114] Stabilized crudes typically have not been distilled and/or
fractionally distilled in a treatment facility to produce multiple
components with specific boiling range distributions (for example,
naphtha, distillates, VGO, and/or lubricating oils). Distillation
includes, but is not limited to, atmospheric distillation methods
and/or vacuum distillation methods. Undistilled and/or
unfractionated stabilized crudes may include components that have a
carbon number above 4 in quantities of at least 0.5 grams of
components per gram of crude. Examples of stabilized crudes include
whole crudes, topped crudes, desalted crudes, desalted topped
crudes, or combinations thereof. "Topped" refers to a crude that
has been treated such that at least some of the components that
have a boiling point below 35.degree. C. at 0.101 MPa (95.degree.
F. at 1 atm) have been removed. Typically, topped crudes will have
a content of at most 0.1 grams, at most 0.05 grams, or at most 0.02
grams of such components per gram of the topped crude.
[0115] Some stabilized crudes have properties that allow the
stabilized crudes to be transported to conventional treatment
facilities by transportation carriers (for example, pipelines,
trucks, or ships). Other crudes have one or more unsuitable
properties that render them disadvantaged. Disadvantaged crudes may
be unacceptable to a transportation carrier and/or a treatment
facility, thus imparting a low economic value to the disadvantaged
crude. The economic value may be such that a reservoir that
includes the disadvantaged crude that is deemed too costly to
produce, transport, and/or treat.
[0116] Properties of disadvantaged crudes may include, but are not
limited to: a) TAN of at least 0.1, at least 0.3, or at least 1; b)
viscosity of at least 10 cSt; c) API gravity at most 19, at most
15, or at most 10; d) a total Ni/V/Fe content of at least 0.00002
grams or at least 0.0001 grams of Ni/V/Fe per gram of crude; e) a
total heteroatoms content of at least 0.005 grams of heteroatoms
per gram of crude; f) a residue content of at least 0.01 grams of
residue per gram of crude; g) a C.sub.5 asphaltenes content of at
least 0.04 grams of C.sub.5 asphaltenes per gram of crude; h) a MCR
content of at least 0.002 grams of MCR per gram of crude; i) a
content of metals in metal salts of organic acids of at least
0.00001 grams of metals per gram of crude; or j) combinations
thereof. In some embodiments, disadvantaged crude may include, per
gram of disadvantaged crude, at least 0.2 grams of residue, at
least 0.3 grams of residue, at least 0.5 grams of residue, or at
least 0.9 grams of residue. In some embodiments, the disadvantaged
crude may have a TAN in a range from 0.1 or 0.3 to 20, 0.3 or 0.5
to 10, or 0.4 or 0.5 to 5. In certain embodiments, disadvantaged
crudes, per gram of disadvantaged crude, may have a sulfur content
of at least 0.005, at least 0.01, or at least 0.02 grams.
[0117] In some embodiments, disadvantaged crudes have properties
including, but not limited to: a) TAN of at least 0.5 or at least
1; b) an oxygen content of at least 0.005 grams of oxygen per gram
of disadvantaged crude; c) a C.sub.5 asphaltenes content of at
least 0.04 grams of C.sub.5 asphaltenes per gram of disadvantaged
crude; d) a higher than desired viscosity (for example, >10 cSt
for a hydrocarbon feed with API gravity of at least 5; e) a content
of metals in metal salts of organic acids of at least 0.00001 grams
of metals per gram of crude; or f) combinations thereof.
[0118] In some embodiments, disadvantaged crudes have properties
including, but not limited to: a) a basic nitrogen content of at
least 0.0001 grams of basic nitrogen compounds per gram of
disadvantaged crude; b) a molybdenum content of at least 0.1 wtppm;
c) a residue content of at least 0.3 grams of residue per gram of
disadvantaged crude; or d) combinations thereof.
[0119] Disadvantaged crudes may include, per gram of disadvantaged
crude: at least 0.001 grams, at least 0.005 grams, or at least 0.01
grams of hydrocarbons with a boiling range distribution between
95.degree. C. and 200.degree. C. at 0.101 MPa; at least 0.01 grams,
at least 0.005 grams, or at least 0.001 grams of hydrocarbons with
a boiling range distribution between 200.degree. C. and 300.degree.
C. at 0.101 MPa; at least 0.001 grams, at least 0.005 grams, or at
least 0.01 grams of hydrocarbons with a boiling range distribution
between 300.degree. C. and 400.degree. C. at 0.101 MPa; and at
least 0.001 grams, at least 0.005 grams, or at least 0.01 grams of
hydrocarbons with a boiling range distribution between 400.degree.
C. and 650.degree. C. at 0.101 MPa.
[0120] Disadvantaged crudes may include, per gram of disadvantaged
crude: at least 0.001 grams, at least 0.005 grams, or at least 0.01
grams of hydrocarbons with a boiling range distribution of at most
100.degree. C. at 0.101 MPa; at least 0.001 grams, at least 0.005
grams, or at least 0.01 grams of hydrocarbons with a boiling range
distribution between 100.degree. C. and 200.degree. C. at 0.101
MPa; at least 0.001 grams, at least 0.005 grams, or at least 0.01
grams of hydrocarbons with a boiling range distribution between
200.degree. C. and 300.degree. C. at 0.101 MPa; at least 0.001
grams, at least 0.005 grams, or at least 0.01 grams of hydrocarbons
with a boiling range distribution between 300.degree. C. and
400.degree. C. at 0.101 MPa; and at least 0.001 grams, at least
0.005 grams, or at least 0.01 grams of hydrocarbons with a boiling
range distribution between 400.degree. C. and 650.degree. C. at
0.101 MPa.
[0121] Some disadvantaged crudes may include, per gram of
disadvantaged crude, at least 0.001 grams, at least 0.005 grams, or
at least 0.01 grams of hydrocarbons with a boiling range
distribution of at most 100.degree. C. at 0.101 MPa, in addition to
higher boiling components. Typically, the disadvantaged crude has,
per gram of disadvantaged crude, a content of such hydrocarbons of
at most 0.2 grams or at most 0.1 grams.
[0122] Some disadvantaged crudes may include, per gram of
disadvantaged crude, at least 0.001 grams, at least 0.005 grams, or
at least 0.01 grams of hydrocarbons with a boiling range
distribution of at least 200.degree. C. at 0.101 MPa.
[0123] Some disadvantaged crudes may include, per gram of
disadvantaged crude, at least 0.001 grams, at least 0.005 grams, or
at least 0.01 grams of hydrocarbons with a boiling range
distribution of at least 650.degree. C.
[0124] Examples of disadvantaged crudes that might be treated using
the processes described herein include, but are not limited to,
crudes from of the following regions of the world: U.S. Gulf Coast
and southern California, Canada Tar sands, Brazilian Santos and
Campos basins, Egyptian Gulf of Suez, Chad, United Kingdom North
Sea, Angola Offshore, Chinese Bohai Bay, Venezuelan Zulia,
Malaysia, and Indonesia Sumatra.
[0125] Treatment of disadvantaged crudes may enhance the properties
of the disadvantaged crudes such that the crudes are acceptable for
transportation and/or treatment.
[0126] The crude feed may be topped, as described herein. The crude
product resulting from treatment of the crude feed, as described
herein, is generally suitable for transporting and/or treatment.
Properties of the crude product produced as described herein are
closer to the corresponding properties of West Texas Intermediate
crude than the crude feed, or closer to the corresponding
properties of Brent crude, than the crude feed, thereby enhancing
the economic value of the crude feed. Such crude product may be
refined with less or no pre-treatment, thereby enhancing refining
efficiencies. Pre-treatment may include desulfurization,
demetallization, and/or atmospheric distillation to remove
impurities.
[0127] Treatment of a hydrocarbon feed in accordance with
inventions described herein may include contacting the hydrocarbon
feed with the catalyst(s) in a contacting zone and/or combinations
of two or more contacting zones. In a contacting zone, at least one
property of a hydrocarbon feed may be changed by contact of the
hydrocarbon feed with one or more catalysts relative to the same
property of the hydrocarbon feed. In some embodiments, contacting
is performed in the presence of a hydrogen source. In some
embodiments, the hydrogen source is one or more hydrocarbons that
under certain contacting conditions react to provide relatively
small amounts of hydrogen to compound(s) in the hydrocarbon
feed.
[0128] FIG. 1 is a schematic of contacting system 100 that includes
an upstream contacting zone 102. The hydrocarbon feed enters
upstream contacting zone 102 via hydrocarbon feed conduit 104. A
contacting zone may be a reactor, a portion of a reactor, multiple
portions of a reactor, or combinations thereof. Examples of a
contacting zone include a stacked bed reactor, a fixed bed reactor,
an ebullating bed reactor, a continuously stirred tank reactor
("CSTR"), a fluidized bed reactor, a spray reactor, and a
liquid/liquid contactor. In certain embodiments, the contacting
system is on or coupled to an offshore facility. Contact of the
hydrocarbon feed with the catalyst(s) in contacting system 100 may
be a continuous process or a batch process.
[0129] The contacting zone may include one or more catalysts (for
example, two catalysts). In some embodiments, contact of the
hydrocarbon feed with a first catalyst of the two catalysts may
reduce TAN of the hydrocarbon feed. Subsequent contact of the
reduced TAN hydrocarbon feed with the second catalyst decreases
heteroatoms content and increases API gravity. In other
embodiments, TAN, viscosity, Ni/V/Fe content, heteroatoms content,
residue content, API gravity, or combinations of these properties
of the crude product change by at least 10% relative to the same
properties of the hydrocarbon feed after contact of the hydrocarbon
feed with one or more catalysts.
[0130] In certain embodiments, a volume of catalyst in the
contacting zone is in a range from 10-60 vol %, 20-50 vol %, or
30-40 vol % of a total volume of hydrocarbon feed in the contacting
zone. In some embodiments, a slurry of catalyst and hydrocarbon
feed may include from 0.001-10 grams, 0.005-5 grams, or 0.01-3
grams of catalyst per 100 grams of hydrocarbon feed in the
contacting zone.
[0131] Contacting conditions in the contacting zone may include,
but are not limited to, temperature, pressure, hydrogen source
flow, hydrocarbon feed flow, or combinations thereof. Contacting
conditions in some embodiments are controlled to produce a crude
product with specific properties. Temperature in the contacting
zone may range from 50.degree. C. to 500.degree. C., 60.degree. C.
to 440.degree. C., 70.degree. C. to 430.degree. C., 80.degree. C.
to 420.degree. C. In some embodiments, temperature in a contacting
zone may range from 350.degree. C. to 450.degree. C., 360.degree.
C. to 44.degree. C., 370.degree. C. to 430.degree. C., or from
380.degree. C. to 410.degree. C. LHSV of the hydrocarbon feed will
generally range from 0.1 to 30 h.sup.-1, 0.4 h.sup.-1 to 25
h.sup.-1 0.5 to 20 h.sup.-1, 1 to 15 h.sup.-1, 1.5 to 10 h.sup.-1,
or 2 to 5 h.sup.-1. In some embodiments, LHSV is at least 5
h.sup.-1, at least 11 h.sup.-1, at least 15 h.sup.-, or at least 20
h.sup.-1. A partial pressure of hydrogen in the contacting zone may
range from 0.1-8 MPa, 1-7 MPa, 2-6 MPa, or 3-5 MPa. In some
embodiments, a partial pressure of hydrogen may be at most 7 MPa,
at most 6 MPa, at most 5 MPa, at most 4 MPa, at most 3 MPa, or at
most 3.5 MPa, or at most 2 MPa.
[0132] In embodiments in which the hydrogen source is supplied as a
gas (for example, hydrogen gas), a ratio of the gaseous hydrogen
source to the hydrocarbon feed typically ranges from 0.1-100,000
Nm.sup.3/m.sup.3, 0.5-10,000 Nm.sup.3/m.sup.3, 1-8,000
Nm.sup.3/m.sup.3, 2-5,000 Nm.sup.3/m.sup.3, 5-3,000
Nm.sup.3/m.sup.3, or 10-800 Nm.sup.3/m.sup.3 contacted with the
catalyst(s). The hydrogen source, in some embodiments, is combined
with carrier gas(es) and recirculated through the contacting zone.
Carrier gas may be, for example, nitrogen, helium, and/or argon.
The carrier gas may facilitate flow of the hydrocarbon feed and/or
flow of the hydrogen source in the contacting zones(s). The carrier
gas may also enhance mixing in the contacting zone(s). In some
embodiments, a hydrogen source (for example, hydrogen, methane or
ethane) may be used as a carrier gas and recirculated through the
contacting zone.
[0133] The hydrogen source may enter upstream contacting zone 102
co-currently with the hydrocarbon feed in hydrocarbon feed conduit
104 or separately via gas conduit 106. In upstream contacting zone
102, contact of the hydrocarbon feed with a catalyst produces a
total product that includes a crude product, and, in some
embodiments, gas. In some embodiments, a carrier gas is combined
with the hydrocarbon feed and/or the hydrogen source in conduit
106. The total product may exit upstream contacting zone 102 and
enter downstream separation zone 108 via total product conduit
110.
[0134] In downstream separation zone 108, the crude product and gas
may be separated from the total product using generally known
separation techniques, for example, gas-liquid separation. The
crude product may exit downstream separation zone 108 via crude
product conduit 112, and then be transported to transportation
carriers, pipelines, storage vessels, refineries, other processing
zones, or a combination thereof. The gas may include gas formed
during processing (for example, hydrogen sulfide, carbon dioxide,
and/or carbon monoxide), excess gaseous hydrogen source, and/or
carrier gas. The excess gas may be recycled to contacting system
100, purified, transported to other processing zones, storage
vessels, or combinations thereof.
[0135] In some embodiments, contacting the hydrocarbon feed with
the catalyst(s) to produce a total product is performed in two or
more contacting zones. The total product may be separated to form
the crude product and gas(es).
[0136] FIGS. 2-3 are schematics of embodiments of contacting system
100 that includes two or three contacting zones. In FIGS. 2A and
2B, contacting system 100 includes upstream contacting zone 102 and
downstream contacting zone 114. FIGS. 3A and 3B include contacting
zones 102, 114, 116. In FIGS. 2A and 3A, contacting zones 102, 114,
116 are depicted as separate contacting zones in one reactor. The
hydrocarbon feed enters upstream contacting zone 102 via
hydrocarbon feed conduit 104.
[0137] In some embodiments, the carrier gas is combined with the
hydrogen source in gas conduit 106 and is introduced into the
contacting zones as a mixture. In certain embodiments, as shown in
FIGS. 3A and 3B, the hydrogen source and/or the carrier gas may
enter the one or more contacting zones with the hydrocarbon feed
separately via gas conduit 106 and/or in a direction counter to the
flow of the hydrocarbon feed via, for example, gas conduit 106'.
Addition of the hydrogen source and/or the carrier gas counter to
the flow of the hydrocarbon feed may enhance mixing and/or contact
of the hydrocarbon feed with the catalyst.
[0138] Contact of the hydrocarbon feed with catalyst(s) in upstream
contacting zone 102 forms a feed stream. The feed stream flows from
upstream contacting zone 102 to downstream contacting zone 114. In
FIGS. 3A and 3B, the feed stream flows from downstream contacting
zone 114 to additional downstream contacting zone 116.
[0139] Contacting zones 102, 114, 116 may include one or more
catalysts. As shown in FIG. 2B, the feed stream exits upstream
contacting zone 102 via feed stream conduit 118 and enters
downstream contacting zone 114. As shown in FIG. 3B, the feed
stream exits downstream contacting zone 114 via conduit 118 and
enters additional downstream contacting zone 116.
[0140] The feed stream may be contacted with additional catalyst(s)
in downstream contacting zone 114 and/or additional downstream
contacting zone 116 to form the total product. The total product
exits downstream contacting zone 114 and/or additional downstream
contacting zone 116 and enters downstream separation zone 108 via
total product conduit 110. The crude product and/or gas is (are)
separated from the total product. The crude product exits
downstream separation zone 108 via crude product conduit 112.
[0141] FIG. 4 is a schematic of an embodiment of a separation zone
upstream of contacting system 100. The disadvantaged crude (either
topped or untopped) enters upstream separation zone 120 via crude
conduit 122. In upstream separation zone 120, at least a portion of
the disadvantaged crude is separated using techniques known in the
art (for example, sparging, membrane separation, pressure
reduction) to produce the hydrocarbon feed. For example, water may
be at least partially separated from the disadvantaged crude. In
another example, components that have a boiling range distribution
below 95.degree. C. or below 100.degree. C. may be at least
partially separated from the disadvantaged crude to produce the
hydrocarbon feed. In some embodiments, at least a portion of
naphtha and compounds more volatile than naphtha are separated from
the disadvantaged crude. In some embodiments, at least a portion of
the separated components exit upstream separation zone 120 via
conduit 124.
[0142] The hydrocarbon feed obtained from upstream separation zone
120, in some embodiments, includes a mixture of components with a
boiling range distribution of at least 100.degree. C. or, in some
embodiments, a boiling range distribution of at least 120.degree.
C. Typically, the separated hydrocarbon feed includes a mixture of
components with a boiling range distribution between
100-1000.degree. C., 120-900.degree. C., or 200-800.degree. C. At
least a portion of the hydrocarbon feed exits upstream separation
zone 120 and enters contacting system 100 (see, for example, the
contacting zones in FIGS. 1-3) via additional hydrocarbon feed
conduit 126 to be further processed to form a crude product. In
some embodiments, upstream separation zone 120 may be positioned
upstream or downstream of a desalting unit. After processing, the
crude product exits contacting system 100 via crude product conduit
112.
[0143] In some embodiments, the crude product is blended with a
crude that is the same as or different from the hydrocarbon feed.
For example, the crude product may be combined with a crude having
a different viscosity thereby resulting in a blended product having
a viscosity that is between the viscosity of the crude product and
the viscosity of the crude. In another example, the crude product
may be blended with crude having a TAN that is different, thereby
producing a product that has a TAN that is between the TAN of the
crude product and the crude. The blended product may be suitable
for transportation and/or treatment.
[0144] As shown in FIG. 5, in certain embodiments, hydrocarbon feed
enters contacting system 100 via hydrocarbon feed conduit 104, and
at least a portion of the crude product exits contacting system 100
via conduit 128 and is introduced into blending zone 130. In
blending zone 130, at least a portion of the crude product is
combined with one or more process streams (for example, a
hydrocarbon stream such as naphtha produced from separation of one
or more hydrocarbon feeds), a crude, a hydrocarbon feed, or
mixtures thereof, to produce a blended product. The process
streams, hydrocarbon feed, crude, or mixtures thereof are
introduced directly into blending zone 130 or upstream of such
blending zone via stream conduit 132. A mixing system may be
located in or near blending zone 130. The blended product may meet
product specifications designated by refineries and/or
transportation carriers. Product specifications include, but are
not limited to, a range of or a limit of API gravity, TAN,
viscosity, or combinations thereof. The blended product exits
blending zone 130 via blend conduit 134 to be transported or
processed.
[0145] In FIG. 6, the disadvantaged crude enters upstream
separation zone 120 through crude conduit 122, and the
disadvantaged crude is separated as previously described to form
the hydrocarbon feed. The hydrocarbon feed then enters contacting
system 100 through additional hydrocarbon feed conduit 126. At
least some components from the disadvantaged crude exit separation
zone 120 via conduit 124. At least a portion of the crude product
exits contacting system 100 and enters blending zone 130 through
crude product conduit 128. Other process streams and/or crudes
enter blending zone 130 directly or via stream conduit 132 and are
combined with the crude product to form a blended product. The
blended product exits blending zone 130 via blend conduit 134.
[0146] In some embodiments, the crude product and/or the blended
product are transported to a refinery and distilled and/or
fractionally distilled to produce one or more distillate fractions.
The distillate fractions may be processed to produce commercial
products such as transportation fuel, lubricants, or chemicals.
[0147] In some embodiments, after contact of the hydrocarbon feed
with the catalyst, the crude product has a TAN of at most 90%, at
most 50%, or at most 10% of the TAN of the hydrocarbon feed. In
certain embodiments, the crude product has a TAN of at most 1, at
most 0.5, at most 0.3, at most 0.2, at most 0.1, or at most 0.05.
TAN of the crude product will frequently be at least 0.0001 and,
more frequently, at least 0.001. In some embodiments, TAN of the
crude product may be in a range from 0.001 to 0.5, 0.01 to 0.2, or
0.05 to 0.1. In some embodiments, TAN of the crude product may
range from 0.001 to 0.5, 0.004 to 0.4, from 0.01 to 0.3, or from
0.1 to 0.2.
[0148] In some embodiments, the crude product has a total Ni/V/Fe
content of at most 90%, at most 50%, at most 10%, at most 5%, or at
most 3% of the Ni/V/Fe content of the hydrocarbon feed. In certain
embodiments, the crude product has, per gram of crude product a
total Ni/V/Fe content in a range from 1.times.10.sup.-7 grams to
5.times.10.sup.-5 grams, 3.times.10.sup.-7 grams to
2.times.10.sup.-5 grams, or 1.times.10.sup.-6 grams to
1.times.10.sup.-5 grams. In certain embodiments, the crude product
has at most 2.times.10.sup.-5 grams of Ni/V/Fe. In some
embodiments, a total Ni/V/Fe content of the crude product is
70-130%, 80-120%, or 90-110% of the Ni/V/Fe content of the
hydrocarbon feed.
[0149] In some embodiments, the crude product has a total
molybdenum content of at most 90%, at most 50%, at most 10%, at
most 5%, or at most 3% of the molybdenum content of the hydrocarbon
feed. In certain embodiments, the crude product has a total
molybdenum content ranging from 0.001 wtppm to 1 wtppm, from 0.005
wtppm to 0.05 wtppm, or from 0.01 to 0.1 wtppm.
[0150] In some embodiments, the crude product has a total content
of metals in metal salts of organic acids of at most 90%, at most
50%, at most 10%, or at most 5% of the total content of metals in
metal salts of organic acids in the hydrocarbon feed. Organic acids
that generally form metal salts include, but are not limited to,
carboxylic acids, thiols, imides, sulfonic acids, and sulfonates.
Examples of carboxylic acids include, but are not limited to,
naphthenic acids, phenanthrenic acids, and benzoic acid. The metal
portion of the metal salts may include alkali metals (for example,
lithium, sodium, and potassium), alkaline-earth metals (for
example, magnesium, calcium, and barium), Column 12 metals (for
example, zinc and cadmium), Column 15 metals (for example arsenic),
Column 6 metals (for example, chromium), or mixtures thereof.
[0151] In certain embodiments, the crude product has a total
content of metals in metal salts of organic acids, per gram of
crude product, in a range from 0.0000001 grams to 0.00005 grams,
0.0000003 grams to 0.00002 grams, or 0.000001 grams to 0.00001
grams of metals in metal salt of organic acids per gram of crude
product. In some embodiments, a total content of metals in metal
salts of organic acids of the crude product is 70-130%, 80-120%, or
90-110% of the total content of metals in metal salts of organic
acids in the hydrocarbon feed.
