U.S. patent application number 12/974435 was filed with the patent office on 2011-04-28 for process for activating a hydrotreating catalyst.
Invention is credited to Toshiyuki ADO, Marcel Adriaan JANSEN, Tetsuro KAMO, Naohiro NISHIMOTO, Franciscus Wilhelmus VAN HOUTERT.
Application Number | 20110094939 12/974435 |
Document ID | / |
Family ID | 34923992 |
Filed Date | 2011-04-28 |
United States Patent
Application |
20110094939 |
Kind Code |
A1 |
JANSEN; Marcel Adriaan ; et
al. |
April 28, 2011 |
PROCESS FOR ACTIVATING A HYDROTREATING CATALYST
Abstract
The invention pertains to a process for activating an
hydrotreating catalyst comprising a Group VIB metal oxide and a
Group VIII metal oxide which process comprises contacting the
catalyst with an acid and an organic additive which has a boiling
point in the range of 80-500.degree. C. and a solubility in water
of at least 5 grams per liter (20.degree. C., atmospheric
pressure), optionally followed by drying under such conditions that
at least 50% of the additive is maintained in the catalyst. The
hydrotreating catalyst may be a fresh hydrotreating catalyst or a
used hydrotreating catalyst which has been regenerated.
Inventors: |
JANSEN; Marcel Adriaan;
(Nieuw Vennep, NL) ; VAN HOUTERT; Franciscus
Wilhelmus; (Landsmeer, NL) ; ADO; Toshiyuki;
(Yokohama-shi, JP) ; KAMO; Tetsuro; (Niihama-shi,
JP) ; NISHIMOTO; Naohiro; (Kami-shi, JP) |
Family ID: |
34923992 |
Appl. No.: |
12/974435 |
Filed: |
December 21, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10574228 |
Jun 11, 2007 |
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PCT/EP04/10982 |
Sep 30, 2004 |
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12974435 |
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60516714 |
Nov 3, 2003 |
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Current U.S.
Class: |
208/264 ;
502/159; 502/172; 502/173; 502/313 |
Current CPC
Class: |
B01J 23/85 20130101;
B01J 38/62 20130101; C10G 2300/703 20130101; B01J 31/0201 20130101;
B01J 23/883 20130101; C10G 45/08 20130101; B01J 23/94 20130101;
B01J 37/0203 20130101; B01J 23/882 20130101; B01J 38/60 20130101;
B01J 38/52 20130101 |
Class at
Publication: |
208/264 ;
502/313; 502/173; 502/172; 502/159 |
International
Class: |
C10G 45/04 20060101
C10G045/04; B01J 23/24 20060101 B01J023/24 |
Foreign Application Data
Date |
Code |
Application Number |
Oct 3, 2003 |
EP |
03078071.2 |
Claims
1-15. (canceled)
16. The hydrotreating catalyst obtainable by a process comprising
contacting the catalyst with an acid and an organic additive which
has a boiling point in the range of 80-500.degree. C. and a
solubility in water of at least 5 grams per liter (20.degree. C.,
atmospheric pressure), optionally followed by drying under such
conditions that at least 50 wt % of the additive is maintained in
the catalyst.
17. A hydrotreating catalyst comprising a Group VIII metal oxide
and a Group VI metal oxide, which catalyst additionally comprises
an acid and an organic additive which has a boiling point in the
range of 80-500.degree. C. and a solubility in water of at least 5
grams per liter (20.degree. C., atmospheric pressure).
18. The hydrotreating catalyst according to claim 16, wherein the
catalyst is a regenerated used catalyst or a calcined fresh
catalyst and wherein the catalyst comprises a crystalline fraction
below 5 wt % (expressed as weight fraction of crystalline compounds
of Group VIB and Group VIII metals relative to the total weight of
the catalyst).
19. A process for hydrotreating a hydrocarbon feed in which a
hydrocarbon feed is contacted under hydrotreating conditions with a
catalyst according to claim 17, which optionally has been
(pre)sulfided before it is contacted with the hydrocarbon feed.