[0152] In certain embodiments, API gravity of the crude product
produced from contact of the hydrocarbon feed with catalyst, at the
contacting conditions, is 70-130%, 80-120%, 90-110%, or 100-130% of
the API gravity of the hydrocarbon feed. In certain embodiments,
API gravity of the crude product is from 14-40, 15-30, or
16-25.
[0153] In certain embodiments, the crude product has a viscosity of
at most 90%, at most 80%, or at most 70% of the viscosity of the
hydrocarbon feed. In some embodiments, the viscosity of the crude
product is at most 90% of the viscosity of the hydrocarbon feed
while the API gravity of the crude product is 70-130%, 80-120%, or
90-110% of the API gravity the hydrocarbon feed.
[0154] In some embodiments, the crude product has a total
heteroatoms content of at most 90%, at most 50%, at most 10%, or at
most 5% of the total heteroatoms content of the hydrocarbon feed.
In certain embodiments, the crude product has a total heteroatoms
content of at least 1%, at least 30%, at least 80%, or at least 99%
of the total heteroatoms content of the hydrocarbon feed.
[0155] In some embodiments, the sulfur content of the crude product
may be at most 90%, at most 50%, at most 10%, or at most 5% of the
sulfur content of the crude product. In certain embodiments, the
crude product has a sulfur content of at least 1%, at least 30%, at
least 80%, or at least 99% of the sulfur content of the hydrocarbon
feed. In some embodiments, the sulfur content of the crude product
is 70-130%, 80-120%, or 90-110% of the sulfur content of the
hydrocarbon feed.
[0156] In some embodiments, total nitrogen content of the crude
product may be at most 90%, at most 80%, at most 10%, or at most 5%
of a total nitrogen content of the hydrocarbon feed. In certain
embodiments, the crude product has a total nitrogen content of at
least 1%, at least 30%, at least 80%, or at least 99% of the total
nitrogen content of the hydrocarbon feed.
[0157] In some embodiments, basic nitrogen content of the crude
product may at most 95%, at most 90%, at most 50%, at most 10%, or
at most 5% of the basic nitrogen content of the hydrocarbon feed.
In certain embodiments, the crude product has a basic nitrogen
content of at least 1%, at least 30%, at least 80%, or at least 99%
of the basic nitrogen content of the hydrocarbon feed.
[0158] In some embodiments, the oxygen content of the crude product
may be at most 90%, at most 50%, at most 30%, at most 10%, or at
most 5% of the oxygen content of the hydrocarbon feed. In certain
embodiments, the crude product has a oxygen content of at least 1%,
at least 30%, at least 80%, or at least 99% of the oxygen content
of the hydrocarbon feed. In some embodiments, the total content of
carboxylic acid compounds of the crude product may be at most 90%,
at most 50%, at most 10%, at most 5% of the content of the
carboxylic acid compounds in the hydrocarbon feed. In certain
embodiments, the crude product has a total content of carboxylic
acid compounds of at least 1%, at least 30%, at least 80%, or at
least 99% of the total content of carboxylic acid compounds in the
hydrocarbon feed.
[0159] In some embodiments, selected organic oxygen compounds may
be reduced in the hydrocarbon feed. In some embodiments, carboxylic
acids and/or metal salts of carboxylic acids may be chemically
reduced before non-carboxylic containing organic oxygen compounds.
Carboxylic acids and non-carboxylic containing organic oxygen
compounds in a crude product may be differentiated through analysis
of the crude product using generally known spectroscopic methods
(for example, infrared analysis, mass spectrometry, and/or gas
chromatography).
[0160] The crude product, in certain embodiments, has an oxygen
content of at most 90%, at most 80%, at most 70%, or at most 50% of
the oxygen content of the hydrocarbon feed, and TAN of the crude
product is at most 90%, at most 70%, at most 50%, or at most 40% of
the TAN of the hydrocarbon feed. In certain embodiments, the crude
product has an oxygen content of at least 1%, at least 30%, at
least 80%, or at least 99% of the oxygen content of the hydrocarbon
feed, and the crude product has a TAN of at least 1%, at least 30%,
at least 80%, or at least 99% of the TAN of the hydrocarbon
feed.
[0161] Additionally, the crude product may have a content of
carboxylic acids and/or metal salts of carboxylic acids of at most
90%, at most 70%, at most 50%, or at most 40% of the hydrocarbon
feed, and a content of non-carboxylic containing organic oxygen
compounds within 70-130%, 80-120%, or 90-110% of the non-carboxylic
containing organic oxygen compounds of the hydrocarbon feed.
[0162] In some embodiments, the crude product includes, in its
molecular structures, from 0.05-0.15 grams or from 0.09-0.13 grams
of hydrogen per gram of crude product. The crude product may
include, in its molecular structure, from 0.8-0.9 grams or from
0.82-0.88 grams of carbon per gram of crude product. A ratio of
atomic hydrogen to atomic carbon (H/C) of the crude product may be
within 70-130%, 80-120%, or 90-110% of the atomic H/C ratio of the
hydrocarbon feed. A crude product atomic H/C ratio within 10-30% of
the hydrocarbon feed atomic H/C ratio indicates that uptake and/or
consumption of hydrogen in the process is relatively small, and/or
that hydrogen is produced in situ.
[0163] The crude product includes components with a range of
boiling points. In some embodiments, the crude product includes,
per gram of the crude product: at least 0.001 grams, or from
0.001-0.5 grams of hydrocarbons with a boiling range distribution
of at most 100.degree. C. at 0.101 MPa; at least 0.001 grams, or
from 0.001-0.5 grams of hydrocarbons with a boiling range
distribution between 100.degree. C. and 200.degree. C. at 0.101
MPa; at least 0.001 grams, or from 0.001-0.5 grams of hydrocarbons
with a boiling range distribution between 200.degree. C. and
300.degree. C. at 0.101 MPa; at least 0.001 grams, or from
0.001-0.5 grams of hydrocarbons with a boiling range distribution
between 300.degree. C. and 400.degree. C. at 0.101 MPa; and at
least 0.001 grams, or from 0.001-0.5 grams of hydrocarbons with a
boiling range distribution between 400.degree. C. and 538.degree.
C. at 0.101 MPa.
[0164] In some embodiments the crude product includes, per gram of
crude product, at least 0.001 grams of hydrocarbons with a boiling
range distribution of at most 100.degree. C. at 0.101 MPa and/or at
least 0.001 grams of hydrocarbons with a boiling range distribution
between 100.degree. C. and 200.degree. C. at 0.101 MPa.
[0165] In some embodiments, the crude product may have at least
0.001 grams, or at least 0.01 grams of naphtha per gram of crude
product. In other embodiments, the crude product may have a naphtha
content of at most 0.6 grams, or at most 0.8 grams of naphtha per
gram of crude product.
[0166] In some embodiments, the crude product has a distillate
content of 70-130%, 80-120%, or 90-110% of the distillate content
of the hydrocarbon feed. The distillate content of the crude
product may be, per gram of crude product, in a range from
0.00001-0.5 grams, 0.001-0.3 grams, or 0.002-0.2 grams.
[0167] In certain embodiments, the crude product has a VGO content
of 70-130%, 80-120%, or 90-110% of the VGO content of the
hydrocarbon feed. In some embodiments, the crude product has, per
gram of crude product, a VGO content in a range from 0.00001-0.8
grams, 0.001-0.5 grams, 0.002-0.4 grams, or 0.001-0.3 grams.
[0168] In some embodiments, the crude product has a residue content
of at most 90%, at most 80%, at most 50%, at most 30%, at most 20%,
at most 10%, or at most 3% of the residue content of the
hydrocarbon feed. In certain embodiments, the crude product has a
residue content of 70-130%, 80-120%, or 90-110% of the residue
content of the hydrocarbon feed. The crude product may have, per
gram of crude product, a residue content in a range from
0.00001-0.8 grams, 0.0001-0.5 grams, 0.0005-0.4 grams, 0.001-0.3
grams, 0.005-0.2 grams, or 0.01-0.1 grams.
[0169] In some embodiments, the crude product has a total C.sub.5
and C.sub.7 asphaltenes content of at most 90%, at most 50%, at
most 30%, or at most 10% of the total C.sub.5 and C.sub.7
asphaltenes content of the hydrocarbon feed. In certain
embodiments, the hydrocarbon feed has, per gram of hydrocarbon
feed, a total C.sub.5 and C.sub.7 asphaltenes content ranging from
0.001 grams to 0.2 grams, 0.01 to 0.15 grams, or 0.05 grams to 0.1
grams.
[0170] In certain embodiments, the crude product has a MCR content
of 70-130%, 80-120%, or 90-110% of the MCR content of the
hydrocarbon feed, while the crude product has a C.sub.5 asphaltenes
content of at most 90%, at most 80%, or at most 50% of the C.sub.5
asphaltenes content of the hydrocarbon feed. In certain
embodiments, the C.sub.5 asphaltenes content of the hydrocarbon
feed is at least 10%, at least 60%, or at least 70% of the C.sub.5
asphaltenes content of the hydrocarbon feed while the MCR content
of the crude product is within 10-30% of the MCR content of the
hydrocarbon feed. In some embodiments, decreasing the C.sub.5
asphaltenes content of the hydrocarbon feed while maintaining a
relatively stable MCR content may increase the stability of the
hydrocarbon feed/total product mixture.
[0171] In some embodiments, the C.sub.5 asphaltenes content and MCR
content may be combined to produce a mathematical relationship
between the high viscosity components in the crude product relative
to the high viscosity components in the hydrocarbon feed. For
example, a sum of a hydrocarbon feed C.sub.5 asphaltenes content
and a hydrocarbon feed MCR content may be represented by S. A sum
of a crude product C.sub.5 asphaltenes content and a crude product
MCR content may be represented by S'. The sums may be compared (S'
to S) to assess the net reduction in high viscosity components in
the hydrocarbon feed. S' of the crude product may be in a range
from 1-99%, 10-90%, or 20-80% of S. In some embodiments, a ratio of
MCR content of the crude product to C.sub.5 asphaltenes content is
in a range from 1.0-3.0, 1.2-2.0, or 1.3-1.9.
[0172] In certain embodiments, the crude product has an MCR content
that is at most 90%, at most 80%, at most 50%, or at most 10% of
the MCR content of the hydrocarbon feed. The crude product has, in
some embodiments, from 0.0001-0.1 grams, 0.005-0.08 grams, or
0.01-0.05 grams of MCR per gram of crude product. In some
embodiments, the crude product includes from greater than 0 grams,
but less than 0.01 grams, 0.000001-0.001 grams, or 0.00001-0.0001
grams of total catalyst per gram of crude product. The catalyst may
assist in stabilizing the crude product during transportation
and/or treatment. The catalyst may inhibit corrosion, inhibit
friction, and/or increase water separation abilities of the crude
product. Methods described herein may be configured to add one or
more catalysts described herein to the crude product during
treatment.
[0173] The crude product produced from contacting system 100 has
properties different than properties of the hydrocarbon feed. Such
properties may include, but are not limited to: a) reduced TAN; b)
reduced viscosity; c) reduced total Ni/V/Fe content; d) reduced
content of sulfur, oxygen, nitrogen, or combinations thereof; e)
reduced residue content; f) reduced content of C.sub.5 and C.sub.7
asphaltenes; g) reduced MCR content; h) increased API gravity; i) a
reduced content of metals in metal salts of organic acids; j)
reduced basic nitrogen content; or k) combinations thereof. In some
embodiments, one or more properties of the crude product, relative
to the hydrocarbon feed, may be selectively changed while other
properties are not changed as much, or do not substantially change.
For example, it may be desirable to only selectively reduce one or
more components (for example, residue and/or viscosity) in a
hydrocarbon feed without significantly changing the amount of
Ni/V/Fe in the hydrocarbon feed. In this manner, hydrogen uptake
during contacting may be "concentrated" on residue reduction, and
not reduction of other components. Since less of such hydrogen is
also being used to reduce other components in the hydrocarbon feed,
the amount of hydrogen used during the process may be minimized.
For example, a disadvantaged crude may have a high residue, but a
Ni/V/Fe content that is acceptable to meet treatment and/or
transportation specifications. Such hydrocarbon feed may be more
efficiently treated by reducing residue without also reducing
Ni/V/Fe.
[0174] Catalysts used in one or more embodiments of the inventions
may include one or more bulk metals and/or one or more metals on a
support. The metals may be in elemental form or in the form of a
compound of the metal. The catalysts described herein may be
introduced into the contacting zone as a precursor, and then become
active as a catalyst in the contacting zone (for example, when
sulfur and/or a hydrocarbon feed containing sulfur is contacted
with the precursor). The catalyst or combination of catalysts used
as described herein may or may not be commercial catalysts.
Examples of commercial catalysts that are contemplated to be used
as described herein include HDS3; HDS22; HDN60; C234; C311; C344;
C411; C424; C344; C444; C447; C454; C448; C524; C534; DC2531;
DN120; DN130; DN140; DN190; DN200; DN800; DN2118; DN2318; DN3100;
DN3110; DN3300; DN3310; DN3330; RC400; RC410; RN412; RN400; RN420;
RN440; RN450; RN650; RN5210; RN5610; RN5650; RM430; RM5030; Z603;
Z623; Z673: Z703; Z713; Z723; Z753; and Z763, which are available
from CRI International, Inc. (Houston, Tex., U.S.A.).
[0175] In some embodiments, catalysts used to change properties of
the hydrocarbon feed include one or more Columns 5-10 metals on a
support. Columns 5-10 metal(s) include, but are not limited to,
vanadium, chromium, molybdenum, tungsten, manganese, technetium,
rhenium, iron, cobalt, nickel, ruthenium, palladium, rhodium,
osmium, iridium, platinum, or mixtures thereof. The catalyst may
have, per gram of catalyst, a total Columns 5-10 metal(s) content
in a range from at least 0.0001 grams, at least 0.001 grams, at
least 0.01 grams, or in a range 0.0001-0.6 grams, 0.001-0.3 grams,
0.005-0.1 grams, or 0.01-0.08 grams. In some embodiments, the
catalyst includes Column 15 element(s) in addition to the Columns
5-10 metal(s). Examples of Column 15 elements include phosphorus.
The catalyst may have a total Column 15 element content, per gram
of catalyst, in range from 0.000001-0.1 grams, 0.00001-0.06 grams,
0.00005-0.03 grams, or 0.0001-0.001 grams.
[0176] In certain embodiments, the catalyst includes Column 6
metal(s). The catalyst may have, per gram of catalyst, a total
Column 6 metal(s) content of at least 0.00001, at least 0.01 grams,
at least 0.02 grams and/or in a range from 0.0001-0.6 grams,
0.001-0.3 grams, 0.005-0.1 grams, or 0.01-0.08 grams. In some
embodiments, the catalyst includes from 0.0001-0.06 grams of Column
6 metal(s) per gram of catalyst. In some embodiments, the catalyst
includes Column 15 element(s) in addition to the Column 6
metal(s).
[0177] In some embodiments, the catalyst includes a combination of
Column 6 metal(s) with one or more metals from Column 5 and/or
Columns 7-10. A molar ratio of Column 6 metal to Column 5 metal may
be in a range from 0.1-20, 1-10, or 2-5. A molar ratio of Column 6
metal to Columns 7-10 metal may be in a range from 0.1-20, 1-10, or
2-5. In some embodiments, the catalyst includes Column 15
element(s) in addition to the combination of Column 6 metal(s) with
one or more metals from Columns 5 and/or 7-10. In other
embodiments, the catalyst includes Column 6 metal(s) and Column 10
metal(s). A molar ratio of the total Column 10 metal to the total
Column 6 metal in the catalyst may be in a range from 1-10, or from
2-5. In certain embodiments, the catalyst includes Column 5
metal(s) and Column 10 metal(s). A molar ratio of the total Column
10 metal to the total Column 5 metal in the catalyst may be in a
range from 1-10, or from 2-5.
[0178] In some embodiments, Columns 5-10 metal(s) are incorporated
in, or deposited on, a support to form the catalyst. In certain
embodiments, Columns 5-10 metal(s) in combination with Column 15
element(s) are incorporated in, or deposited on, the support to
form the catalyst. In embodiments in which the metal(s) and/or
element(s) are supported, the weight of the catalyst includes all
support, all metal(s), and all element(s). The support may be
porous and may include refractory oxides, porous carbon based
materials, zeolites, or combinations thereof. Refractory oxides may
include, but are not limited to, alumina, silica, silica-alumina,
titanium oxide, zirconium oxide, magnesium oxide, or mixtures
thereof. Supports may be obtained from a commercial manufacturer
such as Criterion Catalysts and Technologies LP (Houston, Tex.,
U.S.A.). Porous carbon based materials include, but are not limited
to, activated carbon and/or porous graphite. Examples of zeolites
include Y-zeolites, beta zeolites, mordenite zeolites, ZSM-5
zeolites, and ferrierite zeolites. Zeolites may be obtained from a
commercial manufacturer such as Zeolyst (Valley Forge, Pa.,
U.S.A.).
[0179] The support, in some embodiments, is prepared such that the
support has an average pore diameter of at least 150 .ANG., at
least 170 .ANG., or at least 180 .ANG.. In certain embodiments, a
support is prepared by forming an aqueous paste of the support
material. In some embodiments, an acid is added to the paste to
assist in extrusion of the paste. The water and dilute acid are
added in such amounts and by such methods as required to give the
extrudable paste a desired consistency. Examples of acids include,
but are not limited to, nitric acid, acetic acid, sulfuric acid,
and hydrochloric acid.
[0180] The paste may be extruded and cut using generally known
catalyst extrusion methods and catalyst cutting methods to form
extrudates. The extrudates may be heat treated at a temperature in
a range from 65-260.degree. C. or from 85-235.degree. C. for a
period of time (for example, for 0.5-8 hours) and/or until the
moisture content of the extrudate has reached a desired level. The
heat treated extrudate may be further heat treated at a temperature
in a range from 800-1200.degree. C. or 900-1100.degree. C.) to form
the support having an average pore diameter of at least 150
.ANG..
[0181] In certain embodiments, the support includes gamma alumina,
theta alumina, delta alumina, alpha alumina, or combinations
thereof. The amount of gamma alumina, delta alumina, alpha alumina,
or combinations thereof, per gram of catalyst support, may be in a
range from 0.0001-0.99 grams, 0.001-0.5 grams, 0.01-0.1 grams, or
at most 0.1 grams as determined by x-ray diffraction. In some
embodiments, the support has, either alone or in combination with
other forms of alumina, a theta alumina content, per gram of
support, in a range from 0.1-0.99 grams, 0.5-0.9 grams, or 0.6-0.8
grams, as determined by x-ray diffraction. In some embodiments, the
support may have at least 0.1 grams, at least 0.3 grams, at least
0.5 grams, or at least 0.8 grams of theta alumina, as determined by
x-ray diffraction.
[0182] Supported catalysts may be prepared using generally known
catalyst preparation techniques. Examples of catalyst preparations
are described in U.S. Pat. Nos. 6,919,018 to Bhan; 6,759,364 to
Bhan; 6,218,333 to Gabrielov et al.; 6,290,841 to Gabrielov et al.;
and 5,744,025 to Boon et al.
[0183] In some embodiments, the support may be impregnated with
metal to form a catalyst. In certain embodiments, the support is
heat treated at temperatures in a range from 400-1200.degree. C.,
450-1000.degree. C., or 600-900.degree. C. prior to impregnation
with a metal. In some embodiments, impregnation aids may be used
during preparation of the catalyst. Examples of impregnation aids
include a citric acid component, ethylenediaminetetraacetic acid
(EDTA), ammonia, or mixtures thereof.
[0184] In certain embodiments, a catalyst may be formed by adding
or incorporating the Columns 5-10 metal(s) to heat treated shaped
mixtures of support ("overlaying"). Overlaying a metal on top of
the heat treated shaped support having a substantially or
relatively uniform concentration of metal often provides beneficial
catalytic properties of the catalyst. Heat treating of a shaped
support after each overlay of metal tends to improve the catalytic
activity of the catalyst. Methods to prepare a catalyst using
overlay methods are described in U.S. Pat. No. 6,759,364 to
Bhan.
[0185] The Columns 5-10 metal(s) and support may be mixed with
suitable mixing equipment to form a Columns 5-10 metal(s)/support
mixture. The Columns 5-10 metal(s)/support mixture may be mixed
using suitable mixing equipment. Examples of suitable mixing
equipment include tumblers, stationary shells or troughs, Muller
mixers (for example, batch type or continuous type), impact mixers,
and any other generally known mixer, or generally known device,
that will suitably provide the Columns 5-10 metal(s)/support
mixture. In certain embodiments, the materials are mixed until the
Columns 5-10 metal(s) is (are) substantially homogeneously
dispersed in the support.
[0186] In some embodiments, the catalyst is heat treated at
temperatures from 150-750.degree. C., from 200-740.degree. C., or
from 400-730.degree. C. after combining the support with the
metal.
[0187] In some embodiments, the catalyst may be heat treated in the
presence of hot air and/or oxygen rich air at a temperature in a
range between 400.degree. C. and 1000.degree. C. to remove volatile
matter such that at least a portion of the Columns 5-10 metals are
converted to the corresponding metal oxide.
[0188] In other embodiments, however, the catalyst may be heat
treated in the presence of air at temperatures in a range from
35.degree. C. to 500.degree. C., from 100.degree. C. to 400.degree.
C., or from 150.degree. C. to 300.degree. C. for a period of time
in a range from 1-3 hours to remove a majority of the volatile
components without converting the Columns 5-10 metals to the metal
oxide. Catalysts prepared by such a method are generally referred
to as "uncalcined" catalysts or "dried". When catalysts are
prepared in this manner in combination with a sulfiding method, the
active metals may be substantially dispersed in the support.
Preparations of uncalcined catalysts are described in U.S. Pat.
Nos. 6,218,333 to Gabrielov et al., and 6,290,841 to Gabrielov et
al.
[0189] In certain embodiments, a theta alumina support may be
combined with Columns 5-10 metals to form a theta alumina
support/Columns 5-10 metals mixture. The theta alumina
support/Columns 5-10 metals mixture may be heat treated at a
temperature of at least 400.degree. C. to form the catalyst having
a pore size distribution with a median pore diameter of at least
230 .ANG.. Typically, such heat treating is conducted at
temperatures of at most 1200.degree. C.
[0190] In some embodiments, the support (either a commercial
support or a support prepared as described herein) may be combined
with a supported catalyst and/or a bulk metal catalyst. In some
embodiments, the supported catalyst may include Column 15 metal(s).
For example, the supported catalyst and/or the bulk metal catalyst
may be crushed into a powder with an average particle size from
1-50 microns, 2-45 microns, or 5-40 microns. The powder may be
combined with support to form an embedded metal catalyst. In some
embodiments, the powder may be combined with the support and then
extruded using standard techniques to form a catalyst having a pore
size distribution with a median pore diameter in a range from
80-200 .ANG. or 90-180 .ANG., or 120-130 .ANG..