Description
[0001] The invention pertains to a process for activating a
hydrotreating catalyst. The hydrotreating catalyst to be activated
may be either a fresh hydrotreating catalyst or a hydrotreating
catalyst which has been used and regenerated. The present invention
also pertains to the hydrotreating catalyst obtainable by said
process and to its use in hydrotreating.
[0002] In general, the object of catalytically hydrotreating
hydrocarbon-containing feeds is the removal of impurities. Common
impurities are sulfur compounds and nitrogen compounds. The at
least partial removal of such impurities from a feed will ensure
that, when the final product is burnt, fewer sulfur oxides and/or
nitrogen oxides harmful to the environment will be released. In
addition, sulfur compounds and nitrogen compounds are toxic to many
of the catalysts employed in the oil industry for converting feeds
into ready-for-use products. Examples of such catalysts include
cracking catalysts, hydrocracking catalysts, and reforming
catalysts. It is therefore customary for feeds to be subjected to a
catalytic hydrotreatment prior to their being processed in, say, a
cracking unit. Catalytic hydrotreatment implies contacting a feed
with hydrogen at elevated temperature and pressure in the presence
of a hydrotreating catalyst. In this process the sulfur compounds
and nitrogen compounds present in the feed are converted into
readily removable hydrogen sulfide and ammonia.
[0003] In general, hydrotreating catalysts are composed of a
carrier with deposited thereon a Group VI metal component and a
Group VIII metal component. The most commonly employed Group VI
metals are molybdenum and tungsten, while cobalt and nickel are the
conventional Group VIII metals. Phosphorus may also be present in
the catalyst. The prior art processes for preparing these catalysts
are characterised in that a carrier material is composited with
hydrogenation metal components, for example by impregnation, after
which the composite is calcined to convert the metal components
into their oxides. Before being used in hydrotreating, the
catalysts are generally presulfided to convert the hydrogenation
metals into their sulfides.
[0004] Because the requirements as to the legally permitted sulfur
and nitrogen contents in fuels are becoming ever stricter, there is
a continuous need for hydrotreating catalysts with improved
activity. Further, at a given final sulfur content a more active
catalyst will make it possible to operate under milder process
conditions (energy saving) or to increase the lifespan of a
catalyst between regenerations (cycle length).
[0005] WO 96/41848 describes a process wherein a hydrotreating
catalyst comprising a Group VIII hydrogenation metal oxide and a
Group VI hydrogenation metal oxide on a carrier is activated by
contacting it with an additive which is at least one compound
selected from the group of compounds comprising at least two
hydroxyl groups and 2-10 carbon atoms, and the (poly)ethers of
these compounds, after which the catalyst is dried under such
conditions that the additive substantially remains in the catalyst.
The additives described in this reference include sugars and
various ethers and polyethers. The catalyst may be either a fresh
(not used) catalyst or a used catalyst which has been
regenerated.
[0006] WO 01/02092 describes a process for regenerating and
activating a used additive-based catalyst by contacting it with an
oxygen-containing gas at a maximum temperature of 500.degree. C.,
followed by activating it by contacting with an organic additive,
if necessary followed by drying at such a temperature that at least
50% of the additive is maintained in the catalyst. The preferred
additives described in this reference are those selected from the
group of compounds comprising at least two oxygen-containing
moieties and 2-10 carbon atoms and the compounds built up from
these compounds. Cited examples include acids,
aliphatic-dialcohols, ethers thereof, sugars, and N-containing
compounds.
[0007] It has now been found, however, that the process described
in these references can be improved if the catalyst is activated
with the combination of an acid and a specified additive.
Accordingly, the present invention pertains to a process for
activating an hydrotreating catalyst comprising a Group VIB metal
oxide and a Group VIII metal oxide which process comprises
contacting the catalyst with an acid and an organic additive which
has a boiling point in the range of 80-500.degree. C. and a
solubility in water of at least 5 grams per liter (20.degree. C.,
atmospheric pressure), optionally followed by drying under such
conditions that at least 50 wt % of the additive (relative to the
total original amount of additive) is maintained in the catalyst.
The process of the present invention is suitable for activating
fresh hydrotreating catalysts, but also for activating catalysts
which have been used in the hydrotreating of hydrocarbon feeds.
[0008] The inventors have found that in view of obtaining a high
activity after reactivated catalyst it is preferred that in the
process according to the invention the activated hydrotreating
catalyst comprises a crystalline fraction (defined as weight
fraction of crystalline compounds of Group VIB and Group VIII
metals relative to the total weight of the catalyst) below 5 wt %,
more preferably below 2.5 wt %, even more preferably below 1 wt %
and most preferably below 0.5 wt %. Ideally, the activated
hydrotreating catalyst comprises substantially no crystalline
fraction. The crystalline compounds can be a single crystalline
compound or a mixture of different crystalline compounds. For
example, in case of a cobalt molybdenum catalyst it was found that
the active hydrotreating metals can crystallise in alfa-cobalt
molybdate (.alpha. CoMoO4). Depending on the hydrotreating metal
composition of the catalysts different crystalline compounds can be
formed for example nickel molybdate, cobalt tungstate and nickel
tungstate, mixtures thereof or mixed metal crystals can be found.
The crystalline fraction can be measured by x-ray diffraction
techniques.
[0009] It was found that the advantages of the process according to
the invention can be obtained not only in used regenerated catalyst
but also in fresh hydrotreating catalysts. In particular in fresh
hydrotreating catalysts that have been calcined, a considerable
improvement of the activity can be obtained by using the activation
process according to the invention. In calcined fresh hydrotreating
catalysts a considerable crystalline fraction was found, in
particular when calcined at a temperature above 350.degree. C., or
even more so when calcined above 400.degree. C., 450.degree. C. or
above 500.degree. C. Very good activity improvements can be
obtained when in the process according to the invention the fresh
hydrotreating catalyst comprises a crystalline fraction of at least
0.5 wt %, preferably at least 1 wt %, more preferably at least 2.5
wt % and most preferably at least 5 wt %.
[0010] The invention also relates to a hydrotreating catalyst
obtainable by the processes described above. In particular, to a
hydrotreating catalyst comprising a Group VIII metal oxide and a
Group VI metal oxide, which catalyst additionally comprises an acid
and an organic additive which has a boiling point in the range of
80-500.degree. C. and a solubility in water of at least 5 grams per
liter (20.degree. C., atmospheric pressure). The catalyst is
preferably a regenerated used catalyst or a calcined fresh catalyst
wherein the catalyst preferably comprises a crystalline fraction
below 5 wt %, more preferably below 2.5 wt %, most preferably below
1 wt % (expressed as weight fraction of crystalline compounds of
Group VIB and Group VIII metals relative to the total weight of the
catalyst).
[0011] EP-A-0601722 describes a method for preparing a catalyst by
impregnation of an alumina carrier substance with a solution
containing hydrotreating metal elements, phosphoric acid and
organic additives followed by drying at a temperature below
200.degree. C. to prevent decomposition or evaporation of the
additives. This method does not concern activation of a fresh or
used and regenerated hydrotreating catalyst. In this method the
active hydrotreating metals are deposited in the presence of, and
complexed with, phosphoric acid and an organic additive in the
impregnation solution. It is surprising that used and regenerated
or fresh hydrotreating catalyst, in which the hydrotreating metals
are already deposited, can be activated with an acid and organic
additive having the specified boiling point and solubility
features.
[0012] The starting material for the process according to the
invention is a hydrotreating catalyst comprising a Group VIII
hydrogenation metal oxide and a Group VI hydrogenation metal oxide,
further indicated as an oxidic catalyst. Generally at least 80% of
all of the Group VIII and Group VI hydrogenation metal present in
the catalyst is in the oxidic form, preferably at least 90%, more
preferably at least 95%, still more preferably at least 98%. The
percentage of metals present in the catalyst in oxidic form can be
determined by X-ray fluorescence spectroscopy (XRF) or inductively
coupled plasma spectroscopy (ICP). The percentages are weight
percentages relative to the total weight of the metals.