[0191] Combining the catalyst with the support allows, in some
embodiments, at least a portion of the metal to reside under the
surface of the embedded metal catalyst (for example, embedded in
the support), leading to less metal on the surface than would
otherwise occur in the unembedded metal catalyst. In some
embodiments, having less metal on the surface of the catalyst
extends the life and/or catalytic activity of the catalyst by
allowing at least a portion of the metal to move to the surface of
the catalyst during use. The metals may move to the surface of the
catalyst through erosion of the surface of the catalyst during
contact of the catalyst with a hydrocarbon feed.
[0192] In some embodiments, the catalyst is prepared by combining
one or more Columns 6-10 metal(s), mineral oxides having a particle
size of at most 500 micrometers, and a support. The mineral oxides
may include, alumina, silica, silica-alumina, titanium oxide,
zirconium oxide, magnesium oxide, or mixtures thereof. The mineral
oxides may be obtained from an extrudate process to produce
support. For example, alumina fines can be obtained from an alumina
extrudate production to produce catalyst supports. In some
embodiments, mineral oxide fines may have a particle size of at
most 500 micrometers, at most 150 micrometers, at most 100
micrometers, or at most 75 micrometers. The particle size of the
mineral oxides may range from 0.2 micrometers to 500 micrometers,
0.3 micrometers to 100 micrometers, or 0.5 micrometers to 75
micrometers. Combining mineral oxides with one or more Columns 6-10
metal and a support may allow less metal to reside on the surface
of the catalyst.
[0193] Intercalation and/or mixing of the components of the
catalysts changes, in some embodiments, the structured order of the
Column 6 metal in the Column 6 oxide crystal structure to a
substantially random order of Column 6 metal in the crystal
structure of the embedded catalyst. The order of the Column 6 metal
may be determined using powder x-ray diffraction methods. The order
of elemental metal in the catalyst relative to the order of
elemental metal in the metal oxide may be determined by comparing
the order of the Column 6 metal peak in an x-ray diffraction
spectrum of the Column 6 oxide to the order of the Column 6 metal
peak in an x-ray diffraction spectrum of the catalyst. From
broadening and/or absence of patterns associated with Column 6
metal in an x-ray diffraction spectrum, it is possible to estimate
that the Column 6 metal(s) are substantially randomly ordered in
the crystal structure.
[0194] For example, molybdenum trioxide and the alumina support
having a median pore diameter of at least 180 .ANG. may be combined
to form an alumina/molybdenum trioxide mixture. The molybdenum
trioxide has a definite pattern (for example, definite D.sub.001,
D.sub.002 and/or D.sub.003 peaks). The alumina/Column 6 trioxide
mixture may be heat treated at a temperature of at least
538.degree. C. (1000.degree. F.) to produce a catalyst that does
not exhibit a pattern for molybdenum dioxide in an x-ray
diffraction spectrum (for example, an absence of the D.sub.001
peak).
[0195] In some embodiments, the catalyst may be prepared by
combining a supported catalyst and/or a used catalyst with a
support and one or more Columns 6-10 metals to produce the
catalyst. In some embodiments, the Columns 6-10 metals (for
example, molybdenum oxides and/or tungsten oxides) have a particle
size of at most 500 micrometers, at most 150 micrometers, at most
100 micrometers, or at most 75 micrometers. The particle size of
the Columns 6-10 metals may range from 0.1 micrometers to 500
micrometers, 1 micrometers to 100 micrometers, or 10 micrometers to
75 micrometers. In some embodiments, at least 50 percent of the
particles have a particle size between 2 micrometers to 15
micrometers. The mixture of the used catalyst with a support and
one or more Columns 6-10 metals is dried at temperatures of at
least 100.degree. C. to remove any low boiling components and then
heated to at least 500.degree. C., at least 1000.degree. C., at
least 1200.degree. C. or at least 1300.degree. C. to convert the
Columns 6-10 metals to metal oxides. The median pore diameter of
the catalyst may range from 50 .ANG. to 150 .ANG., 60 .ANG. to 140
.ANG., or 70 .ANG. to 130 .ANG..
[0196] The catalyst may include at least 0.01 grams, at least 0.1
grams, or at least 0.2 grams of used catalyst per gram of catalyst
and at most 0.3 grams, at most 0.2 grams, or at most 0.1 grams of
Columns 6-10 metal(s). In some embodiments, the catalyst includes
from 0.001 grams to 0.3 grams, from 0.05 to 0.2 grams, or from 0.01
grams to 0.1 grams of used catalyst, per gram of catalyst. In
certain embodiments, the ultrastable catalyst includes from 0.001
grams to 0.2 grams or 0.01 grams to 0.1 grams of Column 6 metal(s).
In some embodiments, the ultrastable catalyst may include from
0.001 grams to 0.1 grams, 0.005 to 0.05 grams, or from 0.01 grams
to 0.03 grams of Column 10 metal(s). In certain embodiments, the
ultrastable catalyst may include from 0.001 grams to 0.1 grams,
0.005 grams to 0.05 grams, or from 0.01 grams to 0.03 grams of
Column 9 metal(s). In some embodiments, the ultrastable catalyst
includes from 0.0001 to 0.01 grams, 0.0005 grams to 0.005 grams, or
0.0008 to 0.003 grams of Column 15 element(s).
[0197] The catalyst, after sulfiding, when analyzed using scanning
electron microscopy, exhibits a significantly lower degree of
molybdenum disulfide (MoS.sub.2) slab stacking with the stacks
having reduced heights and length as compared to alternative
molybdenum-containing hydroprocessing catalysts. Preparation of
such catalysts are described in U.S. patent applications entitled
"A Catalyst and Process for the Manufacture of Ultra-Low Sulfur
Distillate Product" and "A Highly Stable Heavy Hydrocarbon
Hydrodesulfurization Catalyst and Method of Making and Use Thereof"
to Bhan.
[0198] In commercial applications, after sulfidation of the
hydroprocessing catalysts, the hydroprocessing catalysts are
typically heated to 400.degree. C. over one or more months to
control the generation of hydrogen sulfide. Slowly heating of
hydroprocessing catalysts may inhibit deactivation of the catalyst.
The catalyst described herein has enhanced stability in the
presence of hydrogen sulfide when heated to 400.degree. C. in less
than three weeks. Being able to preheat the catalyst over a shorter
period of time may increase the amount of hydrocarbon feed that can
be processed through a contacting system.
[0199] In some embodiments, catalysts may be characterized by pore
structure. Various pore structure parameters include, but are not
limited to, pore diameter, pore volume, surface areas, or
combinations thereof. The catalyst may have a distribution of total
quantity of pore sizes versus pore diameters. The median pore
diameter of the pore size distribution may be in a range from
30-1000 .ANG., 50-500 .ANG., or 60-300 .ANG.. In some embodiments,
catalysts that include at least 0.5 grams of gamma alumina per gram
of catalyst have a pore size distribution with a median pore
diameter in a range from 50 to 200 .ANG.; 90 to 180 .ANG., 100 to
140 .ANG., or 120 to 130 .ANG.. In some embodiments, the gamma
alumina catalyst has a pore size distribution with a median pore
diameter ranging from 50 .ANG. to 150 .ANG., from 60 .ANG. to 135
.ANG., or from 70 .ANG. to 120 .ANG.. In other embodiments,
catalysts that include at least 0.1 grams of theta alumina per gram
of catalyst have a pore size distribution with a median pore
diameter in a range from 180-500 .ANG., 200-300 .ANG., or 230-250
.ANG.. In some embodiments, the median pore diameter of the pore
size distribution is at least 120 .ANG., at least 150 .ANG., at
least 180 .ANG., at least 200 .ANG., at least 220 .ANG., at least
230 .ANG., or at least 300 .ANG.. Such median pore diameters are
typically at most 1000 .ANG..
[0200] The catalyst may have a pore size distribution with a median
pore diameter of at least 60 .ANG. or at least 90 .ANG.. In some
embodiments, the catalyst has a pore size distribution with a
median pore diameter in a range from 90-180 .ANG., 100-140 .ANG.,
or 120-130 .ANG., with at least 60% of a total number of pores in
the pore size distribution having a pore diameter within 45 .ANG.,
35 .ANG., or 25 .ANG. of the median pore diameter. In certain
embodiments, the catalyst has a pore size distribution with a
median pore diameter in a range from 70-180 .ANG., with at least
60% of a total number of pores in the pore size distribution having
a pore diameter within 45 .ANG., 35 .ANG., or 25 .ANG. of the
median pore diameter.
[0201] In embodiments in which the median pore diameter of the pore
size distribution is at least 180 .ANG., at least 200 .ANG., or at
least 230 .ANG., greater that 60% of a total number of pores in the
pore size distribution have a pore diameter within 50 .ANG., 70
.ANG., or 90 .ANG. of the median pore diameter. In some
embodiments, the catalyst has a pore size distribution with a
median pore diameter in a range from 180-500 .ANG., 200-400 .ANG.,
or 230-300 .ANG., with at least 60% of a total number of pores in
the pore size distribution having a pore diameter within 50 .ANG.,
70 .ANG., or 90 .ANG. of the median pore diameter.
[0202] In some embodiments, pore volume of pores may be at least
0.3 cm.sup.3/g, at least 0.7 cm.sup.3/g, or at least 0.9
cm.sup.3/g. In certain embodiments, pore volume of pores may range
from 0.3-0.99 cm.sup.3/g, 0.4-0.8 cm.sup.3/g, or 0.5-0.7
cm.sup.3/g.
[0203] The catalyst having a pore size distribution with a median
pore diameter in a range from 50-180 .ANG. may, in some
embodiments, have a surface area of at least 100 m.sup.2/g, at
least 120 m.sup.2/g, at least 170 m.sup.2/g, at least 220, or at
least 270 m.sup.2/g. Such surface area may be in a range from
100-300 m.sup.2/g, 120-270 m.sup.2/g, 130-250 m.sup.2/g, or 170-220
m.sup.2/g.
[0204] In certain embodiments, the catalyst having a pore size
distribution with a median pore diameter in a range from 180-300
.ANG. may have a surface area of at least 60 m.sup.2/g, at least 90
m.sup.2/g, least 100 m.sup.2/g, at least 120 m.sup.2/g, or at least
270 m.sup.2/g. Such surface area may be in a range from 60-300
m.sup.2/g, 90-280 m.sup.2/g, 100-270 m.sup.2/g, or 120-250
m.sup.2/g.
[0205] In some embodiments, the catalyst is characterized using
Raman spectroscopy. The catalyst that includes theta alumina and
metals from Columns 6-10 may exhibit bands in a region between 800
cm.sup.-1 and 900 cm.sup.-1. Bands observed in the 800 cm.sup.-1 to
900 cm.sup.-1 region may be attributed to Metal-Oxygen-Metal
antisymmetric stretching. In some embodiments, the catalyst that
includes theta alumina and Column 6 metals exhibits bands near 810
cm.sup.-1, near 835 cm.sup.-1, and 880 cm.sup.-1. In some
embodiments, the Raman shift of a molybdenum catalyst at these
bands may indicate that the catalyst includes a species
intermediate between Mo.sub.7O.sub.24.sup.6- and MO.sub.4.sup.2-.
In some embodiments, the intermediate species is crystalline.
[0206] In some embodiments, the catalyst that includes metals from
Columns 5 may exhibit bands in a region between 650 cm.sup.-1 and
1000 cm.sup.-1. Bands observed near 650 cm.sup.-1 and 1000
cm.sup.-1 may be attributed to V.dbd.O motions. In some
embodiments, the catalyst that includes theta alumina and Columns 5
and 6 metals exhibits bands near 670 cm.sup.-1 and 990
cm.sup.-1.
[0207] In certain embodiments, the catalyst exists in shaped forms,
for example, pellets, cylinders, and/or extrudates. The catalyst
typically has a flat plate crush strength in a range from 50-500
N/cm, 60-400 N/cm, 100-350 N/cm, 200-300 N/cm, or 220-280 N/cm.
[0208] In some embodiments, the catalyst and/or the catalyst
precursor is sulfided to form metal sulfides (prior to use) using
techniques known in the art (for example, ACTICAT.TM. process, CRI
International, Inc.). In some embodiments, the catalyst may be
dried then sulfided. Alternatively, the catalyst may be sulfided in
situ by contact of the catalyst with a hydrocarbon feed that
includes sulfur-containing compounds. In-situ sulfurization may
utilize either gaseous hydrogen sulfide in the presence of
hydrogen, or liquid-phase sulfurizing agents such as organosulfur
compounds (including alkylsulfides, polysulfides, thiols, and
sulfoxides). Ex-situ sulfurization processes are described in U.S.
Pat. Nos. 5,468,372 to Seamans et al., and 5,688,736 to Seamans et
al.
[0209] In certain embodiments, a first type of catalyst ("first
catalyst") includes Columns 5-10 metal(s) in combination with a
support, and has a pore size distribution with a median pore
diameter in a range from 150-250 .ANG.. The first catalyst may have
a surface area of at least 100 m.sup.2/g. The pore volume of the
first catalyst may be at least 0.5 cm.sup.3/g. The first catalyst
may have a gamma alumina content of at least 0.5 grams of gamma
alumina, and typically at most 0.9999 grams of gamma alumina, per
gram of first catalyst. The first catalyst has, in some
embodiments, a total content of Column 6 metal(s), per gram of
catalyst, in a range from 0.0001 to 0.1 grams. The first catalyst
is capable of removing a portion of the Ni/V/Fe from a hydrocarbon
feed, removing a portion of the components that contribute to TAN
of a hydrocarbon feed, removing at least a portion of the C.sub.5
asphaltenes from a hydrocarbon feed, removing at least a portion of
the metals in metal salts of organic acids in the hydrocarbon feed,
or combinations thereof. Other properties (for example, sulfur
content, VGO content, API gravity, residue content, or combinations
thereof) may exhibit relatively small changes when the hydrocarbon
feed is contacted with the first catalyst. Being able to
selectively change properties of a hydrocarbon feed while only
changing other properties in relatively small amounts may allow the
hydrocarbon feed to be more efficiently treated. In some
embodiments, one or more first catalysts may be used in any
order.
[0210] In certain embodiments, the second type of catalyst ("second
catalyst") includes Columns 5-10 metal(s) in combination with a
support, and has a pore size distribution with a median pore
diameter in a range from 90 .ANG. to 180 .ANG.. At least 60% of the
total number of pores in the pore size distribution of the second
catalyst have a pore diameter within 45 .ANG. of the median pore
diameter. Contact of the hydrocarbon feed with the second catalyst
under suitable contacting conditions may produce a crude product
that has selected properties (for example, TAN) significantly
changed relative to the same properties of the hydrocarbon feed
while other properties are only changed by a small amount. A
hydrogen source, in some embodiments, may be present during
contacting.
[0211] The second catalyst may reduce at least a portion of the
components that contribute to the TAN of the hydrocarbon feed, at
least a portion of the components that contribute to relatively
high viscosities, and reduce at least a portion of the Ni/V/Fe
content of the crude feed. Additionally, contact of hydrocarbon
feeds with the second catalyst may produce a crude product with a
relatively small change in the sulfur content relative to the
sulfur content of the hydrocarbon feed. For example, the crude
product may have a sulfur content of 70%-130% of the sulfur content
of the hydrocarbon feed. The crude product may also exhibit
relatively small changes in distillate content, VGO content, and
residue content relative to the hydrocarbon feed.
[0212] In some embodiments, the hydrocarbon feed may have a
relatively low content of Ni/V/Fe (for example, at most 50 wtppm),
but a relatively high TAN, asphaltenes content, or content of
metals in metal salts of organic acids. A relatively high TAN (for
example, TAN of at least 0.3) may render the hydrocarbon feed
unacceptable for transportation and/or refining. A disadvantaged
crude with a relatively high C.sub.5 asphaltenes content may
exhibit less stability during processing relative to other crudes
with relatively low C.sub.5 asphaltenes content. Contact of the
hydrocarbon feed with the second catalysts, may remove acidic
components and/or C.sub.5 asphaltenes contributing to TAN from the
hydrocarbon feed. In some embodiments, reduction of C.sub.5
asphaltenes and/or components contributing to TAN may reduce the
viscosity of the hydrocarbon feed/total product mixture relative to
the viscosity of the hydrocarbon feed. In certain embodiments, one
or more combinations of second catalysts may enhance stability of
the total product/crude product mixture, increase catalyst life,
allow minimal net hydrogen uptake by the hydrocarbon feed, or
combinations thereof, when used to treat hydrocarbon feed as
described herein.
[0213] In some embodiments, a third type of catalyst ("third
catalyst") may be obtainable by combining a support with Column 6
metal(s) to produce a catalyst precursor. The catalyst precursor
may be heated in the presence of one or more sulfur containing
compounds at a temperature below 500.degree. C. (for example, below
482.degree. C.) for a relatively short period of time to form the
uncalcined third catalyst. Typically, the catalyst precursor is
heated to at least 100.degree. C. for 2 hours. In certain
embodiments, the third catalyst may, per gram of catalyst, have a
Column 15 element content in a range from 0.001-0.03 grams,
0.005-0.02 grams, or 0.008-0.01 grams. The third catalyst may
exhibit significant activity and stability when used to treat the
hydrocarbon feed as described herein. In some embodiments, the
catalyst precursor is heated at temperatures below 500.degree. C.
in the presence of one or more sulfur compounds.
[0214] The third catalyst may reduce at least a portion of the
components that contribute to the TAN of the hydrocarbon feed,
reduce at least a portion of the metals in metal salts of organic
acids, reduce a Ni/V/Fe content of the crude product, and reduce
the viscosity of the crude product. Additionally, contact of
hydrocarbon feeds with the third catalyst may produce a crude
product with a relatively small change in the sulfur content
relative to the sulfur content of the hydrocarbon feed and with
relatively minimal net hydrogen uptake by the hydrocarbon feed. For
example, a crude product may have a sulfur content of 70%-130% of
the sulfur content of the hydrocarbon feed. The crude product
produced using the third catalyst may also exhibit relatively small
changes in API gravity, distillate content, VGO content, and
residue content relative to the hydrocarbon feed. The ability to
reduce the TAN, the metals in metal salts of organic salts, the
Ni/V/Fe content, and the viscosity of the crude product while also
only changing by a small amount the API gravity, distillate
content, VGO content, and residue contents relative to the
hydrocarbon feed, may allow the crude product to be used by a
variety of treatment facilities.
[0215] The third catalyst, in some embodiments, may reduce at least
a portion of the MCR content of the hydrocarbon feed, while
maintaining hydrocarbon feed/total product stability. In certain
embodiments, the third catalyst may have a Column 6 metal(s)
content in a range from 0.0001-0.1 grams, 0.005-0.05 grams, or
0.001-0.01 grams and a Column 10 metal(s) content in a range from
0.0001-0.05 grams, 0.005-0.03 grams, or 0.001-0.01 grams per gram
of catalyst. A Columns 6 and 10 metal(s) catalyst may facilitate
reduction of at least a portion of the components that contribute
to MCR in the hydrocarbon feed at temperatures in a range from
300-500.degree. C. or 350-450.degree. C. and pressures in a range
from 0.1-10 MPa, 1-8 MPa, or 2-5 MPa.
[0216] In certain embodiments, a fourth type of catalyst ("fourth
catalyst") includes Column 5 metal(s) in combination with a theta
alumina support. The fourth catalyst has a pore size distribution
with a median pore diameter of at least 180 .ANG.. In some
embodiments, the median pore diameter of the fourth catalyst may be
at least 220 .ANG., at least 230 .ANG., at least 250 .ANG., or at
least 300 .ANG.. The support may include at least 0.1 grams, at
least 0.5 grams, at least 0.8 grams, or at least 0.9 grams of theta
alumina per gram of support. The fourth catalyst may include, in
some embodiments, at most 0.1 grams of Column 5 metal(s) per gram
of catalyst, and at least 0.0001 grams of Column 5 metal(s) per
gram of catalyst. In certain embodiments, the Column 5 metal is
vanadium.
[0217] In some embodiments, the hydrocarbon feed may be contacted
with an additional catalyst subsequent to contact with the fourth
catalyst. The additional catalyst may be one or more of the
following: the first catalyst, the second catalyst, the third
catalyst, the fifth catalyst, the sixth catalyst, the seventh
catalyst, commercial catalysts described herein, or combinations
thereof.
[0218] In some embodiments, hydrogen may be generated during
contacting of the hydrocarbon feed with the fourth catalyst at a
temperature in a range from 300-400.degree. C., 320-380.degree. C.,
or 330-370.degree. C. The crude product produced from such
contacting may have a TAN of at most 90%, at most 80%, at most 50%,
or at most 10% of the TAN of the hydrocarbon feed. Hydrogen
generation may be in a range from 1-50 Nm.sup.3/m.sup.3, 10-40
Nm.sup.3/m.sup.3, or 15-25 Nm.sup.3/m.sup.3. The crude product may
have a total Ni/V/Fe content of at most 90%, at most 80%, at most
70%, at most 50%, at most 10%, or at least 1% of total Ni/V/Fe
content of the hydrocarbon feed.
[0219] In certain embodiments, a fifth type of catalyst ("fifth
catalyst") includes Column 6 metal(s) in combination with a theta
alumina support. The fifth catalyst has a pore size distribution
with a median pore diameter of at least 180 .ANG., at least 220
.ANG., at least 230 .ANG., at least 250 .ANG., at least 300 .ANG.,
or at most 500 .ANG.. The support may include at least 0.1 grams,
at least 0.5 grams, or at most 0.999 grams of theta alumina per
gram of support. In some embodiments, the support has an alpha
alumina content of below 0.1 grams of alpha alumina per gram of
catalyst. The catalyst includes, in some embodiments, at most 0.1
grams of Column 6 metal(s) per gram of catalyst and at least 0.0001
grams of Column 6 metal(s) per gram of catalyst. In some
embodiments, the Column 6 metal(s) are molybdenum and/or
tungsten.
[0220] In certain embodiments, net hydrogen uptake by the
hydrocarbon feed may be relatively low (for example, from 0.01-100
Nm.sup.3/m.sup.3) when the hydrocarbon feed is contacted with the
fifth catalyst at a temperature in a range from 310-400.degree. C.,
from 320-370.degree. C., or from 330-360.degree. C. Net hydrogen
uptake by the hydrocarbon feed may be in a range from 1-20
Nm.sup.3/m.sup.3, 2-15 Nm.sup.3/m.sup.3, or 3-10 Nm.sup.3/m.sup.3.
The crude product produced from contact of the hydrocarbon feed
with the fifth catalyst may have a TAN of at most 90%, at most 80%,
at most 50%, or at most 10% of the TAN of the hydrocarbon feed. TAN
of the crude product may be in a range from 0.01-0.1, 0.03-0.05, or
0.02-0.03.
[0221] In certain embodiments, a sixth type of catalyst ("sixth
catalyst") includes Column 5 metal(s) and Column 6 metal(s) in
combination with the theta alumina support. The sixth catalyst has
a pore size distribution with a median pore diameter of at least
180 .ANG.. In some embodiments, the median pore diameter of pore
size distribution may be at least 220 .ANG., at least 230 .ANG., at
least 250 .ANG., at least 300 .ANG., or at most 500 .ANG.. The
support may include at least 0.1 grams, at least 0.5 grams, at
least 0.8 grams, at least 0.9 grams, or at most 0.99 grams of theta
alumina per gram of support. The catalyst may include, in some
embodiments, a total of Column 5 metal(s) and Column 6 metal(s) of
at most 0.1 grams per gram of catalyst, and at least 0.0001 grams
of Column 5 metal(s) and Column 6 metal(s) per gram of catalyst. In
some embodiments, the molar ratio of total Column 6 metal to total
Column 5 metal may be in a range from 0.1-20, 1-10, or 2-5. In
certain embodiments, the Column 5 metal is vanadium and the Column
6 metal(s) are molybdenum and/or tungsten.