[0013] The oxidic hydrotreating catalyst used as starting material
in the process according to the invention may thus be an oxidic
hydrotreating catalyst prepared by a process in which hydrogenation
metal components are composited with a carrier, after which the
composite material is subjected to a calcination step to convert
the hydrogenation metal components into their if oxides. However,
it may also be a used hydrotreating catalyst which has been
regenerated by removing coke therefrom. In this case the catalyst
may or may not have contained an additive before its first use.
[0014] The starting catalyst comprises a Group VIII metal oxide and
a Group VI metal oxide, generally on a carrier. As Group VI metals
may be mentioned molybdenum, tungsten, and chromium, with
molybdenum or tungsten being preferred. Molybdenum is especially
preferred. Group VIII metals include nickel, cobalt, and iron.
Nickel, cobalt, or their combination is preferred. The catalyst
usually has a metal content in the range of 0.1 to 50 wt. %,
calculated as oxides on the overall weight of the catalyst. The
Group VI metal component is generally present in an amount of 5-40
wt %, calculated as trioxide, preferably 10-35 wt. %; more
preferably 15-30 wt. %. The Group VIII metal component is generally
present in an amount of 1-10 wt. %, preferably 2-8 wt. %,
calculated as oxide. If so desired, the catalyst may also contain
other components, such as phosphorus, halogens, and boron.
Particularly, the presence of phosphorus in an amount of 1-10 wt.
%, calculated as P.sub.2O.sub.5, to improve the
hydrodenitrogenation activity of the catalyst may be preferred.
[0015] The catalyst carrier may comprise the conventional oxides,
e.g., alumina, silica, silica-alumina, alumina with silica-alumina
dispersed therein, silica-coated alumina, magnesia, zirconia,
boria, and titania, as well as mixtures of these oxides. As a rule,
preference is given to the carrier being of alumina,
silica-alumina, alumina with silica-alumina dispersed therein, or
silica-coated alumina. Special preference is given to alumina and
alumina containing up to 10 wt. % of silica. A carrier containing a
transition alumina, for example an eta, theta, or gamma alumina is
preferred within this group, wherein a gamma-alumina carrier is
most especially preferred.
[0016] The catalyst's pore volume (measured via mercury
penetration, contact angle 140.degree., surface tension of 480
dyn/cm) is not critical to the process according to the invention
and will generally be in the range of 0.2 to 2 ml/g, preferably
0.4-1 ml/g. The specific surface area is not critical to the
process according to the invention either and will generally be in
the range of 50 to 400 m.sup.2/g (measured using the BET method).
Preferably, the catalyst will have a median pore diameter in the
range of 7-15 nm, as determined by mercury porosimetry, and at
least 60% of the total pore volume will be in the range of .+-.2 nm
from the median pore diameter.
[0017] The catalyst is employed in the conventional manner in the
form of spheres or extrudates. Examples of suitable types of
extrudates have been disclosed in the literature (see, int. al.,
U.S. Pat. No. 4,028,227). Highly suitable for use are cylindrical
particles (which may be hollow or not) as well as symmetrical and
asymmetrical polylobed particles (2, 3 or 4 lobes).
[0018] In the process according to the invention the oxidic
hydrotreating catalyst is contacted with an acid and an organic
additive having a boiling point in the range of 80-500.degree. C.
and a solubility in water of at least 5 grams per liter.
[0019] The acid and the additive are incorporated into the catalyst
in the liquid form by impregnation. For the acid this will
generally mean it being in the dissolved state. For the additive,
whether or not a solvent is necessary will depend on its
properties. If the additive is sufficiently fluid to enter the
catalyst's pores without a solvent being present, a solvent can be
dispensed with. Generally, however, a solvent will be used. The
solvent generally is water, although other compounds, such as
methanol, ethanol, and other alcohols may also be suitable,
depending on the nature of the additive and the acid.
[0020] In a preferred embodiment of the process of the invention,
the catalyst is subjected to an aging step after the incorporation
of the acid. The aging step is effected while the catalyst is still
wet, that is, before the solvent is removed from the catalyst. It
has been found that the aging step is particularly advantageous
when a catalyst which has been used in the hydrotreating of
hydrocarbon feed is to be reactivated. The aging time applied in
the aging step is a function of temperature. Generally, the aging
time decreases with increasing aging temperature. The aging step
typically takes at least 15 minutes. After a certain time, for
example after more than 48 hours, no additional activity
improvement is observed. If the aging step is carried out at a
temperature between 0.degree. and 50.degree. C., the aging time is
typically at least 1 hour, preferably at least 2 hours, more
preferably at least 6 hours. If the aging step is carried out at a
temperature above 50.degree. C., the aging time is generally at
least 0.5 hours, preferably at least 1 hour, more preferably at
least 2 hours. It is also possible to effect the aging step at a
temperature of above 100.degree. C. under hydrothermal conditions
for a period of over 15 minutes. The aging step can also be
performed by heating the catalyst with microwaves or induction
heating. Preferably, the catalyst composition is aged for a time
sufficient to reduce the crystalline fraction below 5 wt percent,
more preferably below 2.5 wt %. It was further found, that the time
of aging can be considerably reduced and/or significantly better
results can be achieved if in the process according to the
invention the acid concentration is at least 5 wt %, preferably at
least 7 wt %, most preferably at least 10 wt % (relative to the
total weight of the catalyst).
[0021] If solvent has been used to incorporate the additive and/or
the acid into the catalyst, the catalyst may be dried after the
impregnation step has been completed to remove at least part of the
solvent, generally at least 50%, preferably at least 70%, more
preferably at least 80% (in weight percent relative to the original
weight of the compound). It is essential to the process according
to the invention that any drying step is effected in such a manner
that at least part of the additive remains in the catalyst. The
catalyst is hence not calcined. In consequence, the drying
conditions to be applied depend heavily on the temperature at which
the specific additive boils or decomposes. In the context of the
present invention, the drying step should be carried out under such
conditions that at least 50%, preferably 70%, more preferably 90%
of the additive incorporated into the catalyst in the impregnation
step is still present in the catalyst after the drying step. Of
course, it is preferred to keep as much additive as possible in the
catalyst during the drying step, but with the more volatile
compounds evaporation during the drying step cannot always be
avoided. The drying step may, e.g., be carried out in air, under
vacuum, or in inert gas. Generally, it is advantageous to have a
drying temperature below 220.degree. C., although a higher or lower
temperature may be necessary, depending on the nature of the
additive.
[0022] The acid and the additive may be incorporated into the
catalyst simultaneously or sequentially in no particular order.
[0023] In one embodiment, the starting material is contacted with a
solution of an acid, optionally followed by drying. Then, the
organic additive is incorporated into the catalyst, optionally
followed by a drying step under such conditions that at least 50%
of the additive remains in the catalyst (in weight percent relative
to the original weight of the compound). If in this embodiment an
aging step is carried out, it may be performed before or after the
organic additive has been incorporated into the catalyst
composition.
[0024] In another embodiment, in a first step the organic additive
is incorporated into the starting material, optionally followed by
a drying step under such conditions that at least 50% of the
additive remains in the catalyst. Then, the resulting material is
contacted with a solution of an acid, optionally followed by an
aging step and/or by drying under such conditions that at least 50%
of the additive remain in the catalyst.
[0025] The advantage of incorporating the acid and the additive
into the catalyst in separate steps is that the properties of the
impregnation solutions may be tailored to meet the requirements of
the acid and the additive. Nevertheless, for reasons of efficiency,
it is preferred to contact the starting catalyst with a single
impregnation solution comprising both the acid and the additive,
optionally followed by an aging step and/or a drying step under
such conditions that at least 50% of the additive remains in the
catalyst.