[0222] When the hydrocarbon feed is contacted with the sixth
catalyst at a temperature in a range from 310-400.degree. C., from
320-370.degree. C., or from 330-360.degree. C., net hydrogen uptake
by the hydrocarbon feed may be in a range from -10 Nm.sup.3/m.sup.3
to 20 Nm.sup.3/m.sup.3, -7 Nm.sup.3/m.sup.3 to 10 Nm.sup.3/m.sup.3,
or -5 Nm.sup.3/m.sup.3 to 5 Nm.sup.3/m.sup.3. Negative net hydrogen
uptake is one indication that hydrogen is being generated in situ.
The crude product produced from contact of the hydrocarbon feed
with the sixth catalyst may have a TAN of at most 90%, at most 80%,
at most 50%, at most 10%, or at least 1% of the TAN of the
hydrocarbon feed. TAN of the crude product may be in a range from
0.01-0.1, 0.02-0.05, or 0.03-0.04.
[0223] Low net hydrogen uptake during contacting of the hydrocarbon
feed with the fourth, fifth, or sixth catalyst reduces the overall
requirement of hydrogen during processing while producing a crude
product that is acceptable for transportation and/or treatment.
Since producing and/or transporting hydrogen is costly, minimizing
the usage of hydrogen in a process decreases overall processing
costs.
[0224] In some embodiments, contact of hydrocarbon feed with the
fourth catalyst, the fifth catalyst, the sixth catalyst or
combinations thereof at a temperature in a range from 360.degree.
C. to 500.degree. C., from 380.degree. C. to 480.degree. C., from
400.degree. C. to 470.degree. C., or from 410.degree. C. to
460.degree. C., produces the crude product with a residue content
of at least 90%, at least 80%, at least 50%, at least 30% or at
least 10% of the residue content of the hydrocarbon feed.
[0225] At elevated temperatures (for example greater than
360.degree. C.), impurities and/or coke may form during contact of
the hydrocarbon feed with one or more catalysts. When contact is
performed in a continuously stirred reactor, formation of
impurities and/or coke may be determined by measuring an amount of
sediment produced during contacting. In some embodiments, the
content of sediment produced may be at most 0.002 grams or at most
0.001 grams, per gram of hydrocarbon feed/total product. When the
content of sediment approaches 0.001 grams, adjustment of
contacting conditions may be necessary to prevent shutdown of the
process and/or to maintain a suitable flow rate of hydrocarbon feed
through the contacting zone. The sediment content may range, per
gram of hydrocarbon feed/total product, from 0.00001 grams to 0.03
grams, from 0.0001 grams to 0.02 grams, from 0.001 to 0.01 grams.
Contact of the crude product with the fourth catalyst, the fifth
catalyst, the sixth catalyst, or combinations thereof at elevated
temperatures allows reduction of residue with minimal formation of
sediment.
[0226] In certain embodiments, a seventh type of catalyst ("seventh
catalyst") has a total content of Column 6 metal(s) in a range from
0.0001-0.06 grams of Column 6 metal(s) per gram of catalyst. The
Column 6 metal is molybdenum and/or tungsten. The seventh catalyst
is beneficial in producing a crude product that has a TAN of at
most 90% of the TAN of the hydrocarbon feed.
[0227] In certain embodiments, an eighth type of catalyst ("eighth
catalyst") includes Columns 6-10 metal(s) in combination with a
support, and has a pore size distribution with a median pore
diameter in a range from 50 .ANG. to 180 .ANG.. The eighth catalyst
may have a surface area of at least 200 m.sup.2/g. The pore volume
of the eighth catalyst may be at least 0.5 cm.sup.3/g. The eighth
catalyst may have a gamma alumina content of at least 0.5 grams of
gamma alumina, and typically at most 0.9999 grams of gamma alumina,
per gram of eighth catalyst. The eighth catalyst has, in some
embodiments, a total content of Column 6 metal(s), per gram of
eighth catalyst, in a range from 0.0001 grams to 0.1 grams, or from
0.01 grams to 0.05 grams. The eighth catalyst is capable of
removing a portion of the Ni/V/Fe and/or a portion of the
molybdenum from the hydrocarbon feed. In some embodiments, the
eighth catalyst selectively removes organometallic compounds (for
example, vanadium, molybdenum, and/or nickel porphyrins) while only
changing the amount of inorganic metal compounds (for example,
nickel oxides, nickel sulfide, vanadium oxides and/or vanadium
sulfides) by a relatively small amount. The concentration of
organometallic compounds in a hydrocarbon feed may be monitored by
spectrophotometric methods as described by Yen in "The Role of
Trace Metals in Petroleum" (Ann Arbor Science Publishers, Inc. Ann
Arbor Mich., 1975, page 36). Removal of organometallic compounds
may enhance lives of catalysts positioned downstream of the eighth
catalyst.
[0228] In some embodiments, a ninth type of catalyst ("ninth
catalyst") includes Columns 6-10 metal(s) in combination with a
support and has a pore size distribution with a median pore
diameter in a range from 50 .ANG. to 180 .ANG.. The ninth catalyst
support may include at least 0.01 grams, at least 0.05 grams, or at
least 0.1 grams of silica-alumina per gram of ninth catalyst. The
ninth catalyst may have a Column 6 metal(s) content in a range from
0.0001 to 0.3 grams, 0.005 grams to 0.2 grams, or 0.001 grams to
0.1 grams and a Column 10 metal(s) content in a range from 0.0001
grams to 0.05 grams, 0.005 grams to 0.03 grams, or 0.001 grams to
0.01 grams per gram of ninth catalyst. In certain embodiments, the
ninth catalyst may, per gram of ninth catalyst, have a Column 15
element content in a range from 0.001 grams to 0.03 grams, 0.005
grams to 0.02 grams, or 0.008 grams to 0.01 grams. The ninth
catalyst may facilitate reduction of at least a portion of the
components that contribute to residue, at least a portion of the
C.sub.5 and C.sub.7 asphaltenes, and at least a portion of
components that contribute to high viscosities in the hydrocarbon
feed at temperatures in a range from 300.degree. C. to 500.degree.
C., 350.degree. C. to 450.degree. C., or 370.degree. C. to
430.degree. C. and pressures in a range from 0.1 to 8 MPa, 1 to 7
MPa, or 2 to 5 MPa. In some embodiments, the ninth catalyst may
reduce at least a portion of components that contribute to the MCR
content of the hydrocarbon feed, while maintaining hydrocarbon
feed/total product stability. In certain embodiments, the ninth
catalyst may reduce at least a portion of the basic nitrogen
components in a hydrocarbon feed at temperatures of at least
200.degree. C. and pressures of at least 3 MPa.
[0229] Contact of a hydrocarbon feed with the eighth and ninth
catalyst at temperatures of at most 500.degree. C. and pressure of
at most 7 MPa may produce a crude product having a residue content,
a total C.sub.5 asphaltenes and C.sub.7 asphaltenes content, and/or
a viscosity of at most 90%, at most 80%, at most 70%, at most 50%,
at most 30% of the residue content, the total C.sub.5 asphaltenes
and C.sub.7 asphaltenes content, and/or the viscosity of the
hydrocarbon feed while maintaining a Ni/V/Fe content between 70%
and 130%, between 80% and 120%, or between 90 and 110% of the
hydrocarbon feed Ni/V/Fe content. In some embodiments, the
viscosity of the crude product is at most 99% of the viscosity of
the hydrocarbon feed after contact with the eighth and ninth
catalysts.
[0230] In some embodiments, a tenth type of catalyst ("tenth
catalyst") includes Columns 6-10 metal(s) in combination with a
support and has a pore size distribution with a median pore
diameter in a range from 50 .ANG. to 120 .ANG.. The tenth catalyst
support may include at least 0.01 grams, at least 0.05 grams, at
least 0.1 grams of silica-alumina per gram of tenth catalyst. The
tenth catalyst may have a Column 6 metal(s) content in a range from
0.0001 grams to 0.1 grams, 0.005 grams to 0.03 grams, or 0.001
grams to 0.05 grams and a Column 10 metal(s) content in a range
from 0.0001 grams to 0.05 grams, 0.005 grams to 0.03 grams, or
0.001 grams to 0.01 grams per gram of catalyst. The tenth catalyst
may facilitate reduction of at least a portion of the components
that contribute to residue, at least a portion of the C.sub.5 and
C.sub.7 asphaltenes, and at least a portion of components that
contribute to high viscosities in the hydrocarbon feed. In some
embodiments, the tenth catalyst may reduce at least a portion of
components that contribute to the MCR content of the hydrocarbon
feed, while maintaining hydrocarbon feed/total product
stability.
[0231] In certain embodiments, an eleventh type of catalyst
("eleventh catalyst") is obtainable by combining a used catalyst
with a support and Columns 6-10 metals to produce an the eleventh
catalyst. The eleventh catalyst may have from 0.001 grams to 0.3
grams, 0.005 grams to 0.2 grams, or 0.01 grams to 0.1 grams of
Column 6 metal(s) per gram of eleventh catalyst. In some
embodiments, the eleventh catalyst may have at most 0.1 grams of
Column 6 metal(s). In some embodiments, the eleventh catalyst may
include from 0.001 grams to 0.1 grams, 0.005 to 0.05 grams, or from
0.01 grams to 0.03 grams of Column 10 metal(s) per gram of eleventh
catalyst. In certain embodiments, the eleventh catalyst may include
from 0.001 grams to 0.1 grams, 0.005 to 0.05 grams, or from 0.01
grams to 0.03 grams of Column 9 metal(s) per gram of eleventh
catalyst. The eleventh catalyst has, in some embodiments, a pore
size distribution with a median pore diameter from 50 .ANG. to 130
.ANG.. The eleventh catalyst may reduce at least a portion of the
components that contribute to higher viscosities, a portion of the
components that contribute to residue and/or basic nitrogen
compounds in the hydrocarbon feed.
[0232] In some embodiments, a twelfth type of catalyst ("twelfth
catalyst") may be obtainable by combining a support with Column 6
metal(s) to produce a catalyst precursor. The catalyst precursor
may be heated in the presence of one or more sulfur containing
compounds at a temperature below 300.degree. C. or below
150.degree. C. for a time period of less than 24 hours, less than
12 hours, less than 8 hours, or less than 6 hours to form the dried
twelfth catalyst. Typically, the catalyst precursor is heated from
100.degree. C. to 150.degree. C. for 8 hours. In certain
embodiments, the twelfth catalyst may, per gram of catalyst, have a
Column 15 element content in a range from 0.001 grams to 0.03
grams, 0.005 grams to 0.02 grams, or 0.008 grams to 0.01 grams. The
twelfth catalyst may exhibit significant activity and stability
when used to treat the hydrocarbon feed as described herein. In
some embodiments, the dried catalyst may be sulfided in situ with a
hydrocarbon feed having sufficient sulfur content to convert a
portion of the metal oxides to metal sulfides. The twelfth catalyst
may reduce at least a portion of the components that contribute to
higher viscosities, a portion of the components that contribute to
residue, basic nitrogen compounds, C.sub.5 asphaltenes and C.sub.7
asphaltenes in the hydrocarbon feed.
[0233] A thirteenth type of catalyst ("thirteenth" catalyst may be
prepared by combining Columns 6-10 metal(s) with mineral oxides
having a particle size of at most 500 micrometer, and a support.
The thirteenth catalyst may have from 0.001 grams to 0.3 grams,
0.005 grams to 0.2 grams, or 0.01 grams to 0.1 grams of Column 6
metal(s), per gram of thirteenth catalyst. In some embodiments, the
thirteenth catalyst may have at most 0.1 grams of Column 6
metal(s). In certain embodiments, the thirteenth catalyst has at
most 0.06 grams of Column 6 metal(s) per gram of thirteenth
catalyst. In some embodiments, the thirteenth catalyst may include
from 0.001 grams to 0.1 grams, 0.005 grams to 0.05 grams, or from
0.01 grams to 0.03 grams of Column 10 metal(s) per gram of
catalyst. In certain embodiments, the thirteenth catalyst may
include from 0.001 grams to 0.1 grams, 0.005 to 0.05 grams, or from
0.01 grams to 0.03 grams of Column 9 metal(s) and/or Columns 10
metal(s) per gram of thirteenth catalyst. The thirteenth catalyst
may include, per gram of thirteenth catalyst, from 0.01 grams to
0.8 grams, 0.02 grams to 0.7 grams, or 0.03 grams to 0.6 grams of
mineral oxides. The thirteenth catalyst has, in some embodiments, a
pore size distribution with a median pore diameter from 50 .ANG. to
130 .ANG.. The thirteenth catalyst may have less than 1% of pores
having a pore size of at most 70 .ANG.; from 20% to 30% of pores
having a pore size between 70-100 .ANG.; from 30% to 40% of pores
having a pore size between 100-130 .ANG.; from 1% to 10% of pores
having a pore size between 130-150 .ANG.; from 0.1% to 5% of pores
having a pore size between 150-180 .ANG.; from 0.1% to 5% of pores
having a pore size between 150-180 .ANG.; from 0.1 to 5% of pores
having a pore size between 180-200 .ANG.; from 0.001% to 1% of
pores having a pore size between 200-1000 .ANG.; from 1% to 10% of
pores having a pore size between 1000-5000 .ANG.; from 20% to 25%
of pores having a pore size of at least 5000 .ANG. The thirteenth
catalyst may reduce at least a portion of the components that
contribute to higher viscosities, a portion of the components that
contribute to residue, C.sub.5 asphaltenes, and/or basic nitrogen
compounds in the hydrocarbon feed.
[0234] Other embodiments of the first through thirteenth catalysts
may also be made and/or used as is otherwise described herein.
[0235] Selecting the catalyst(s) of this application and
controlling operating conditions may allow a crude product to be
produced that has TAN and/or selected properties changed relative
to the hydrocarbon feed while other properties of the hydrocarbon
feed are not significantly changed. The resulting crude product may
have enhanced properties relative to the hydrocarbon feed and,
thus, be more acceptable for transportation and/or refining.
[0236] Arrangement of two or more catalysts in a selected sequence
may control the sequence of property improvements for the
hydrocarbon feed. For example, TAN, API gravity, at least a portion
of the C.sub.5 asphaltenes, at least a portion of the iron, at
least a portion of the nickel, and/or at least a portion of the
vanadium in the hydrocarbon feed can be reduced before at least a
portion of heteroatoms in the hydrocarbon feed are reduced.
[0237] Arrangement and/or selection of the catalysts may, in some
embodiments, improve lives of the catalysts and/or the stability of
the hydrocarbon feed/total product mixture. Improvement of a
catalyst life and/or stability of the hydrocarbon feed/total
product mixture during processing may allow a contacting system to
operate for at least 3 months, at least 6 months, or at least 1
year without replacement of the catalyst in the contacting
zone.
[0238] Combinations of selected catalysts may allow reduction in at
least a portion of the Ni/V/Fe, at least a portion of the C.sub.5
asphaltenes, at least a portion of the metals in metal salts of
organic acids, at least a portion of the components that contribute
to TAN, at least a portion of the residue, or combinations thereof,
from the hydrocarbon feed before other properties of the
hydrocarbon feed are changed, while maintaining the stability of
the hydrocarbon feed/total product mixture during processing (for
example, maintaining a hydrocarbon feed P-value of above 1.5).
Alternatively, C.sub.5 asphaltenes, TAN, and/or API gravity may be
incrementally reduced by contact of the hydrocarbon feed with
selected catalysts. The ability to incrementally and/or selectively
change properties of the hydrocarbon feed may allow the stability
of the hydrocarbon feed/total product mixture to be maintained
during processing.
[0239] In some embodiments, the first catalyst (described above)
may be positioned upstream of a series of catalysts. Such
positioning of the first catalyst may allow removal of high
molecular weight contaminants, metal contaminants, and/or metals in
metal salts of organic acids, while maintaining the stability of
the hydrocarbon feed/total product mixture.
[0240] The first catalyst allows, in some embodiments, for removal
of at least a portion of Ni/V/Fe, removal of acidic components,
removal of components that contribute to a decrease in the life of
other catalysts in the system, or combinations thereof, from the
hydrocarbon feed. For example, reducing at least a portion of
C.sub.5 asphaltenes in the hydrocarbon feed/total product mixture
relative to the hydrocarbon feed inhibits plugging of other
catalysts positioned downstream, and thus, increases the length of
time the contacting system may be operated without replenishment of
catalyst. Removal of at least a portion of the Ni/V/Fe from the
hydrocarbon feed may, in some embodiments, increase a life of one
or more catalysts positioned after the first catalyst.
[0241] The second catalyst(s) and/or the third catalyst(s) may be
positioned downstream of the first catalyst. Further contact of the
hydrocarbon feed/total product mixture with the second catalyst(s)
and/or third catalyst(s) may further reduce TAN, reduce the content
of Ni/V/Fe, reduce sulfur content, reduce oxygen content, and/or
reduce the content of metals in metal salts of organic acids.
[0242] In some embodiments, contact of the hydrocarbon feed with
the second catalyst(s) and/or the third catalyst(s) may produce a
hydrocarbon feed/total product mixture that has a reduced TAN, a
reduced sulfur content, a reduced oxygen content, a reduced content
of metals in metal salts of organic acids, a reduced asphaltenes
content, a reduced viscosity, or combinations thereof, relative to
the respective properties of the hydrocarbon feed while maintaining
the stability of the hydrocarbon feed/total product mixture during
processing. The second catalyst may be positioned in series, either
with the second catalyst being upstream of the third catalyst, or
vice versa.
[0243] The ability to deliver hydrogen to specified contacting
zones tends to minimize hydrogen usage during contacting.
Combinations of catalysts that facility generation of hydrogen
during contacting, and catalysts that uptake a relatively low
amount of hydrogen during contacting, may be used to change
selected properties of a crude product relative to the same
properties of the hydrocarbon feed. For example, the fourth
catalyst may be used in combination with the first catalyst(s),
second catalyst(s), third catalyst(s), fifth catalyst(s), sixth
catalyst(s), and/or seventh catalyst(s) to change selected
properties of a hydrocarbon feed, while only changing other
properties of the hydrocarbon feed by selected amounts, and/or
while maintaining hydrocarbon feed/total product stability. The
order and/or number of catalysts may be selected to minimize net
hydrogen uptake while maintaining the hydrocarbon feed/total
product stability. Minimal net hydrogen uptake allows residue
content, VGO content, distillate content, API gravity, or
combinations thereof of the hydrocarbon feed to be maintained
within 20% of the respective properties of the hydrocarbon feed,
while the TAN and/or the viscosity of the crude product is at most
90% of the TAN and/or the viscosity of the hydrocarbon feed.
[0244] Reduction in net hydrogen uptake by the hydrocarbon feed may
produce a crude product that has a boiling range distribution
similar to the boiling point distribution of the hydrocarbon feed,
and a reduced TAN relative to the TAN of the hydrocarbon feed. The
atomic H/C of the crude product may also only change by relatively
small amounts as compared to the atomic H/C of the hydrocarbon
feed.
[0245] Hydrogen generation in specific contacting zones may allow
selective addition of hydrogen to other contacting zones and/or
allow selective reduction of properties of the hydrocarbon feed. In
some embodiments, fourth catalyst(s) may be positioned upstream,
downstream, or between additional catalyst(s) described herein.
Hydrogen may be generated during contacting of the hydrocarbon feed
with the fourth catalyst(s), and hydrogen may be delivered to the
contacting zones that include the additional catalyst(s). The
delivery of the hydrogen may be counter to the flow of the
hydrocarbon feed. In some embodiments, the delivery of the hydrogen
may be concurrent to the flow of the hydrocarbon feed.
[0246] For example, in a stacked configuration (see, for example,
FIG. 2B), hydrogen may be generated during contacting in one
contacting zone (for example, contacting zone 102 in FIG. 2B), and
hydrogen may be delivered to an additional contacting zone (for
example, contacting zone 114 in FIG. 2B) in a direction that is
counter to flow of the hydrocarbon feed. In some embodiments, the
hydrogen flow may be concurrent with the flow of the hydrocarbon
feed. Alternatively, in a stacked configuration (see, for example,
FIG. 3B), hydrogen may be generated during contacting in one
contacting zone (for example, contacting zone 102 in FIG. 3B). A
hydrogen source may be delivered to a first additional contacting
zone in a direction that is counter to flow of the hydrocarbon feed
(for example, adding hydrogen through conduit 106' to contacting
zone 114 in FIG. 3B), and to a second additional contacting zone in
a direction that is concurrent to the flow of the hydrocarbon feed
(for example, adding hydrogen through conduit 106' to contacting
zone 116 in FIG. 3B).
[0247] In some embodiments, the fourth catalyst and the sixth
catalyst are used in series, either with the fourth catalyst being
upstream of the sixth catalyst, or vice versa. The combination of
the fourth catalyst with an additional catalyst(s) may reduce TAN,
reduce Ni/V/Fe content, and/or reduce a content of metals in metal
salts of organic acids, with low net uptake of hydrogen by the
hydrocarbon feed. Low net hydrogen uptake may allow other
properties of the crude product to be only changed by small amounts
relative to the same properties of the hydrocarbon feed.
[0248] In some embodiments, two different seventh catalysts may be
used in combination. The seventh catalyst used upstream from the
downstream seventh catalyst may have a total content of Column 6
metal(s), per gram of catalyst, in a range from 0.0001-0.06 grams.
The downstream seventh catalyst may have a total content of Column
6 metals(s), per gram of downstream seventh catalyst, that is equal
to or larger than the total content of Column 6 metal(s) in the
upstream seventh catalyst, or at least 0.02 grams of Column 6
metal(s) per gram of catalyst. In some embodiments, the position of
the upstream seventh catalyst and the downstream seventh catalyst
may be reversed. The ability to use a relatively small amount of
catalytic active metal in the downstream seventh catalyst may allow
other properties of the crude product to be only changed by small
amounts relative to the same properties of the hydrocarbon feed
(for example, a relatively small change in heteroatom content, API
gravity, residue content, VGO content, or combinations
thereof).
[0249] Contact of the hydrocarbon feed with the upstream and
downstream seventh catalysts may produce a crude product that has a
TAN of at most 90%, at most 80%, at most 50%, at most 10%, or at
least 1% of the TAN of the hydrocarbon feed. In some embodiments,
the TAN of the hydrocarbon feed may be incrementally reduced by
contact with the upstream and downstream seventh catalysts (for
example, contact of the hydrocarbon feed with a catalyst to form an
initial crude product with changed properties relative to the
hydrocarbon feed, and then contact of the initial crude product
with an additional catalyst to produce the crude product with
changed properties relative to the initial crude product). The
ability to reduce TAN incrementally may assist in maintaining the
stability of the hydrocarbon feed/total product mixture during
processing.
[0250] In some embodiments, catalyst selection and/or order of
catalysts in combination with controlled contacting conditions (for
example, temperature and/or hydrocarbon feed flow rate) may assist
in reducing hydrogen uptake by the hydrocarbon feed, maintaining
hydrocarbon feed/total product mixture stability during processing,
and changing one or more properties of the crude product relative
to the respective properties of the hydrocarbon feed. Stability of
the hydrocarbon feed/total product mixture may be affected by
various phases separating from the hydrocarbon feed/total product
mixture. Phase separation may be caused by, for example,
insolubility of the hydrocarbon feed and/or crude product in the
hydrocarbon feed/total product mixture, flocculation of asphaltenes
from the hydrocarbon feed/total product mixture, precipitation of
components from the hydrocarbon feed/total product mixture, or
combinations thereof.
[0251] At certain times during the contacting period, the
concentration of hydrocarbon feed and/or total product in the
hydrocarbon feed/total product mixture may change. As the
concentration of the total product in the hydrocarbon feed/total
product mixture changes due to formation of the crude product,
solubility of the components of the hydrocarbon feed and/or
components of the total product in the hydrocarbon feed/total
product mixture tends to change. For example, the hydrocarbon feed
may contain components that are soluble in the hydrocarbon feed at
the beginning of processing. As properties of the hydrocarbon feed
change (for example, TAN, MCR, C.sub.5 asphaltenes, P-value, or
combinations thereof), the components may tend to become less
soluble in the hydrocarbon feed/total product mixture. In some
instances, the hydrocarbon feed and the total product may form two
phases and/or become insoluble in one another. Solubility changes
may also result in the hydrocarbon feed/total product mixture
forming two or more phases. Formation of two phases, through
flocculation of asphaltenes, change in concentration of hydrocarbon
feed and total product, and/or precipitation of components, tends
to reduce the life of one or more of the catalysts. Additionally,
the efficiency of the process may be reduced. For example, repeated
treatment of the hydrocarbon feed/total product mixture may be
necessary to produce a crude product with desired properties.
[0252] During processing, the P-value of the hydrocarbon feed/total
product mixture may be monitored and the stability of the process,
hydrocarbon feed, and/or hydrocarbon feed/total product mixture may
be assessed. Typically, a P-value that is at most 1.0 indicates
that flocculation of asphaltenes from the hydrocarbon feed
generally occurs. If the P-value is initially at least 1.0, and
such P-value increases or is relatively stable during contacting,
then this indicates that the hydrocarbon feed is relatively stabile
during contacting. Hydrocarbon feed/total product mixture
stability, as assessed by P-value, may be controlled by controlling
contacting conditions, by selection of catalysts, by selective
ordering of catalysts, or combinations thereof. Such controlling of
contacting conditions may include controlling LHSV, temperature,
pressure, hydrogen uptake, hydrocarbon feed flow, or combinations
thereof.
[0253] Typically, hydrocarbon feed having viscosities that inhibit
the hydrocarbon feed from being transported and/or pumped are
contacted at elevated hydrogen pressures (for example, at least 7
MPa, at least 10 MPa or at least 15 MPa) to produce products that
are more fluid. At elevated hydrogen pressures coke formation is
inhibited, thus the properties of the hydrocarbon feed may be
changed with minimal coke production. Since reduction of viscosity,
residue and C.sub.5/C.sub.7 asphaltenes is not dependent on
hydrogen pressure reduction of these properties may not occur
unless the contacting temperature is at least 300.degree. C. For
some hydrocarbon feeds, temperatures of at least 350.degree. C. may
be required to reduce desired properties of the hydrocarbon feed to
produce a product that meets the desired specifications. At
increased temperatures coke formation may occur, even at elevated
hydrogen pressures. As the properties of the hydrocarbon feed are
changed, the P-value of the hydrocarbon feed/total product may
decrease below 1.0 and/or sediment may form, causing the product
mixture to become unstable. Since, elevated hydrogen pressures
require large amounts of hydrogen, a process capable of reducing
properties that are independent of pressure at minimal temperatures
is desirable.
[0254] Contact of a hydrocarbon feed having a viscosity of at least
10 cSt at 37.8.degree. C. (for example, at least 100 cSt, at least
1000 cSt, or at least 2000 cSt) in a controlled temperature range
of 370.degree. C. to 450.degree. C., 390.degree. C. to 440.degree.
C., or from 400.degree. C. to 430.degree. C. at pressures of at
most 7 MPa with one or more catalysts described herein produces a
crude product having changed properties (for example, viscosity,
residue and C.sub.5/C.sub.7 asphaltenes) of at most 50%, at most
30%, at most 20%, at most 10%, at most 1% of the respective
property of the hydrocarbon feed. During contact, the P-value
remains may be kept above 1.0 by controlling the contacting
temperature. For example, in some embodiments, if the temperature
increases above 450.degree. C., the P-value drops below 1.0 and the
hydrocarbon feed/total product mixture becomes unstable. If the
temperature decreases below 370.degree. C., minimal changes to the
hydrocarbon feed properties occurs.
[0255] In some embodiments, contacting temperatures are controlled
such that C.sub.5 asphaltenes and/or other asphaltenes are removed
while maintaining the MCR content of the hydrocarbon feed.
Reduction of the MCR content through hydrogen uptake and/or higher
contacting temperatures may result in formation of two phases that
may reduce the stability of the hydrocarbon feed/total product
mixture and/or life of one or more of the catalysts. Control of
contacting temperature and hydrogen uptake in combination with the
catalysts described herein allows the C.sub.5 asphaltenes to be
reduced while the MCR content of the hydrocarbon feed only changes
by a relatively small amount.
[0256] In some embodiments, contacting conditions are controlled
such that temperatures in one or more contacting zones may be
different. Operating at different temperatures allows for selective
change in hydrocarbon feed properties while maintaining the
stability of the hydrocarbon feed/total product mixture. The
hydrocarbon feed enters a first contacting zone at the start of a
process. A first contacting temperature is the temperature in the
first contacting zone. Other contacting temperatures (for example,
second temperature, third temperature, fourth temperature, et
cetera) are the temperatures in contacting zones that are
positioned after the first contacting zone. A first contacting
temperature may be in a range from 100-420.degree. C. and a second
contacting temperature may be in a range that is 20-100.degree. C.,
30-90.degree. C., or 40-60.degree. C. different than the first
contacting temperature. In some embodiments, the second contacting
temperature is greater than the first contacting temperature.
Having different contacting temperatures may reduce TAN and/or
C.sub.5 asphaltenes content in a crude product relative to the TAN
and/or the C.sub.5 asphaltenes content of the hydrocarbon feed to a
greater extent than the amount of TAN and/or C.sub.5 asphaltene
reduction, if any, when the first and second contacting
temperatures are the same as or within 10.degree. C. of each
other.
[0257] For example, a first contacting zone may include a first
catalyst(s) and/or a fourth catalyst(s) and a second contacting
zone may include other catalyst(s) described herein. The first
contacting temperature may be 350.degree. C. and the second
contacting temperature may be 300.degree. C. Contact of the
hydrocarbon feed in the first contacting zone with the first
catalyst and/or fourth catalyst at the higher temperature prior to
contact with the other catalyst(s) in the second contacting zone
may result in greater TAN and/or C.sub.5 asphaltenes reduction in
the hydrocarbon feed relative to the TAN and/or C.sub.5 asphaltenes
reduction in the same hydrocarbon feed when the first and second
contacting temperatures are within 10.degree. C.
[0258] In some embodiments, contacting conditions are controlled
such that the total hydrogen partial pressure of the contacting
zone is maintained at a desired pressure, at a set flow rate and
elevated temperatures. The ability to operate at partial pressures
of hydrogen of at most 3.5 MPa allows an increase in LHSV (for
example an increase to at least 0.5 h.sup.-1, at least 1 h.sup.-1,
at least 2 h.sup.-1, at least 5 h.sup.-1, or at least 10 h.sup.-1)
with the same or longer catalyst life as contacting at hydrogen
partial pressures of at least 4 MPa. Operating at lower partial
pressures of hydrogen decreases the cost of the operation and
allows contacting to be performed where limited amounts of hydrogen
are available.
[0259] For example, a contacting zone may include a fourth catalyst
and/or a fifth catalyst. The contacting conditions may be:
temperature of above 360.degree. C., a LHSV of 1 h.sup.-1, a total
hydrogen partial pressure of 3.5 MPa. Contact of the hydrocarbon
feed with the fourth and/or fifth catalyst at these conditions may
allow continuous use of a catalyst for at least 500 hours, while
reducing desired properties of the hydrocarbon feed.
[0260] In some embodiments, removal of at least a portion of the
organometallic compounds and/or metals from the hydrocarbon feed is
performed before the hydrocarbon feed is contacted with other
catalysts. For example, a small amount of organomolybdenum (for
example, at most 50 wtppm, at most 20 wtppm, or at most 10 wtppm)
in a hydrocarbon feed may reduce the activity of a catalyst upon
contact of the hydrocarbon feed with the catalyst. Organomolybdenum
may form molybdenum sulfides during contacting with the catalyst.
The molybdenum sulfides may precipitate from solution causing solid
molybdenum compounds to accumulate in the reactor. The accumulation
of precipitates in the reactor may lead to a pressure drop in the
contacting zone, thus inhibiting hydrocarbon feed from passing
through the contacting zone at desired flow rates. Organometallic
compounds may also promote formation of coke during contacting.
Removal of at least a portion of the "active" organometallic
compounds and/or metals from the hydrocarbon feed may increase the
lives of catalysts used in a hydroprocessing process and/or
increase efficiency of the treatment process. Removal of the active
organometallic compounds may further allow the hydrocarbon feed to
be processed in a more efficient manner. For example, a first
contacting zone may include an eighth catalyst and a second
contacting zone may include a ninth catalyst. Contact of a
hydrocarbon feed having at least 0.1 wtppm of molybdenum at
contacting temperatures of at most 7 MPa, a LHSV of at least 0.1
h.sup.-1, and a temperature of at least 300.degree. C. with the
eight catalyst may result in reduction of at least a portion of the
organomolybdenum in the hydrocarbon feed. Contact of the reduced
molybdenum hydrocarbon feed with the ninth catalyst may result in
at least a portion of the Ni/V/Fe and at least a portion of the
components contributing residue, C.sub.5/C.sub.7 asphaltenes,
and/or viscosity to be reduced to produce a crude product suitable
for transportation and/or further processing.
[0261] In some embodiments, a sixth catalyst and/or tenth catalyst
may be positioned in a third contacting zone downstream of the
first contacting zone and upstream of the second contacting zone.
Contact of the reduced molybdenum hydrocarbon feed with the
catalyst in the third contacting zone may reduce additional amounts
of Ni/V/Fe without an increasing the operating pressure above 7
MPa.
[0262] Hydrocarbon feeds having an API gravity of at most 10 (for
example, bitumen and/or heavy oil/tar sands crude) may be converted
into various hydrocarbons streams through a series of processing
steps. For example, crude may be mined from a hydrocarbon formation
and bitumen may be extracted from the crude. During the extraction
process, the bitumen is diluted with naphtha. Before the bitumen is
treated, the diluent naphtha is removed and the resulting product
is vacuum distilled unit to produce light hydrocarbons and heavy
hydrocarbons. The light hydrocarbons are transported for further
processing. The heavier bitumen components are typically processed
in one or more cokers and one or more residue hydrocracking units
(for example, ebullating bed units such as an LC-Finer). Coking
(for example, fluid coking and/or delayed coking processes)
involves the thermal cracking of bitumen molecules into lighter
components.
[0263] In the residue hydrocracking unit, heavier bitumen
components are contacted with a catalyst in the presence of
hydrocarbons to produce lighter components and an unconverted
residual stream. The unconverted residual stream may be sent to the
fluid cokers to supplement the feed to those units. The residue
hydrocracking unit may process 50,000 barrels per day of a 60/40
mix of bitumen and vacuum topped bitumen feed.
[0264] Reduction of the viscosity and/or residue content of a
hydrocarbon feed to produce a feed stream that may be processed in
a residue hydrocracking unit may enhance the processing rate of
hydrocarbon feed. A system using the methods and catalysts
described herein to change properties of a hydrocarbon feed may be
positioned upstream of one or more cracking units (for example, an
ebullating bed cracking unit, a fluid catalytic cracking unit,
thermal cracking unit, or other units known to convert hydrocarbon
feed to lighter components). Treatment of the hydrocarbon feed in
one or more systems described herein may produce a feed that
improves the processing rate of the cracking unit by at least a
factor of 2, at least a factor of 4, at least a factor of 10, or at
least a factor of 100. For example, a system for treating a
hydrocarbon feed having a viscosity of at least 100 cSt at
37.8.degree. C. and/or 0.1 grams of residue per gram of hydrocarbon
feed may include one or more contacting systems described herein
positioned upstream of a cracking unit. The contacting system may
include one or more catalysts described herein capable of producing
a crude product having a viscosity of at most 50% of the viscosity
of the hydrocarbon feed at 37.8.degree. C. and/or at most 90% of
the residue of the hydrocarbon feed. The crude product and/or a
mixture of the crude product and hydrocarbon feed may enter a
residue hydrocracking unit. Since the crude product and/or mixture
of the crude product and hydrocarbon feed has a lower viscosity
than the original hydrocarbon feed, the processing rate through the
cracking unit may be improved.
[0265] Hydrocarbon feeds having at least 0.01 grams of C.sub.5
asphaltenes may be deasphalted prior to hydroprocessing treatment
in a refinery operation. Deasphalting processes may involve solvent
extraction and/or contacting the crude with a catalyst to remove
asphaltenes. Reduction of at least a portion of the components that
contribute to viscosity, at least a portion of the components that
contribute to residue and/or asphaltenes prior to the deasphalting
process may eliminate the need for solvent extraction, reduce the
amount of required solvent, and/or enhance the efficiency of the
deasphalting process. For example, a system for treating a
hydrocarbon feed having, per gram of hydrocarbon feed, at least
0.01 grams of C.sub.5 asphaltenes and/or 0.1 grams of residue and a
viscosity of at least 10 cSt at 37.8.degree. C. may include one or
more contacting systems described herein positioned upstream of an
deasphalting unit. The contacting system may include one or more
catalysts described herein capable of producing a crude product
having a C.sub.5 asphaltenes content of at most 50% of the
hydrocarbon feed C.sub.5 asphaltenes content, a residue content of
at most 90% of the hydrocarbon feed residue content, a viscosity of
at most 50% of the hydrocarbon viscosity or combinations thereof.
The crude product and/or a mixture of the crude product and
hydrocarbon feed may enter the deasphalting unit. Since the crude
product and/or mixture of the crude product and the hydrocarbon
feed has a lower asphaltene, residue and/or viscosity than the
original hydrocarbon feed, the processing efficiency of the
deasphalting unit may be increased by at least 5%, at least 10%, at
least 20% or at least 50% of the original efficiency.
[0266] In some embodiments, contact of a crude feed with one or
more catalysts described herein produces a crude product that has
enhanced concentrations of naphtha. The naphtha may be separated
from the crude product and mixed with crude feed to produce a feed
that is suitable for transportation and/or meets pipeline
specification. For example, a crude feed may be contacted with at
least a third catalyst and a zeolite catalyst. The zeolite catalyst
may be a 10 wt %, 20 wt %, 30 wt %, or 40 wt % USY zeolite
catalyst, and/or an ultra stable Y zeolite catalyst. The zeolite
catalyst may reduce a portion of the hydrocarbons to produce
naphtha. The naphtha may be separated from the crude product using
known fractional distillation methods and mixed with the crude
feed, a different crude feed, and/or other hydrocarbons to form a
blend.
EXAMPLES
[0267] Non-limiting examples of support preparation, catalyst
preparations, and systems with selected arrangement of catalysts
and controlled contacting conditions are set forth below.
Example 1
Preparation of a Catalyst Support
[0268] A support was prepared by mulling 576 grams of alumina
(Criterion Catalysts and Technologies LP, Michigan City, Mich.,
U.S.A.) with 585 grams of water and 8 grams of glacial nitric acid
for 35 minutes. The resulting mulled mixture was extruded through a
1.3 Trilobe.TM. die plate, dried between 90 and 125.degree. C., and
then calcined at 918.degree. C., which resulted in 650 grams of a
calcined support with a median pore diameter of 182 .ANG.. The
calcined support was placed in a Lindberg furnace. The furnace
temperature was raised to 1000-1100.degree. C. over 1.5 hours, and
then held in this range for 2 hours to produce the support. The
support included, per gram of support, 0.0003 grams of gamma
alumina, 0.0008 grams of alpha alumina, 0.0208 grams of delta
alumina, and 0.9781 grams of theta alumina, as determined by x-ray
diffraction. The support had a surface area of 110 m.sup.2/g and a
total pore volume of 0.821 cm.sup.3/g. The support had a pore size
distribution with a median pore diameter of 232 .ANG., with 66.7%
of the total number of pores in the pore size distribution having a
pore diameter within 85 .ANG. of the median pore diameter.
[0269] This example demonstrates how to prepare a support that has
a pore size distribution of at least 180 .ANG. and includes at
least 0.1 grams of theta alumina.
Example 2
Preparation of a Vanadium Catalyst Having a Pore Size Distribution
with a Median Pore Diameter of at Least 230 .ANG.
[0270] The vanadium catalyst was prepared in the following manner.
The alumina support, prepared by the method described in Example 1,
was impregnated with a vanadium impregnation solution prepared by
combining 7.69 grams of VOSO.sub.4 with 82 grams of deionized
water. A pH of the solution was 2.27.
[0271] The alumina support (100 g) was impregnated with the
vanadium impregnation solution, aged for 2 hours with occasional
agitation, dried at 125.degree. C. for several hours, and then
calcined at 480.degree. C. for 2 hours. The resulting catalyst
contained 0.04 grams of vanadium, per gram of catalyst, with the
balance being support. The vanadium catalyst had a pore size
distribution with a median pore diameter of 350 .ANG., a pore
volume of 0.69 cm.sup.3/g, and a surface area of 110 m.sup.2/g.
Additionally, 66.7% of the total number of pores in the pore size
distribution of the vanadium catalyst had a pore diameter within 70
.ANG. of the median pore diameter.
[0272] This example demonstrates the preparation of a Column 5
catalyst having a pore size distribution with a median pore
diameter of at least 230 .ANG..
Example 3
Preparation of a Molybdenum Catalyst Having a Pore Size
Distribution with a Median Pore Diameter of at Least 230 .ANG.
[0273] The molybdenum catalyst was prepared in the following
manner. The alumina support prepared by the method described in
Example 1 was impregnated with a molybdenum impregnation solution.
The molybdenum impregnation solution was prepared by combining 4.26
grams of (NH.sub.4).sub.2Mo.sub.2O.sub.7, 6.38 grams of MoO.sub.3,
1.12 grams of 30% H.sub.2O.sub.2, 0.27 grams of monoethanolamine
(MEA), and 6.51 grams of deionized water to form a slurry. The
slurry was heated to 65.degree. C. until dissolution of the solids.
The heated solution was cooled to room temperature. The pH of the
solution was 5.36. The solution volume was adjusted to 82 mL with
deionized water.
[0274] The alumina support (100 grams) was impregnated with the
molybdenum impregnation solution, aged for 2 hours with occasional
agitation, dried at 125.degree. C. for several hours, and then
calcined at 480.degree. C. for 2 hours. The resulting catalyst
contained 0.04 grams of molybdenum per gram of catalyst, with the
balance being support. The molybdenum catalyst had a pore size
distribution with a median pore diameter of 250 .ANG., a pore
volume of 0.77 cm.sup.3/g, and a surface area of 116 m.sup.2/g.
Additionally, 67.7% of the total number of pores in the pore size
distribution of the molybdenum catalyst had a pore diameter within
86 .ANG. of the median pore diameter.
[0275] The molybdenum catalyst exhibited bands near 810 cm.sup.-1,
834 cm.sup.-1, and 880 cm.sup.-1 when analyzed by Raman
Spectroscopy. The Raman spectrum of the catalyst was obtained on a
Chromex Raman 200 spectrometer operated at four-wavenumber
resolution. The excitation wavelength was 785 nm at a power of
approximately 45 mW at the sample. The spectrometer wavenumber
scale was calibrated using the known bands of 4-acetominophenol.
The band positions of 4-actiominophenol were reproduced to within
.+-.cm.sup.-1. A molybdenum catalyst with a gamma alumina support
did not exhibit bands between 810 cm.sup.-1 and 900 cm.sup.-1 when
analyzed by Raman Spectroscopy. FIG. 7 depicts the spectrum of the
two catalysts. Plot 138 represents the molybdenum catalyst having a
pore size distribution with a median pore diameter of 250 .ANG..
Plot 140 represents a Column 6/Column 10 metal catalyst that
includes at least 0.5 grams of gamma alumina having a pore size
distribution with a median pore diameter of 120 .ANG..
[0276] This example demonstrates the preparation of a Column 6
metal catalyst having a pore size distribution with a median pore
diameter of at least 230 .ANG.. This example also demonstrates
preparation of a Column 6 metal catalyst having bands near 810
cm.sup.-1, 834 cm.sup.-1, and 880 cm.sup.-1, as determined by Raman
Spectroscopy. The catalyst prepared by this method is different
than a gamma alumina catalyst having a pore size distribution with
a median pore diameter of at least 100 .ANG..
Example 4
Preparation of a Molybdenum/Vanadium Catalyst Having a Pore Size
Distribution with a Median Pore Diameter of at Least 230 .ANG.
[0277] The molybdenum/vanadium catalyst was prepared in the
following manner. The alumina support, prepared by the method
described in Example 1, was impregnated with a molybdenum/vanadium
impregnation solution prepared as follows. A first solution was
made by combining 2.14 grams of (NH.sub.4).sub.2Mo.sub.2O.sub.7,
3.21 grams of MoO.sub.3, 0.56 grams of 30% hydrogen peroxide
(H.sub.2O.sub.2), 0.14 grams of monoethanolamine (MEA), and 3.28
grams of deionized water to form a slurry. The slurry was heated to
65.degree. C. until dissolution of the solids. The heated solution
was cooled to room temperature.
[0278] A second solution was made by combining 3.57 grams of
VOSO.sub.4 with 40 grams of deionized water. The first solution and
second solution were combined and sufficient deionized water was
added to bring the combined solution volume up to 82 ml to yield
the molybdenum/vanadium impregnation solution. The alumina was
impregnated with the molybdenum/vanadium impregnation solution,
aged for 2 hours with occasional agitation, dried at 125.degree. C.
for several hours, and then calcined at 480.degree. C. for 2 hours.
The resulting catalyst contained, per gram of catalyst, 0.02 grams
of vanadium and 0.02 grams of molybdenum, with the balance being
support. The molybdenum/vanadium catalyst had a pore size
distribution with a median pore diameter of 300 .ANG..