[0026] The acid may be an inorganic or an organic acid. Inorganic
acids are defined as acidic components which do not contain a
carbon atom. Examples of inorganic acids include HCl,
H.sub.2SO.sub.4, HNO.sub.3, H.sub.3PO.sub.4,
(NH.sub.4)H.sub.2PO.sub.4, (NH.sub.4).sub.2HPO.sub.4,
H.sub.2PHO.sub.3, H.sub.2P.sub.2H.sub.2O.sub.5, and
H.sub.(n+2)P.sub.nO.sub.(3n+1). Within the group of inorganic
acids, the phosphorus-containing acids are preferred, since
phosphorus in itself can positively influence the activity of a
hydrotreating catalyst. H.sub.3PO.sub.4 is particularly
preferred.
[0027] One disadvantage to the use of inorganic acids is that the
counterion, e.g., chloride, sulfate, or nitrate, is incorporated
into the catalyst composition. If the activation process of the
present invention is repeated a number of times this may lead to an
undesirable build-up of these counterions in the catalyst
composition. However, depending on the nature of the counterion and
on the number of regeneration steps envisaged, this may not be a
problem. Organic acids are preferred because they do not have said
disadvantage.
[0028] In the context of the present specification, an organic acid
is defined as a compound comprising at least one carboxylic group
(COOH). The organic acid is generally a carboxylic acid comprising
at least one carboxylgroup and 1-20 carbon atoms (carbon atoms in
the carboxylgroup included). Suitable acids include acetic acid,
citric acid, malic acid, maleic acid, formic acid, glycolic acid,
hydroxypropionic acid, hydroxybutyric acid, hydroxyhexanoic acid,
tartaric acid, glyceric acid, gluconic acid, oxalic acid, malonic
acid, polyacrylic acid, ascorbic acid, and N-containing acids like
EDTA and CyDTA (1,2,-cyclohexanediaminetetra-acetic acid) etc.
Within this group, compounds comprising at least two carboxylic
groups are preferred. For combined costs and activity, citric acid,
malic acid, maleic acid, malonic acid, and tartaric acid are
preferred. Citric acid is particularly preferred.
[0029] The organic additive used in combination with the acid in
the process according to the invention is an organic compound, viz.
a compound comprising at least one carbon atom and at least one
hydrogen atom, with a boiling point in the range of 80-500.degree.
C. and a solubility in water of at least 5 grams per liter at room
temperature (20.degree. C.) (atmospheric pressure). Preferably the
additive is an oxygen- or nitrogen-containing compound.
[0030] The boiling point of the additive is preferably in the range
of 100-400.degree. C., more is preferably 150-350.degree. C. The
boiling point of the additive is balanced between on the one hand
the desire that the additive remain on the catalyst during the
preparation process, including the drying step, and on the other
hand the need for the additive to be removed from the catalyst
during catalyst use or sulfidation. In case the organic additive
has no boiling point but instead decomposes in the specified
temperature range, the term boiling point is meant to be synonymous
with the composition temperature.
[0031] The solubility of the additive is at least 5 grams per liter
at room temperature, preferably at least 10 grams. It is noted that
the solubility requirement for the additive has a two-fold basis.
In the first place, compounds meeting this solubility requirement
are convenient to apply in impregnation solutions. Additionally it
has appeared that compounds which meet these solubility
requirements somehow interact with the metal components present in
the catalyst leading to an increase in activity of the final
product.
[0032] Within this definition, various groups of additives may be
distinguished.