[0279] This example demonstrates the preparation of a Column 6
metal and a Column 5 metal catalyst having a pore size distribution
with a median pore diameter of at least 230 .ANG.. The
vanadium/molybdenum catalyst exhibited bands near 770 cm.sup.-1 and
990 cm.sup.-1 when analyzed by Raman Spectroscopy. FIG. 7 depicts
the spectrum of the vanadium catalyst. Plot 142 represents the
molybdenum catalyst having a pore size distribution with a median
pore diameter of 250 .ANG..
[0280] This example also demonstrates the preparation of a Column 5
catalyst having bands near 770 cm.sup.-1 and 990 cm.sup.-1 when
analyzed by Raman Spectroscopy.
Example 5
Contact of a Crude Feed with Three Catalysts
[0281] A tubular reactor with a centrally positioned thermowell was
equipped with thermocouples to measure temperatures throughout a
catalyst bed. The catalyst bed was formed by filling the space
between the thermowell and an inner wall of the reactor with
catalysts and silicon carbide (20-grid, Stanford Materials; Aliso
Viejo, Calif.). Such silicon carbide is believed to have low, if
any, catalytic properties under the process conditions described
herein. All catalysts were blended with an equal volume amount of
silicon carbide before placing the mixture into the contacting zone
portions of the reactor.
[0282] The crude feed flow to the reactor was from the top of the
reactor to the bottom of the reactor. Silicon carbide was
positioned at the bottom of the reactor to serve as a bottom
support. A bottom catalyst/silicon carbide mixture (42 cm.sup.3)
was positioned on top of the silicon carbide to form a bottom
contacting zone. The bottom catalyst had a pore size distribution
with a median pore diameter of 77 .ANG., with 66.7% of the total
number of pores in the pore size distribution having a pore
diameter within 20 .ANG. of the median pore diameter. The bottom
catalyst contained 0.095 grams of molybdenum and 0.025 grams of
nickel per gram of catalyst, with the balance being an alumina
support.
[0283] A middle catalyst/silicone carbide mixture (56 cm.sup.3) was
positioned on top of the bottom contacting zone to form a middle
contacting zone. The middle catalyst had a pore size distribution
with a median pore diameter of 98 .ANG., with 66.7% of the total
number of pores in the pore size distribution having a pore
diameter within 24 .ANG. of the median pore diameter. The middle
catalyst contained 0.02 grams of nickel and 0.08 grams of
molybdenum per gram of catalyst, with the balance being an alumina
support.
[0284] A top catalyst/silicone carbide mixture (42 cm.sup.3) was
positioned on top of the middle contacting zone to form a top
contacting zone. The top catalyst had a pore size distribution with
a median pore diameter of 192 .ANG. and contained 0.04 grams of
molybdenum per gram of catalyst, with the balance being primarily a
gamma alumina support.
[0285] Silicon carbide was positioned on top of the top contacting
zone to fill dead space and to serve as a preheat zone. The
catalyst bed was loaded into a Lindberg furnace that included five
heating zones corresponding to the preheat zone, the top, middle,
and bottom contacting zones, and the bottom support.
[0286] The catalysts were sulfided by introducing a gaseous mixture
of 5 vol % hydrogen sulfide and 95 vol % hydrogen gas into the
contacting zones at a rate of 1.5 liter of gaseous mixture per
volume (mL) of total catalyst (silicon carbide was not counted as
part of the volume of catalyst). Temperatures of the contacting
zones were increased to 204.degree. C. (400.degree. F.) over 1 hour
and held at 204.degree. C. for 2 hours. After holding at
204.degree. C., the contacting zones were increased incrementally
to 316.degree. C. (600.degree. F.) at a rate of 10.degree. C.
(50.degree. F.) per hour. The contacting zones were maintained at
316.degree. C. for an hour, then incrementally raised to
370.degree. C. (700.degree. F.) over 1 hour and held at 370.degree.
C. for two hours. The contacting zones were allowed to cool to
ambient temperature.
[0287] Crude from the Mars platform in the Gulf of Mexico was
filtered, then heated in an oven at a temperature of 93.degree. C.
(200.degree. F.) for 12-24 hours to form the crude feed having the
properties summarized in Table 1, FIG. 8. The crude feed was fed to
the top of the reactor. The crude feed flowed through the preheat
zone, top contacting zone, middle contacting zone, bottom
contacting zone, and bottom support of the reactor. The crude feed
was contacted with each of the catalysts in the presence of
hydrogen gas. Contacting conditions were as follows: ratio of
hydrogen gas to the crude feed provided to the reactor was 328
Nm.sup.3/m.sup.3 (2000 SCFB), LHSV was 1 h.sup.-1, and pressure was
6.9 MPa (1014.7 psi). The three contacting zones were heated to
370.degree. C. (700.degree. F.) and maintained at 370.degree. C.
for 500 hours. Temperatures of the three contacting zones were then
increased and maintained in the following sequence: 379.degree. C.
(715.degree. F.) for 500 hours, and then 388.degree. C.
(730.degree. F.) for 500 hours, then 390.degree. C. (734.degree.
F.) for 1800 hours, and then 394.degree. C. (742.degree. F.) for
2400 hours.
[0288] The total product (that is, the crude product and gas)
exited the catalyst bed. The total product was introduced into a
gas-liquid phase separator. In the gas-liquid separator, the total
product was separated into the crude product and gas. Gas input to
the system was measured by a mass flow controller. Gas exiting the
system was measured by a wet test meter. The crude product was
periodically analyzed to determine a weight percentage of
components of the crude product. The results listed are averages of
the determined weight percentages of components. Crude product
properties are summarized in Table 1 of FIG. 8.
[0289] As shown in Table 1, the crude product had, per gram of
crude product, a sulfur content of 0.0075 grams, a residue content
of 0.255 grams, an oxygen content of 0.0007 grams. The crude
product had a ratio of MCR content to C.sub.5 asphaltenes content
of 1.9 and a TAN of 0.09. The total of nickel and vanadium was 22.4
wtppm.
[0290] The lives of the catalysts were determined by measuring a
weighted average bed temperature ("WABT") versus run length of the
crude feed. The catalysts lives may be correlated to the
temperature of the catalyst bed. It is believed that as catalyst
life decreases, a WABT increases. FIG. 9 is a graphical
representation of WABT versus time for improvement of the crude
feed in the contacting zones described in this example. Plot 144
represents the average WABT of the three contacting zones versus
hours of run time for contacting a crude feed with the top, middle,
and bottom catalysts. Over a majority of the run time, the WABT of
the contacting zones only changed approximately 20.degree. C. From
the relatively stable WABT, it was possible to estimate that the
catalytic activity of the catalyst had not been affected.
Typically, a pilot unit run time of 3000-3500 hours correlates to 1
year of commercial operation.
[0291] This example demonstrates that contacting the crude feed
with one catalyst having a pore size distribution with a median
pore diameter of at least 180 .ANG. and additional catalysts having
a pore size distribution with a median pore diameter in a range
between 90-180 .ANG., with at least 60% of the total number of
pores in the pore size distribution having a pore diameter within
45 .ANG. of the median pore diameter, with controlled contacting
conditions, produced a total product that included the crude
product. As measured by P-value, crude feed/total product mixture
stability was maintained. The crude product had reduced TAN,
reduced Ni/V/Fe content, reduced sulfur content, and reduced oxygen
content relative to the crude feed, while the residue content and
the VGO content of the crude product was 90%-110% of those
properties of the crude feed.
Example 6
Contact of a Crude Feed with Two Catalysts that have a Pore Size
Distribution with a Median Pore Diameter in a Range Between 90-180
.ANG.
[0292] The reactor apparatus (except for the number and content of
contacting zones), catalyst sulfiding method, method of separating
the total product and method of analyzing the crude product were
the same as described in Example 5. Each catalyst was mixed with an
equal volume of silicon carbide.
[0293] The crude feed flow to the reactor was from the top of the
reactor to the bottom of the reactor. The reactor was filled from
bottom to top in the following manner. Silicon carbide was
positioned at the bottom of the reactor to serve as a bottom
support. A bottom catalyst/silicon carbide mixture (80 cm.sup.3)
was positioned on top of the silicon carbide to form a bottom
contacting zone. The bottom catalyst had a pore size distribution
with a median pore diameter of 127 .ANG., with 66.7% of the total
number pores in the pore size distribution having a pore diameter
within 32 .ANG. of the median pore diameter. The bottom catalyst
included 0.11 grams of molybdenum and 0.02 grams of nickel per gram
of catalyst, with the balance being support.
[0294] A top catalyst/silicone carbide mixture (80 cm.sup.3) was
positioned on top of the bottom contacting zone to form the top
contacting zone. The top catalyst had a pore size distribution with
a median pore diameter of 100 .ANG., with 66.7% of the total number
of pores in the pore size distribution having a pore diameter
within 20 .ANG. of the median pore diameter. The top catalyst
included 0.03 grams of nickel and 0.12 grams of molybdenum per gram
of catalyst, with the balance being alumina. Silicon carbide was
positioned on top of the first contacting zone to fill dead space
and to serve as a preheat zone. The catalyst bed was loaded into a
Lindberg furnace that included four heating zones corresponding to
the preheat zone, the two contacting zones, and the bottom
support.
[0295] BS-4 crude (Venezuela) having the properties summarized in
Table 2, FIG. 10, was fed to the top of the reactor. The crude feed
flowed through the preheat zone, top contacting zone, bottom
contacting zone, and bottom support of the reactor. The crude feed
was contacted with each of the catalysts in the presence of
hydrogen gas. The contacting conditions were as follows: ratio of
hydrogen gas to the crude feed provided to the reactor was 160
Nm.sup.3/m.sup.3 (1000 SCFB), LHSV was 1 h.sup.-1, and pressure was
6.9 MPa (1014.7 psi). The two contacting zones were heated to
260.degree. C. (500.degree. F.) and maintained at 260.degree. C.
(500.degree. F.) for 287 hours. Temperatures of the two contacting
zones were then increased and maintained in the following sequence:
270.degree. C. (525.degree. F.) for 190 hours, then 288.degree. C.
(550.degree. F.) for 216 hours, then 315.degree. C. (600.degree.
F.) for 360 hours, and then 343.degree. C. (650.degree. F.) for 120
hours for a total run time of 1173 hours.
[0296] The total product exited the reactor and was separated as
described in Example 5. The crude product had an average TAN of
0.42 and an average API gravity of 12.5 during processing. The
crude product had, per gram of crude product, 0.0023 grams of
sulfur, 0.0034 grams of oxygen, 0.441 grams of VGO, and 0.378 grams
of residue. Additional properties of the crude product are listed
in TABLE 2 in FIG. 10.
[0297] This example demonstrates that contacting the crude feed
with the catalysts having pore size distributions with a median
pore diameter in a range between 90-180 .ANG. produced a crude
product that had a reduced TAN, a reduced Ni/V/Fe content, and a
reduced oxygen content, relative to the properties of the crude
feed, while residue content and VGO content of the crude product
were 99% and 100% of the respective properties of the crude
feed.
Example 7
Contact of a Crude Feed with Two Catalysts
[0298] The reactor apparatus (except for number and content of
contacting zones), catalysts, the total product separation method,
crude product analysis, and catalyst sulfiding method were the same
as described in Example 6.
[0299] A crude feed (BC-10 crude) having the properties summarized
in Table 3, FIG. 11, was fed to the top of the reactor. The crude
feed flowed through the preheat zone, top contacting zone, bottom
contacting zone, and bottom support of the reactor. The contacting
conditions were as follows: ratio of hydrogen gas to the crude feed
provided to the reactor was 80 Nm.sup.3/m.sup.3 (500 SCFB), LHSV
was 2 h.sup.-1, and pressure was 6.9 MPa (1014.7 psi). The two
contacting zones were heated incrementally to 343.degree. C.
(650.degree. F.). A total run time was 1007 hours.
[0300] The crude product had an average TAN of 0.16 and an average
API gravity of 16.2 during processing. The crude product had 1.9
wtppm of calcium, 6 wtppm of sodium, 0.6 wtppm of zinc, and 3 wtppm
of potassium. The crude product had, per gram of crude product,
0.0033 grams of sulfur, 0.002 grams of oxygen, 0.376 grams of VGO,
and 0.401 grams of residue. Additional properties of the crude
product are listed in Table 3 in FIG. 11.
[0301] This example demonstrates that contacting of the crude feed
with the selected catalysts with pore size distributions in a range
of 90-180 .ANG. produced a crude product that had a reduced TAN, a
reduced total calcium, sodium, zinc, and potassium content while
sulfur content, VGO content, and residue content of the crude
product were 76%, 94%, and 103% of the respective properties of the
crude feed.
Examples 8-11
Contact of a Crude Feed with Four Catalyst Systems and at Various
Contacting Conditions
[0302] Each reactor apparatus (except for the number and content of
contacting zones), each total product separation method, and each
crude product analysis were the same as described in Example 5. The
catalysts were sulfided using the method as described in U.S. Pat.
No. 6,290,841 to Gabrielov et al. All catalysts were mixed with
silicon carbide in a volume ratio of 2 parts silicon carbide to 1
part catalyst unless otherwise indicated. The crude feed flow
through each reactor was from the top of the reactor to the bottom
of the reactor. Silicon carbide was positioned at the bottom of
each reactor to serve as a bottom support. Each reactor had a
bottom contacting zone and a top contacting zone. After the
catalyst/silicone carbide mixtures were placed in the contacting
zones of each reactor, silicone carbide was positioned on top of
the top contacting zone to fill dead space and to serve as a
preheat zone in each reactor. Each reactor was loaded into a
Lindberg furnace that included four heating zones corresponding to
the preheat zone, the two contacting zones, and the bottom
support.
[0303] In Example 8, an uncalcined molybdenum/nickel
catalyst/silicon carbide mixture (48 cm.sup.3) was positioned in
the bottom contacting zone. The catalyst included, per gram of
catalyst, 0.146 grams of molybdenum, 0.047 grams of nickel, and
0.021 grams of phosphorus, with the balance being alumina
support.
[0304] A molybdenum catalyst/silicon carbide mixture (12 cm.sup.3)
with the catalyst having a pore size distribution with a median
pore diameter of 180 .ANG. was positioned in the top contacting
zone. The molybdenum catalyst had a total content of 0.04 grams of
molybdenum per gram of catalyst, with the balance being support
that included at least 0.50 grams of gamma alumina per gram of
support.
[0305] In Example 9, an uncalcined molybdenum/cobalt
catalyst/silicon carbide mixture (48 cm.sup.3) was positioned in
the both contacting zones. The uncalcined molybdenum/cobalt
catalyst included 0.143 grams of molybdenum, 0.043 grams of cobalt,
and 0.021 grams of phosphorus with the balance being alumina
support.
[0306] A molybdenum catalyst/silicon carbide mixture (12 cm.sup.3)
was positioned in the top contacting zone. The molybdenum catalyst
was the same as in the top contacting zone of Example 8.
[0307] In Example 10, the molybdenum catalyst as described in the
top contacting zone of Example 8 was mixed with silicon carbide and
positioned in the both contacting zones (60 cm.sup.3).
[0308] In Example 11, an uncalcined molybdenum/nickel
catalyst/silicone carbide mixture (48 cm.sup.3) was positioned in
the bottom contacting zone. The uncalcined molybdenum/nickel
catalyst included, per gram of catalyst, 0.09 grams of molybdenum,
0.025 grams of nickel, and 0.01 grams of phosphorus, with the
balance being alumina support.
[0309] A molybdenum catalyst/silicon carbide mixture (12 cm.sup.3)
was positioned in the top contacting zone. The molybdenum catalyst
was the same as in the top contacting zone of Example 8.
[0310] Crude from the Mars platform (Gulf of Mexico) was filtered,
then heated in an oven at a temperature of 93.degree. C.
(200.degree. F.) for 12-24 hours to form the crude feed for
Examples 8-11 having the properties summarized in Table 4, FIG. 12.
The crude feed was fed to the top of the reactor in these examples.
The crude feed flowed through the preheat zone, top contacting
zone, bottom contacting zone, and bottom support of the reactor.
The crude feed was contacted with each of the catalysts in the
presence of hydrogen gas. Contacting conditions for each example
were as follows: ratio of hydrogen gas to crude feed during
contacting was 160 Nm.sup.3/m.sup.3 (1000 SCFB), and the partial
pressure of hydrogen of each system was 6.9 MPa (1014.7 psi). LHSV
was 2.0 h.sup.-1 during the first 200 hours of contacting, and then
lowered to 1.0 h.sup.-1 for the remaining contacting times.
Temperatures in all contacting zones were 343.degree. C.
(650.degree. F.) for 500 hours of contacting. After 500 hours, the
temperatures in all contacting zones were controlled as follows:
the temperature in the contacting zones were raised to 354.degree.
C. (670.degree. F.), held at 354.degree. C. for 200 hours; raised
to 366.degree. C. (690.degree. F.), held at 366.degree. C. for 200
hours; raised to 371.degree. C. (700.degree. F.), held at
371.degree. C. for 1000 hours; raised to 385.degree. C.
(725.degree. C.), held at 385.degree. C. for 200 hours; then raised
to a final temperature of 399.degree. C. (750.degree. C.) and held
at 399.degree. C. for 200 hours, for a total contacting time of
2300 hours.
[0311] The crude products were periodically analyzed to determine
TAN, hydrogen uptake by the crude feed, P-value, VGO content,
residue content, and oxygen content. Average values for properties
of the crude products produced in Examples 8-11 are listed in Table
4 in FIG. 12.
[0312] FIG. 13 is a graphical representation of P-value of the
crude product versus run time for each of the catalyst systems of
Examples 8-11. The crude feed had a P-value of at least 1.5. Plots
150, 152, 154, and 156 represent the P-value of the crude product
obtained by contacting the crude feed with the four catalyst
systems of Examples 8-11 respectively. For 2300 hours, the P-value
of the crude product remained of at least 1.5 for catalyst systems
of Examples 8-10. In Example 11, the P-value was above 1.5 for most
of the run time. At the end of the run (2300 hours) for Example 11,
the P-value was 1.4. From the P-value of the crude product for each
trial, it may be inferred that the crude feed in each trial
remained relatively stable during contacting (for example, the
crude feed did not phase separate). As shown in FIG. 13, the
P-value of the crude product remained relatively constant during
significant portions of each trial, except in Example 10, in which
the P-value increased.
[0313] FIG. 14 is a graphical representation of net hydrogen uptake
by crude feed versus run time for four catalyst systems in the
presence of hydrogen gas. Plots 158, 160 162, 164 represent net
hydrogen uptake obtained by contacting the crude feed with each of
the catalyst systems of Examples 8-11, respectively. Net hydrogen
uptake by a crude feed over a run time period of 2300 hours was in
a range between 7-48 Nm.sup.3/m.sup.3 (43.8-300 SCFB). As shown in
FIG. 14, the net hydrogen uptake of the crude feed was relatively
constant during each trial.
[0314] FIG. 15 is a graphical representation of residue content,
expressed in weight percentage, of crude product versus run time
for each of the catalyst systems of Examples 8-11. In each of the
four trials, the crude product had a residue content of 88-90% of
the residue content of the crude feed. Plots 166, 168, 170, 172
represent residue content of the crude product obtained by
contacting the crude feed with the catalyst systems of Examples
8-11, respectively. As shown in FIG. 15, the residue content of the
crude product remained relatively constant during significant
portions of each trial.
[0315] FIG. 16 is a graphical representation of change in API
gravity of the crude product versus run time for each of the
catalyst systems of Examples 8-11. Plots 174, 176, 178, 180
represent API gravity of the crude product obtained by contacting
the crude feed with the catalyst systems of Examples 8-11,
respectively. In each of the four trials, each crude product had a
viscosity in a range from 58.3-72.7 cSt. The API gravity of each
crude products increased by 1.5 to 4.1 degrees. The increased API
gravity corresponds to an API gravity of the crude products in a
range from 21.7-22.95. API gravity in this range is 110-117% of the
API gravity of the crude feed.
[0316] FIG. 17 is a graphical representation of oxygen content,
expressed in weight percentage, of the crude product versus run
time for each of the catalyst systems of Examples 8-11. Plots 182,
184, 186, 188 represent oxygen content of the crude product
obtained by contacting the crude feed with the catalyst systems of
Examples 8-11, respectively. Each crude product had an oxygen
content of at most 16% of the crude feed. Each crude product had an
oxygen content in a range from 0.0014-0.0015 grams per gram of
crude product during each trial. As shown in FIG. 17, the oxygen
content of the crude product remained relatively constant after 200
hours of contacting time. The relatively constant oxygen content of
the crude product demonstrates that selected organic oxygen
compounds are reduced during the contacting. Since TAN was also
reduced in these examples, it may be inferred that at least a
portion of the carboxylic containing organic oxygen compounds are
reduced selectively over the non-carboxylic containing organic
oxygen compounds.
[0317] In Example 11, at reaction conditions of: 371.degree. C.
(700.degree. F.), a pressure of 6.9 MPa (1014.7 psi), and a ratio
of hydrogen to crude feed of 160 Nm.sup.3/m.sup.3 (1000 SCFB), the
reduction of crude feed MCR content was 17.5 wt %, based on the
weight of the crude feed. At a temperature of 399.degree. C.
(750.degree. F.), at the same pressure and ratio of hydrogen to
crude feed, the reduction of crude feed MCR content was 25.4 wt %,
based on the weight of the crude feed.
[0318] In Example 9, at reaction conditions of: 371.degree. C.
(700.degree. F.), a pressure of 6.9 MPa (1014.7 psi), and a ratio
of hydrogen to crude feed of 160 Nm.sup.3/m.sup.3 (1000 SCFB), the
reduction of crude feed MCR content was 17.5 wt %, based on the
weight of the crude feed. At a temperature of 399.degree. C.
(750.degree. F.), at the same pressure and ratio of hydrogen to
crude feed, the reduction of crude feed MCR content was 19 wt %,
based on the weight of the crude feed.
[0319] This increased reduction in crude feed MCR content
demonstrates that the uncalcined Columns 6 and 10 metals catalyst
facilitates MCR content reduction at higher temperatures than the
uncalcined Columns 6 and 9 metals catalyst.
[0320] These examples demonstrate that contact of a crude feed with
a relatively high TAN (TAN of 0.8) with one or more catalysts
produces the crude product, while maintaining the crude feed/total
product mixture stability and with relatively small net hydrogen
uptake. Selected crude product properties were at most 70% of the
same properties of the crude feed, while selected properties of the
crude product were within 20-30% of the same properties of the
crude feed.
[0321] Specifically, as shown in Table 4, each of the crude
products was produced with a net hydrogen uptake by the crude feeds
of at most 44 Nm.sup.3/m.sup.3 (275 SCFB). Such products had an
average TAN of at most 4% of the crude feed, and an average total
Ni/V content of at most 61% of the total Ni/V content of the crude
feed, while maintaining a P-value for the crude feed of above 3.
The average residue content of each crude product was 88-90% of the
residue content of the crude feed. The average VGO content of each
crude product was 115-117% of the VGO content of the crude feed.
The average API gravity of each crude product was 110-117% of the
API gravity of the crude feed, while the viscosity of each crude
product was at most 45% of the viscosity of the crude feed.
Examples 12-14
Contact of a Crude Feed with Catalysts Having a Pore Size
Distribution with a Median Pore Diameter of at Least 180 .ANG. with
Minimal Hydrogen Consumption
[0322] In Examples 12-14, each reactor apparatus (except for number
and content of contacting zones), each catalyst sulfiding method,
each total product separation method and each crude product
analysis were the same as described in Example 5. All catalysts
were mixed with an equal volume of silicon carbide. The crude feed
flow to each reactor was from the top of the reactor to the bottom
of the reactor. Silicon carbide was positioned at the bottom of
each reactor to serve as a bottom support. Each reactor contained
one contacting zone. After the catalyst/silicone carbide mixtures
were placed in the contacting zone of each reactor, silicone
carbide was positioned on top of the top contacting zone to fill
dead space and to serve as a preheat zone in each reactor. Each
reactor was loaded into a Lindberg furnace that included three
heating zones corresponding to the preheat zone, the contacting
zone, and the bottom support. The crude feed was contacted with
each of the catalysts in the presence of hydrogen gas.
[0323] A catalyst/silicon carbide mixture (40 cm.sup.3) was
positioned on top of the silicon carbide to form the contacting
zone. For Example 12, the catalyst was the vanadium catalyst as
prepared in Example 2. For Example 13, the catalyst was the
molybdenum catalyst as prepared in Example 3. For Example 14, the
catalyst was the molybdenum/vanadium catalyst as prepared in
Example 4.
[0324] The contacting conditions for Examples 12-14 were as
follows: ratio of hydrogen to the crude feed provided to the
reactor was 160 Nm.sup.3/m.sup.3 (1000 SCFB), LHSV was 1 h.sup.-1,
and pressure was 6.9 MPa (1014.7 psi). The contacting zones were
heated incrementally to 343.degree. C. (650.degree. F.) over a
period of time and maintained at 343.degree. C. for 120 hours for a
total run time of 360 hours.
[0325] Total products exited the contacting zones and were
separated as described in Example 5. Net hydrogen uptake during
contacting was determined for each catalyst system. In Example 12,
net hydrogen uptake was -10.7 Nm.sup.3/m.sup.3 (-65 SCFB), and the
crude product had a TAN of 6.75. In Example 13, net hydrogen uptake
was in a range from 2.2-3.0 Nm.sup.3/m.sup.3 (13.9-18.7 SCFB), and
the crude product had a TAN in a range from 0.3-0.5. In Example 14,
during contacting of the crude feed with the molybdenum/vanadium
catalyst, net hydrogen uptake was in a range from -0.05
Nm.sup.3/m.sup.3 to 0.6 Nm.sup.3/m.sup.3 (-0.36 SCFB to 4.0 SCFB),
and the crude product had a TAN in a range from 0.2-0.5.
[0326] From the net hydrogen uptake values during contacting, it
was estimated that hydrogen was generated at the rate of 10.7
Nm.sup.3/m.sup.3 (65 SCFB) during contacting of the crude feed and
the vanadium catalyst. Generation of hydrogen during contacting
allows less hydrogen to be used in the process relative to an
amount of hydrogen used in conventional processes to improve
properties of disadvantaged crudes. The requirement for less
hydrogen during contacting tends to decrease the costs of
processing a crude.
[0327] Additionally, contact of the crude feed with the
molybdenum/vanadium catalyst produced a crude product with a TAN
that was lower than the TAN of the crude product produced from the
individual molybdenum catalyst.
Examples 15-18
Contact of a Crude Feed with a Vanadium Catalyst and an Additional
Catalyst
[0328] Each reactor apparatus (except for number and content of
contacting zones), each catalyst sulfiding method, each total
product separation method, and each crude product analysis were the
same as described in Example 5. All catalysts were mixed with
silicon carbide in a volume ratio of 2 parts silicon carbide to 1
part catalyst unless otherwise indicated. The crude feed flow to
each reactor was from the top of the reactor to the bottom of the
reactor. Silicon carbide was positioned at the bottom of each
reactor to serve as a bottom support. Each reactor had a bottom
contacting zone and a top contacting zone. After the
catalyst/silicone carbide mixtures were placed in the contacting
zones of each reactor, silicone carbide was positioned on top of
the top contacting zone to fill dead space and to serve as a
preheat zone in each reactor. Each reactor was loaded into a
Lindberg furnace that included four heating zones corresponding to
the preheat zone, the two contacting zones, and the bottom
support.
[0329] In each example, the vanadium catalyst was prepared as
described in Example 2 and used with the additional catalyst.
[0330] In Example 15, an additional catalyst/silicon carbide
mixture (45 cm.sup.3) was positioned in the bottom contacting zone,
with the additional catalyst being the molybdenum catalyst prepared
by the method described in Example 3. The vanadium
catalyst/silicone carbide mixture (15 cm.sup.3) was positioned in
the top contacting zone.
[0331] In Example 16, an additional catalyst/silicon carbide
mixture (30 cm.sup.3) was positioned in the bottom contacting zone,
with the additional catalyst being the molybdenum catalyst prepared
by the method described in Example 3. The vanadium catalyst/silicon
carbide mixture (30 cm.sup.3) was positioned in the top contacting
zone.
[0332] In Example 17, an additional catalyst/silicone mixture (30
cm.sup.3) was positioned in the bottom contacting zone, with the
additional catalyst being the molybdenum/vanadium catalyst as
prepared in Example 4. The vanadium catalyst/silicon carbide
mixture (30 cm.sup.3) was positioned in the top contacting
zone.
[0333] In Example 18, Pyrex.RTM. (Glass Works Corporation, New
York, U.S.A.) beads (30 cm.sup.3) were positioned in each
contacting zone.
[0334] Crude (Santos Basin, Brazil) for Examples 15-18 having the
properties summarized in Table 5, FIG. 18 was fed to the top of the
reactor. The crude feed flowed through the preheat zone, top
contacting zone, bottom contacting zone, and bottom support of the
reactor. The crude feed was contacted with each of the catalysts in
the presence of hydrogen gas. Contacting conditions for each
example were as follows: ratio of hydrogen gas to the crude feed
provided to the reactor was 160 Nm.sup.3/m.sup.3 (1000 SCFB) for
the first 86 hours and 80 Nm.sup.3/m.sup.3 (500 SCFB) for the
remaining time period, LHSV was 1 h.sup.-1, and pressure was 6.9
MPa (1014.7 psi). The contacting zones were heated incrementally to
343.degree. C. (650.degree. F.) over a period of time and
maintained at 343.degree. C. for a total run time of 1400
hours.
[0335] These examples demonstrate that contact of a crude feed with
a Column 5 metal catalyst having a pore size distribution with a
median pore diameter of 350 .ANG. in combination with an additional
catalyst having a pore size distribution with a median pore
diameter in a range from 250-300 .ANG., in the presence of a
hydrogen source, produces a crude product with properties that are
changed relative to the same properties of crude feed, while only
changing by small amounts other properties of the crude product
relative to the same properties of the crude feed. Additionally,
during processing, relatively small hydrogen uptake by the crude
feed was observed.
[0336] Specifically, as shown in Table 5, FIG. 18, the crude
product has a TAN of at most 15% of the TAN of the crude feed for
Examples 15-17. The crude products produced in Examples 15-17 each
had a total Ni/V/Fe content of at most 44%, an oxygen content of at
most 50%, and viscosity of at most 75% relative to the same
properties of the crude feed. Additionally, the crude products
produced in Examples 15-17 each had an API gravity of 100-103% of
the API gravity of the crude feed.
[0337] In contrast, the crude product produced under non-catalytic
conditions (Example 18) produced a product with increased viscosity
and decreased API gravity relative to the viscosity and API gravity
of the crude feed. From the increased viscosity and decreased API
gravity, it may be possible to infer that coking and/or
polymerization of the crude feed was initiated.
Examples 19
Contact of a Crude Feed at Various LHSV
[0338] The contacting systems and the catalysts were the same as
described in Example 6. The properties of the crude feeds are
listed in Table 6 in FIG. 19. The contacting conditions were as
follows: a ratio of hydrogen gas to the crude feed provided to the
reactor was 160 Nm.sup.3/m.sup.3 (1000 SCFB), pressure was 6.9 MPa
(1014.7 psi), and temperature of the contacting zones was
371.degree. C. (700.degree. F.) for the total run time. In Example
19, the LHSV during contacting was increased over a period of time
from 1 h.sup.-1 to 12 h.sup.-1, maintained at 12 h.sup.-1 for 48
hours, and then the LHSV was increased to 20.7 h.sup.-1 and
maintained at 20.7 h.sup.-1 for 96 hours.
[0339] In Example 19, the crude product was analyzed to determine
TAN, viscosity, density, VGO content, residue content, heteroatoms
content, and content of metals in metal salts of organic acids
during the time periods that the LHSV was at 12 h.sup.-1 and at
20.7 h.sup.-1. Average values for the properties of the crude
products are shown in Table 6, FIG. 19.
[0340] As shown in Table 6, FIG. 19, the crude product for Example
19 had a reduced TAN and a reduced viscosity relative to the TAN
and the viscosity of the crude feed, while the API gravity of the
crude product was 104-110% of the API gravity of the crude feed. A
weight ratio of MCR content to C.sub.5 asphaltenes content was at
least 1.5. The sum of the MCR content and C.sub.5 asphaltenes
content was reduced relative to the sum of the MCR content and
C.sub.5 asphaltenes content of the crude feed. From the weight
ratio of MCR content to C.sub.5 asphaltenes content and the reduced
sum of the MCR content and the C.sub.5 asphaltenes, it may be
inferred that asphaltenes rather than components that have a
tendency to form coke are being reduced. The crude product also had
total content of potassium, sodium, zinc, and calcium of at most
60% of the total content of the same metals of the crude feed. The
sulfur content of the crude product was 80-90% of the sulfur
content of the crude feed.
[0341] Examples 6 and 19 demonstrate that contacting conditions can
be controlled such that a LHSV through the contacting zone is
greater than 10 h.sup.-1, as compared to a process that has a LHSV
of 1 h.sup.-1, to produce crude products with similar properties.
The ability to selectively change a property of a crude feed at
liquid hourly space velocities greater than 10 h.sup.-1 allows the
contacting process to be performed in vessels of reduced size
relative to commercially available vessels. A smaller vessel size
may allow the treatment of disadvantaged crudes to be performed at
production sites that have size constraints (for example, offshore
facilities).
Example 20
Contact of a Crude Feed at Various Contacting Temperatures
[0342] The contacting systems and the catalysts were the same as
described in Example 6. The crude feed having the properties listed
in Table 7 in FIG. 20 was added to the top of the reactor and
contacted with the two catalysts in the two contacting zones in the
presence of hydrogen to produce a crude product. The two contacting
zones were operated at different temperatures.
[0343] Contacting conditions in the top contacting zone were as
follows: LHSV was 1 h.sup.-1; temperature in the top contacting
zone was 260.degree. C. (500.degree. F.); a ratio of hydrogen to
crude feed was 160 Nm.sup.3/m.sup.3 (1000 SCFB); and pressure was
6.9 MPa (1014.7 psi).
[0344] Contacting conditions in the bottom contacting zone were as
follows: LHSV was 1 h.sup.-1; temperature in the bottom contacting
zone was 315.degree. C. (600.degree. F.); a ratio of hydrogen to
crude feed was 160 Nm.sup.3/m.sup.3 (1000 SCFB); and pressure was
6.9 MPa (1014.7 psi).
[0345] The total product exited the bottom contacting zone and was
introduced into the gas-liquid phase separator. In the gas-liquid
phase separator, the total product was separated into the crude
product and gas. The crude product was periodically analyzed to
determine TAN and C.sub.5 asphaltenes content.
[0346] Average values for the properties of crude product obtained
during the run are listed in Table 7, FIG. 20. The crude feed had a
TAN of 9.3 and a C.sub.5 asphaltenes content of 0.055 grams of
C.sub.5 asphaltenes per gram of crude feed. The crude product had
an average TAN of 0.7 and an average C.sub.5 asphaltenes content of
0.039 grams of C.sub.5 asphaltenes per gram of crude product. The
C.sub.5 asphaltenes content of the crude product was at most 71% of
the C.sub.5 asphaltenes content of the crude product.
[0347] The total content of potassium and sodium in the crude
product was at most 53% of the total content of the same metals in
the crude feed. The TAN of the crude product was at most 10% of the
TAN of the crude feed. A P-value of 1.5 or higher was maintained
during contacting.
[0348] As demonstrated in Examples 6 and 20, having a first (in
this case, top) contacting temperature that is 50.degree. C. lower
than the contacting temperature of the second (in this case,
bottom) zone tends to enhance the reduction of C.sub.5 asphaltenes
content in the crude product relative to the C.sub.5 asphaltenes
content of the crude feed. Additionally, reduction of the content
of metals in metal salts of organic acids was enhanced using
controlled temperature differentials. For example, reduction in the
total potassium and sodium content of the crude product from
Example 20 was enhanced relative to the reduction of the total
potassium and sodium content of the crude product from Example 6
with a relatively constant crude feed/total product mixture
stability for each example, as measured by P-value.
[0349] Using a lower temperature of a first contacting zone allows
removal of the high molecular weight compounds (for example,
C.sub.5 asphaltenes and/or metals salts of organic acids) that have
a tendency to form polymers and/or compounds having physical
properties of softness and/or stickiness (for example, gums and/or
tars). Removal of these compounds at lower temperature allow such
compounds to be removed before they plug and coat the catalysts,
thereby increasing the life of the catalysts operating at higher
temperatures that are positioned after the first contacting
zone.
Example 21
Contact of a Crude Feed with at Least One Catalyst Having a Pore
Size Distribution with a Median Pore Diameter of at Least 180 .ANG.
for Greater than 500 Hours
[0350] The reactor apparatus (except for number and content of
contacting zones), the total product separation method, crude
product analysis, the catalysts and catalyst sulfiding method were
the same as described in Example 5.
[0351] A molybdenum catalyst (11.25 cm.sup.3) prepared by the
method described in Example 3 and mixed with silicon carbide (22.50
cm.sup.3) to form a molybdenum catalyst/silicon carbide mixture
(37.75 cm.sup.3) was positioned in the bottom contacting zone. A
vanadium catalyst (3.75 cm.sup.3) prepared by the method described
in Example 4 was mixed with silicon carbide (7.5 cm.sup.3) to form
a vanadium catalyst/silicone carbide mixture (11.25 cm.sup.3) was
positioned in the top contacting zone.
[0352] A crude feed (BC-10 crude) having the properties summarized
in Table 8, FIG. 21, was fed to the top of the reactor. The crude
feed flowed through the preheat zone, top contacting zone, bottom
contacting zone, and bottom support of the reactor. The contacting
conditions were as follows: ratio of hydrogen gas to the crude feed
provided to the reactor was 160 Nm.sup.3/m.sup.3 (1000 SCFB), LHSV
was 2 h.sup.-1, and pressure was 3.4 MPa (500 psig). The two
contacting zones were heated incrementally to 343.degree. C.
(650.degree. F.).
[0353] After total run time of 1175 hours, the crude product had a
TAN of 0.44 and an API gravity of 15.9. The crude product had 0.6
wtppm of calcium, 0.8 wtppm of sodium, 0.9 wtppm of zinc, 1.5 wtppm
of potassium, 0.8 wtppm silicon. The crude product had, per gram of
crude product, 0.0043 grams of sulfur, 0.003 grams of oxygen, 0.407
grams of VGO, and 0.371 grams of residue. Additional properties of
the crude product are listed in Table 8 in FIG. 21.
[0354] After total run time of 5207 hours with no catalyst
replacement, the crude product had a TAN of 0.27 and an API gravity
of 15.7. The crude product had 0.4 wtppm of calcium, 1.1 wtppm of
sodium, 0.9 wtppm of zinc, and 1.7 wtppm of potassium. The crude
product had, per gram of crude product, 0.00396 grams of sulfur,
0.407 grams of VGO, and 0.38 grams of residue. Additional
properties of the crude product are listed in Table 8 in FIG.
21.
[0355] This example demonstrates that contacting of the crude feed
with the selected catalysts and at least one of the catalysts
having a pore size distribution with a median pore diameter of
greater than 180 .ANG. produced a crude product that had a reduced
TAN, a reduced total calcium, sodium, zinc, potassium and silicon
content while sulfur content, VGO content, and residue content of
the crude product were 100%, 102%, and 95.6% of the respective
properties of the crude feed. This example also demonstrates that
the TAN of the crude product is at least 30% of the TAN of the
crude feed after 500 hours without replacement of the catalysts.
This example also demonstrates that one or more properties of the
crude feed may be changed at a lower pressure, higher throughput at
elevated temperatures. This example also demonstrates that a Column
6 metal catalyst that exhibits bands between 810 cm.sup.-1 to 870
cm.sup.-1 as determined by Raman Spectroscopy produces a total
product that includes a crude product with a TAN that is at least
90% of the TAN of the crude feed.
Example 22
Contact of a Crude Feed and a Catalyst in an Continuously Stirred
Reactor (CSTR)
[0356] A molybdenum catalyst (25.5 grams, 50 cm.sup.-3) prepared as
in Example 3 was charged to a CSTR. Crude feed (BS-4) having the
properties listed in Table 9 in FIG. 22 was metered at a flow rate
of 24.1 g/hr to produce a LHSV of 0.5 h.sup.-1. A temperature
421.degree. C. (790.degree. F.), a partial pressure of hydrogen of
14 MPa (2000 psig), and ratio of hydrogen source to crude feed of
320 Nm.sup.3/m.sup.3 (2000 SCFB) were maintained through out the
run. Total product was removed from the top of the reactor and
separated into crude product and process gases. During the run, an
amount of sediment was monitored to determine if the reaction
vessel was filling with impurities and/or coke. The amount of
sediment, per gram of crude feed, ranged between 0.0001 grams and
0.00013 grams during the run.
[0357] Properties of the crude product after 286 hours are
tabulated in Table 9 of FIG. 22. The crude product had a TAN of
0.26 and an API gravity of 21.2. The crude product had 2.2 wtppm of
calcium, 0.2 wtppm of sodium, 6.4 wtppm of zinc, 0.7 wtppm of
silicon, 0.2 wtppm of potassium, 2.9 wtppm nickel, 0.6 wtppm
vanadium, and 2.3 wtppm iron. The crude product had, per gram of
crude product, 0.018 grams of sulfur, 0.386 of distillate, 0.41
grams of VGO, and 0.204 grams of residue.
[0358] This example demonstrates that contact of a crude feed with
hydrogen in the presence of at least one molybdenum catalyst that
exhibits bands in the range 810 cm.sup.-1 to 870 cm.sup.-1 as
determined by Raman Spectroscopy produces a total product that
includes a crude product with a residue content of at least 90% of
the residue content of the crude feed. This example also
demonstrates that contact of a crude feed with hydrogen in the
presence of at least one molybdenum catalyst that exhibits bands in
the range 810 cm.sup.-1 to 870 cm.sup.-1 as determined by Raman
Spectroscopy produces a total product that includes a crude product
with a TAN that is at least 90% of the TAN of the crude feed.
Comparative Example 23
Contact of a Crude Feed and a Catalyst in an Continuously Stirred
Reactor (CSTR)
[0359] The reactor apparatus, the total product separation method,
crude product analysis, and catalyst sulfiding method were the same
as described in Example 22. The catalyst had a pore size
distribution with a median pore diameter of 192 .ANG. and contained
0.04 grams of molybdenum per gram of catalyst, with the balance
being primarily a gamma alumina support. The catalyst did not
exhibit absorption in the range .DELTA.810 cm.sup.-1 to .DELTA.870
cm.sup.-1 as determined by Raman Spectroscopy. The properties of
the crude product after 213 hours are tabulated in Table 9 of FIG.
22. At 213 hours a content of sediment, per gram of crude feed, was
0.0019 grams, per gram of crude feed/total product. After 765 hours
the sediment had increased to 0.00329 grams, per gram of crude
feed/total product. An increase in sediment relative to sediment
content of the crude feed/total product mixture when contacting the
crude feed with the molybdenum catalyst of Example 22 indicates
that impurities and/or coke are forming at an increased rate. An
increased rate of sediment formation decreases contacting time
and/or catalyst life, thus the catalyst of Example 22 has a longer
catalyst life than the catalyst of Example 23.
Example 24
Preparation of a Columns 6-10 Metal(s) Catalyst Having at Least 10
Wt % Molybdenum
[0360] A support (200 grams) that contained 0.02 grams of
silica-alumina and 0.98 grams alumina per gram of support was
impregnated with a molybdenum/nickel solution. A first solution was
prepared by combining 62.34 grams of
(NH.sub.4).sub.2Mo.sub.2O.sub.7 and 17.49 grams of MoO.sub.3, 3
grams of monoethanolamine, 12.22 grams of 30% hydrogen peroxide,
and 50.47 grams of deionized water to form a slurry. The slurry was
heated to 63.8.degree. C. (147.degree. C.) until dissolution of the
solids. The solution was cooled to room temperature. The pH of the
solution was 5.34.
[0361] A second solution was prepared by combining 31.93 grams of
Ni(NO.sub.3).sub.8.6H.sub.2O, 9.63 grams of NiCO.sub.3, and 30.56
grams of deionized water to form a slurry. Concentrated phosphoric
acid (39.57 grams of 85.9 wt % H.sub.3PO.sub.4) was added at a rate
sufficient to control foaming. The solution was stirred until the
solids were dissolved. The pH of the solution was 0.29.
[0362] The first solution and second solution were combined and
sufficient deionized water was added to bring the combined solution
volume up to 218.75 mL to yield the molybdenum/nickel impregnation
solution. The pH of the resulting solution was 2.02. The support
was impregnated with the molybdenum/nickel solution, aged for
several hours with occasional agitation, dried at 125.degree. C.
for several hours, and then calcined at 482.degree. C. (900.degree.
F.) for two hours. The resulting catalyst contained, per gram of
catalyst, 0.13 grams of Mo, 0.03 grams Ni, 0.005 grams of
phosphorus with the balance being support. The molybdenum/nickel
catalyst had a median pore diameter of 155 .ANG., with at least 60%
of the total number of pores in the pore sized distribution having
a pore diameter within 28 .ANG. of the median pore diameter, a pore
volume of 0.84 mL/g, and a surface area of 179 m.sup.2/g.
Example 25
Contact of a Hydrocarbon Feed with Two Catalysts at a Pressure of
at Most 7 MPa
[0363] The reactor apparatus (except for number and content of
contacting zones), the total product separation method, crude
product analysis, and catalyst sulfiding method were the same as
described in Example 6.
[0364] A catalyst as prepared in Example 24, (12.5 cm.sup.3) was
mixed with silicon carbide (12.5 cm.sup.3) to form a molybdenum
catalyst/silicon carbide mixture and was positioned in the bottom
contacting zone.
[0365] A molybdenum catalyst (12.5 cm.sup.3) containing 0.039 grams
of molybdenum, 0.01 grams of nickel and 0.0054 grams of phosphorus
with the balance being alumina and having a median pore diameter of
108 .ANG. and a surface area of 266 m.sup.2/g was mixed with
silicon carbide (12.5 cm.sup.3) to form a molybdenum
catalyst/silicon carbide mixture and was positioned in the top
contacting zone.
[0366] After sulfidation of the catalysts, the contacting zones
were raised to a temperature of 385.degree. C. A heated hydrocarbon
feed (Peace River crude) having the properties summarized in Table
10, FIG. 23 was fed to the top of the reactor. The hydrocarbon feed
flowed through the preheat zone, top contacting zone, bottom
contacting zone, and bottom support of the reactor. The hydrocarbon
feed was contacted with each of the catalysts in the presence of
hydrogen gas. Contacting conditions were as follows: ratio of
hydrogen gas to feed was 328 Nm.sup.3/m.sup.3 (2000 SCFB) and LHSV
was 0.5 h.sup.-1. The two contacting zones were heated to
385.degree. C. at a pressure of 13.8 MPa (2000 psig) and the
hydrocarbon feed flowed through the contacting zones for 600 hours.
Temperatures and pressures for the two contacting zones were then
adjusted and maintained in the following sequence: 400.degree. C.,
6.9 MPa (1000 psig) for 1203 hours; 410.degree. C., 3.8 MPa (500
psig) for 1149 hours. The total contact time for the two catalysts
was 2952 hours.
[0367] As shown in FIG. 23, contact of the hydrocarbon feed at
pressures of at most 7 MPa and temperatures of at least 300.degree.
C., produced a crude product that had a molybdenum content of 0.4
wtppm, a Ni/V/Fe content of 251 wtppm, a residue content of 0.275
grams per gram of crude product, a C.sub.5/C.sub.7 asphaltenes
content of 15.4 wt %, and a viscosity of 74.4 cSt at 37.8.degree.
C. During the run at lower temperatures the P value of the
feed/intermediate product was 1.2. The total amount of
C.sub.1-C.sub.4 gas produced during contacting was at most 0.02
grams per gram of total product.
[0368] As shown in Table 10 of FIG. 23, contact of the feed at
controlled contacting conditions of at most 7 MPa and at least
300.degree. C., the molybdenum content was at most 90% of the feed
molybdenum content, the Ni/V/Fe content was between 80% and 120% of
the feed Ni/V/Fe content, C.sub.5/C.sub.7 asphaltenes content was
at most 90% of the C.sub.5/C.sub.7 feed asphaltenes content, the
residue was at most 90% of the feed residue and the viscosity was
at most 90% of the feed viscosity. As shown in FIG. 23, the crude
product has at least 0.1 wtppm of molybdenum, at least 0.01 grams
of hydrocarbons having a boiling range distribution between
38.degree. C. and 200.degree. C. per gram of hydrocarbon
composition; and at least 0.1 grams of hydrocarbons having a
boiling range distribution between 343.degree. C. and 650.degree.
C. per gram of hydrocarbon composition. The crude product also has
at least 0.001 grams of hydrocarbons with a boiling range
distribution between 38.degree. C. and 200.degree. C. at 0.101 MPa;
at least 0.001 grams of hydrocarbons with a boiling range
distribution between 204.degree. C. and 343.degree. C. at 0.101
MPa; at least 0.001 grams of hydrocarbons with a boiling range
distribution between 343.degree. C. and 650.degree. C. at 0.101
MPa; at least 0.001 grams of hydrocarbons with an initial boiling
point of at least 650.degree. C. at 0.101 MPa; at least 0.000150
grams of Ni/V/Fe; and at most 0.01 grams of C.sub.5
asphaltenes.
[0369] This example also demonstrates that at the P-value of a
hydrocarbon feed/total product mixture remains above 1.0 at
pressures when the hydrocarbon feed is contacted with the catalysts
at a pressure of at most 7 MP, at temperatures ranging from
350.degree. C. and 450.degree. C., and at a LHSV of at least 0.1
h.sup.-1.
[0370] Example 25 also demonstrates that at operating conditions of
at most 7 MPa and temperatures of at most 450.degree. C., the
viscosity of the crude product is at most 50% of the hydrocarbon
feed while the consumption of hydrogen is at most 80
Nm.sup.3/m.sup.3.
Example 26
Preparation of Column 6 Metal(s) Catalyst Containing Mineral Oxide
Fines
[0371] The catalyst was prepared in the following manner. MoO.sub.3
(99.44 grams) was combined with 2 wide pore alumina (737.85 grams)
and crushed and sieved alumina fines having a particle size between
5 and 10 micrometers (1050.91 grams) in a muller. With the muller
running, 43.04 grams of 69.7 wt % nitric acid, 4207.62 grams of
deionized water were added to the mixture and the resulting mixture
was mulled for 5 minutes. Superfloc.RTM. 16 (30 grams, Cytec
Industries, West Paterson, N.J., USA) was added to the mixture in
the muller, and the mixture was mulled for at total of 25 minutes.
The resulting mixture had a pH of 6.0 and an LOI of 0.6232 grams
per gram of mixture. The mulled mixture was extruded using 1.3 mm
trilobe dies to form 1.3 trilobe extrudate particles. The extrudate
particles were dried at 125.degree. C. for several hours and then
calcined at 676.degree. C. (1250.degree. F.) for two hours. The
catalyst contained 0.02 grams of molybdenum, with the balance being
mineral oxide and support. The catalyst had a pore size
distribution with a median pore diameter of 117 .ANG. with 66.7% of
the total number of pores in the pore size distribution having a
pore diameter within 33 .ANG. of the median pore diameter, and a
total pore volume of 0.924 ml/g.
[0372] The pore size distribution at theta=140.degree. as a
percentage of total pores was as follows: <70 .ANG. 0.91%;
70-100 .ANG. 20.49%; 100-130 .ANG. 37.09%; 130-150 .ANG. 4.51%;
150-180 .ANG. 2.9%; 150-180 .ANG. 2.9%; 180-200 .ANG. 1.06%;
200-1000 .ANG. 0.85%, 1000-5000 .ANG. 5.79% and >5000 .ANG.
22.04%.
[0373] This example demonstrates a catalyst that includes a
support, mineral oxides, and one or more metals from Column 6 of
the Periodic Table and/or one or more compounds of one or more
metals from Column 6 of the Periodic Table. The catalyst has a pore
size distribution with a median pore diameter of at least 80 .ANG.
and the catalyst is obtainable by combining: a mineral oxide fines;
the one or more of metals from Column 6 of the Periodic Table
and/or the one or more compounds of one or more metals from Column
6 of the Periodic Table; and a support.
Example 27
Contact of a Hydrocarbon Feed with a Column 6 Metal(s) Catalyst
Having Mineral Oxide Fines
[0374] The reactor apparatus (except for number and content of
contacting zones), the total product separation method, crude
product analysis, and catalyst sulfiding method were the same as
described in Example 5.
[0375] A molybdenum catalyst as described in Example 26 was mixed
with silicon carbide (total volume of 30 cm.sup.3) and was
positioned in the bottom contacting zone. A molybdenum catalyst as
described in Example 26 was mixed with silicon carbide (total
volume of 30 cm.sup.3) and was positioned in the top contacting
zone.
[0376] After sulfidation of the catalysts, the temperature of the
contacting zones was raised to a temperature of 400.degree. C. A
hydrocarbon feed (Peace River) having the properties listed in
Table 10, FIG. 23. The hydrocarbon feed flowed through the preheat
zone, top contacting zone, bottom contacting zone, and bottom
support of the reactor. The hydrocarbon feed was contacted with
each of the catalysts in the presence of hydrogen gas. Contacting
conditions were as follows: ratio of hydrogen gas to feed was 318
Nm.sup.3/m.sup.3 (2000 SCFB) and LHSV was 0.5 h.sup.-1. The two
contacting zones were heated to 400.degree. C. and maintained
between 400.degree. C. and 402.degree. C. at a pressure of 3.8 MPa
(500 psig) for 671 hours as the hydrocarbon feed flowed through the
reactor.
[0377] As shown in Table 10, FIG. 23, the crude product had a
viscosity of 53.1 at 37.8.degree. C., a residue content of 0.202
grams, per gram of catalyst, a Ni/V/Fe content of 164 wtppm and a
molybdenum content of 0.5 wtppm.
[0378] This example demonstrates that contact of a hydrocarbon feed
with a Column 6 metal catalyst that is obtainable by combining
mineral oxide fines, one or more metals from Columns 6 of the
Periodic Table and/or one or more compounds of one or more metals
from Columns 6 of the Periodic Table; and a support produces a
crude product having a residue content of at most 90% of
hydrocarbon feed residue. This example also demonstrates that
contact of a hydrocarbon feed with a Column 6 metal catalyst that
is obtainable by combining mineral oxide fines, one or more metals
from Columns 6 of the Periodic Table and/or one or more compounds
of one or more metals from Columns 6 of the Periodic Table; and a
support produces a crude product having a viscosity content of at
most 50% of hydrocarbon feed viscosity at 37.8.degree. C.
Example 28
Contact of a Hydrocarbon Feed with One Catalyst
[0379] In a separate experiment, the hydrocarbon feed was contacted
with the catalyst as prepared in Example 24 at the same conditions
as described in Example 25 and in the absence of the top catalyst
described in Example 25. After approximately 45 hours of passing
hydrocarbon feed through the reactor, the catalyst bed plugged.
This example demonstrates that the top catalyst used in Example 25
removes at least a portion of the compounds (for example,
molybdenum compounds) that contribute to catalyst plugging.
Example 29
Contact of a Hydrocarbon Feed with a Column 6 Metal(s) Catalyst
[0380] The reactor apparatus (except for number and content of
contacting zones), the total product separation method, crude
product analysis, and catalyst sulfiding method were the same as
described in Example 5.
[0381] A molybdenum catalyst (27.5 cm.sup.3) as prepared in Example
24 (3 cm.sup.3) to form a molybdenum catalyst/silicon carbide
mixture was positioned in the bottom contacting zone.
[0382] A molybdenum/vanadium catalyst (3 cm.sup.3) prepared by the
method described in Example 4 and mixed with silicon carbide (3
cm.sup.3) to form a molybdenum/vanadium catalyst/silicon carbide
mixture (37.75 cm.sup.3) was positioned in the top contacting
zone.
[0383] After sulfidation of the catalysts, the temperature of the
contacting zones was raised to a temperature of 385.degree. C. A
hydrocarbon feed (BC-10) having the properties summarized in Table
11, FIG. 24 was fed to the top of the reactor. The hydrocarbon feed
flowed through the preheat zone, top contacting zone, bottom
contacting zone, and bottom support of the reactor. The hydrocarbon
feed was contacted with each of the catalysts in the presence of
hydrogen gas. Contacting conditions were as follows: ratio of
hydrogen gas to feed was 328 Nm.sup.3/m.sup.3 (2000 SCFB) and LHSV
was 0.5 h.sup.-1. The two contacting zones were heated to
390.degree. C. at a pressure of 15.9 MPa (2300 psig) and the
hydrocarbon feed flowed through the reactor for 4703 hours. During
contacting the P-value of the hydrocarbon feed/total product
mixture remained above 1.0.
[0384] As shown in FIG. 24, the crude product had, per gram of
crude product, 0.0665 grams of basic nitrogen, 0.241 grams of
residue, 0.063 grams of total C.sub.5/C.sub.7 asphaltenes, a MCR
content of 0.037 grams, and a viscosity of 45 cSt at 37.8.degree.
C.
[0385] This example demonstrates that contact of a hydrocarbon feed
with a catalyst having a pore size distribution with a median pore
diameter of between 50 angstroms and 180 angstroms produces a crude
product having a basic nitrogen content of at most 90% of the
hydrocarbon feed basic nitrogen content. This example also
demonstrates that contact of a hydrocarbon feed with a catalyst
having Columns 6 and 9 metal(s) produces a crude product having a
MCR content of at most 90% of the MCR content of the hydrocarbon
feed.
Example 30
Preparation of a Catalyst
[0386] The Catalyst was Prepared in the Following Manner. A nickel
solution was made by combining 286.95 grams of
Ni(NO.sub.3).6H.sub.2O, and 99.21 grams of deionized water to form
a slurry. The slurry was heated until clear. A support (3208.56
grams) that contained 0.02 grams of silica-alumina and 0.98 grams
alumina per gram of support was combined with the nickel solution,
a Ni--Mo--P used catalyst (652.39 grams), and MoO.sub.3 (268.85
grams) in a muller. During mulling, HNO.sub.3 (128.94 grams 69.9 wt
%) and deionized water (2948.29 grams) was added to the mixture and
the mixture was mulled for 40 minutes. Superfloc.RTM. 16 (30 grams)
was added to the mixture and the mixture was mulled for 5 minutes.
The resulting mixture had a pH of 4.18 and a LOI of 0.557 grams per
gram of mixture.
[0387] The mulled mixture was extruded using 1.3 mm trilobe dies to
form 1.3 trilobe extrudate particles. The extrudates were dried at
100.degree. C. for several hours and then calcined at 676.6.degree.
C. (1250.degree. F.) for two hours. The resulting catalyst
contained, per gram of catalyst, 0.079 grams of Mo, and 0.022 grams
Ni, with the balance being used catalyst and support. The
molybdenum/nickel catalyst had a median pore diameter of 96 .ANG.,
with at least 60% of the total number of pores in the pore size
distribution having a pore diameter within 39 .ANG. of the median
pore diameter, a pore volume of 0.596 mL/g, and a surface area of
256 m.sup.2/g.
Example 31
Contact of a Hydrocarbon Feed with the Catalyst
[0388] The reactor apparatus (except for number and content of
contacting zones), the total product separation method, crude
product analysis, and catalyst sulfiding method were the same as
described in Example 5.
[0389] A molybdenum catalyst (27 cm.sup.3) as described in Example
30 was mixed with silicon carbide (3 cm.sup.3) and was positioned
in the bottom contacting zone.
[0390] A molybdenum/vanadium catalyst (3 cm.sup.3) prepared by the
method described in Example 4 was mixed with silicon carbide (3
cm.sup.3) to form a molybdenum/vanadium catalyst/silicon carbide
mixture (37.75 cm.sup.3) and was positioned in the top contacting
zone.
[0391] After sulfidation of the catalysts, the contacting zones
were raised to a temperature of 385.degree. C. A hydrocarbon feed
(BC-10) having the properties summarized in Table 11, FIG. 24 was
fed to the top of the reactor. The hydrocarbon feed flowed through
the preheat zone, top contacting zone, bottom contacting zone, and
bottom support of the reactor. The feed was contacted with each of
the catalysts in the presence of hydrogen gas. Contacting
conditions were as follows: ratio of hydrogen gas to feed was 328
Nm.sup.3/m.sup.3 (2000 SCFB) and LHSV was 0.5 h.sup.-1. The two
contacting zones were heated to 390.degree. C. at a pressure of
15.9 MPa (2300 psig) as the hydrocarbon feed flowed through the
contacting zone for 4703 hours. During contacting the P-value of
the hydrocarbon feed/total product mixture remained above 1.0.
[0392] As shown in FIG. 24, the crude product had, per gram of
crude product and 0.255 grams of residue and a viscosity of 48.7
cSt at 37.8.degree. C.
[0393] This example demonstrates that contact of a hydrocarbon feed
with a catalyst prepared by combining a used catalyst, Columns 6-10
metals, and a support produces a crude product having residue
content of at most 90% of hydrocarbon feed residue.
Example 32
Preparation of a Columns 6 and 10 Metal(s) Catalyst
[0394] The catalyst was prepared in the following manner. A nickel
solution was made by combining 377.7 grams of Ni(NO.sub.3), and
137.7 grams of deionized water to form a slurry. The slurry was
heated until clear and sufficient deionized water was added to
bring the combined nickel solution weight up the 3807 grams.
MoO.sub.3 (417.57 grams) was combined with 4047.49 grams of support
containing 0.02 grams of A nickel solution was made by combining
286.95 grams of Ni(NO.sub.3).6H.sub.2O, and 99.21 grams of
deionized water to form a slurry. The slurry was heated until
clear. A support (3208.56 grams) that contained 0.02 grams of
silica-alumina and 0.98 grams alumina per gram of support was
combined with the nickel solution and MoO.sub.3 (417.57 grams) in a
muller. During mulling, 4191.71 deionized water was added to the
mixture and the mixture was mulled for 45 minutes. The resulting
mixture had a pH of 4.75 and a LOI of 0.596 grams per gram of
mixture.
[0395] The mulled mixture was extruded using 1.3 mm trilobe dies to
form 1.3 trilobe extrudate particles. The extrudates were dried at
100.degree. C. for several hours and then calcined at 537.7.degree.
C. (1000.degree. F.) for two hours. The resulting catalyst
contained, per gram of catalyst, 0.079 grams of Mo, and 0.022 grams
Ni, with the balance being support. The molybdenum/nickel catalyst
had a median pore diameter of 67 .ANG., with at least 60% of the
total number of pores in the pore size distribution having a pore
diameter with 25 .ANG. of the median pore diameter, a pore volume
of 0.695 mL/g, and a surface area of 268 m.sup.2/g.
Example 33
Contact of a Hydrocarbon Feed with a Columns 6 and 10 Metal(s)
Catalyst
[0396] The reactor apparatus (except for number and content of
contacting zones), the total product separation method, crude
product analysis, and catalyst sulfiding method were the same as
described in Example 5.
[0397] A molybdenum/nickel catalyst (27 cm.sup.3) as described in
Example 32 was mixed with silicon carbide (3 cm.sup.3) and was
positioned in the bottom contacting zone.
[0398] A molybdenum/vanadium catalyst (3 cm.sup.3) prepared by the
method described in Example 4 was mixed with silicon carbide (3
cm.sup.3) to form a molybdenum/vanadium catalyst/silicon carbide
mixture (37.75 cm.sup.3) and was positioned in the top contacting
zone.
[0399] After sulfidation of the catalysts, the contacting zones
were raised to a temperature of 385.degree. C. A hydrocarbon feed
(BC-10) having the properties summarized in Table 11, FIG. 24 was
fed to the top of the reactor. The hydrocarbon feed flowed through
the preheat zone, top contacting zone, bottom contacting zone, and
bottom support of the reactor. The feed was contacted with each of
the catalysts in the presence of hydrogen gas. Contacting
conditions were as follows: ratio of hydrogen gas to feed was 328
Nm.sup.3/m.sup.3 (2000 SCFB) and LHSV was 0.5 h.sup.-1. The two
contacting zones were heated to 390.degree. C. at a pressure of
15.9 MPa (2300 psig) as the hydrocarbon feed passed through the
contacting zones for 4703 hours. During contacting the P-value of
the hydrocarbon feed/total product mixture remained above 1.0.
[0400] As shown in FIG. 24, the crude product had, per gram of
crude product 0.235 grams of residue and a viscosity of 41.8 cSt at
37.8.degree. C.
[0401] This example demonstrates that contact of a hydrocarbon feed
with a catalyst that has or more metals from Column 6 of the
Periodic Table and/or one or more compounds of one or more metals
from Column 6 of the Periodic Table; and one or more metals from
Columns 9-10 of the Periodic Table and/or one or more compounds of
one or more metals from Columns 9-10 of the Periodic Table and
having a pore size distribution with a median pore diameter between
50 .ANG. and 120 .ANG. produces a crude product having a residue
content of at most 90% of the hydrocarbon feed residue.
Example 34
Preparation of a Dried Catalyst
[0402] The dried catalyst was prepared in the following manner. A
support (200 grams) that contained 0.02 grams of 0.01 grams of
nickel and 0.99 grams alumina per gram of support was impregnated
with a molybdenum/cobalt solution. The solution was prepared by
combining 46.68 grams of MoO.sub.3, 14.07 grams of Co(OH).sub.2,
20.08 grams of 85% H.sub.3PO.sub.4, and 300 grams of deionized
water to form a slurry. The slurry was and heated to 93.3.degree.
C. (200.degree. C.) until dissolution of the solids and then
further heated until volume of the solution was reduced to 166 mL
The solution was then cooled to room temperature. The pH of the
solution was 1.71.
[0403] The support was impregnated with the molybdenum/cobalt
solution, aged for several hours with occasional agitation and
dried at 100.degree. C. for several hours (overnight). The
resulting catalyst contained, per gram of catalyst, 0.115 grams of
Mo, 0.032 grams Co, 0.02 grams of phosphorus, and 0.74 grams of Ni
with the balance being support. The molybdenum/cobalt/nickel
catalyst had a LOI of 0.053 grams per gram of catalyst.
Example 35
Contact of a Hydrocarbon Feed with a Dried Catalyst
[0404] The reactor apparatus (except for number and content of
contacting zones), the total product separation method, and the
crude product analysis were the same as described in Example 5.
[0405] A molybdenum catalyst (33.34 cm.sup.3) as described in
Example 34 was mixed with silicon carbide (33.34 cm.sup.3) and
positioned in the bottom contacting zone.
[0406] A molybdenum catalyst (16.67 cm.sup.3) having a pore size
distribution with a median pore diameter of 192 .ANG. and
containing 0.04 grams of molybdenum per gram of catalyst, with the
balance being primarily a gamma alumina support was mixed with
silicon carbide (16.67 cm.sup.3) and positioned in the top
contacting zone.
[0407] The catalysts were sulfided using the method as described in
U.S. Pat. No. 6,290,841 to Gabrielov et al. After sulfidation of
the catalysts, the temperature of the contacting zones was raised
to a temperature of 405.degree. C. A hydrocarbon feed (Kuwait long
residue) having the properties summarized in Table 12, FIG. 25 was
fed to the top of the reactor. The hydrocarbon feed flowed through
the preheat zone, top contacting zone, bottom contacting zone, and
bottom support of the reactor. The hydrocarbon feed was contacted
with each of the catalysts in the presence of hydrogen gas.
Contacting conditions were as follows: ratio of hydrogen gas to
feed was 656 Nm.sup.3/m.sup.3 (4000 SCFB) and LHSV was 0.33
h.sup.-1. The two contacting zones were heated to 390.degree. C. at
a pressure of 13.13 MPa (1900 psig) as the hydrocarbon feed flowed
through the contacting zones for 2537 hours. During contacting the
P-value of the hydrocarbon feed/total product mixture remained
above 1.0.
[0408] As shown in Table 12, FIG. 25, the crude product had a
viscosity of 63.5 cSt at 37.8.degree. C. and, 0.243 grams of
residue and C.sub.5 asphaltenes content of 0.024 grams per gram of
crude product.
[0409] This example demonstrates that contact of a hydrocarbon feed
with a dried catalyst produces a crude product having a residue
content of at most 90% of hydrocarbon feed residue.
[0410] Further modifications and alternative embodiments of various
aspects of the invention will be apparent to those skilled in the
art in view of this description. Accordingly, this description is
to be construed as illustrative only and is for the purpose of
teaching those skilled in the art the general manner of carrying
out the invention. It is to be understood that the forms of the
invention shown and described herein are to be taken as examples of
embodiments. Elements and materials may be substituted for those
illustrated and described herein, parts and processes may be
reversed and certain features of the invention may be utilized
independently, all as would be apparent to one skilled in the art
after having the benefit of this description of the invention.
Changes may be made in the elements described herein without
departing from the spirit and scope of the invention as described
in the following claims.
* * * * *