[0033] A first, at this point in time preferred, group of additives
is the group of organic compounds comprising at least two oxygen
atoms and 2-20 carbon atoms, preferably 2-10 carbon atoms and the
compounds built up from these compounds. Organic compounds selected
from the group of compounds comprising at least two
oxygen-containing moieties, such as a carboxyl, carbonyl or
hydroxyl moieties, and 2-10 carbon atoms and the compounds built up
from these compounds are preferred. Examples of suitable compounds
include butanediol, pyruvic aldehyde, glycolic aldehyde, and
acetaldol. At this point in time, preference is given within this
group to an additive that is selected from the group of compounds
comprising at least two hydroxyl groups and 2-10 carbon atoms per
molecule, and the (poly)ethers of these compounds. Suitable
compounds from this group include aliphatic alcohols such as
ethylene glycol, propylene glycol, glycerin, trimethylol ethane,
trimethylol propane, etc. Ethers of these compounds include
diethylene glycol, dipropylene glycol, trimethylene glycol,
triethylene glycol, tributylene glycol, tetraethylene glycol,
tetrapentylene glycol. This range can be extrapolated to include
polyethers like polyethylene glycol. Other ethers which are
suitable for use in the present invention include ethylene glycol
monobutyl ether, diethylene glycol monomethyl ether, diethylene
glycol monoethyl ether, diethylene glycol monopropyl ether, and
diethylene glycol monobutyl ether. Of these, ethylene glycol,
diethylene glycol, triethylene glycol, tetraethylene glycol,
propylene glycol, dipropylene glycol, and polyethylene glycol with
a molecular weight between 200 and 600 are preferred. Another group
of compounds comprising at least two hydroxyl groups and 2-10
carbon atoms per molecule are the saccharides. Preferred
saccharides include monosaccharides such as glucose and fructose.
Ethers thereof include disaccharides such as lactose, maltose, and
saccharose. Polyethers of these compounds include the
polysaccharides. The organic compounds of this group are preferably
substantially saturated, as is evidenced by a iodine number of less
than 60, preferably less than 20.
[0034] A second group of organic additives suitable for use in the
present invention are those compounds comprising at least one
covalently bonded nitrogen atom and at least one carbonyl moiety.
This type of organic compound preferably comprises at least two
carbonyl moieties. It is preferred that at least one carbonyl
moiety is present in a carboxyl group. It is furthermore preferred
that at least one nitrogen atom is covalently bonded to at least
two carbon atoms. A preferred organic compound satisfies formula
(I) or (II)
(R1R2)N--R3-N(R1'R2') (I)
N(R1R2R1') (II)
wherein R1, R2, R1' and R2' are independently selected from alkyl,
alkenyl, and allyl, with up to 10 carbon atoms optionally
substituted with one or more groups selected from carbonyl,
carboxyl, ester, ether, amino, or amido. R3 is an alkylene group
with up to 10 carbon atoms which may be interrupted by --O-- or
--NR4-. R4 is selected from the same group as indicated above for
R1. The R3 alkylene group may be substituted with one or more
groups selected from carbonyl, carboxyl, ester, ether, amino, or
amido. As has been set out above, it is essential that the organic
compound of formula (I) or (II) comprises at least one carbonyl
moiety.
[0035] Preferably, at least two of R1, R2, R1' and R2' (formula
(I)) and at least two of R1, R2 and R1' (formula (II)) have the
formula --R5-COOX, wherein R5 is an alkylene group having 1-4
carbon atoms, and X is hydrogen or another cation, such as an
ammonium, sodium, potassium and/or lithium cation. If X is a
multivalent cation, one X can adhere to two or more --R5-COO
groups. Typical examples of a compound of formula (I) are ethylene
diamine(tetra)acetic acid (EDTA), hydroxyethylene diamine triacetic
acid, and diethylene triamine pentaacetic acid. A typical example
of a compound of formula (II) is nitrilotriacetic acid (NTA). For
reasons of solubility, the salts of these compounds may be
preferred.
[0036] It is noted that the above-mentioned description of the
organic additive encompasses various acidic components. Where in
the context of the present invention the combination of an acid and
an organic additive is discussed, this means that (at least) two
different compounds are used wherein one is an acid and wherein the
other meets the requirements as to solubility and boiling point
placed on the organic additive. The latter compound may or may not
also be acidic.
[0037] From an environmental point of view, it is preferred to
employ additives which are essentially free of sulfur. Further,
sulfur-containing additives generally are not stable in relation to
oxygen. Therefore, if sulfur-containing additives were to be
employed, all subsequent process steps would have to be carried out
under an inert atmosphere. Also for this reason it is preferred to
employ sulfur-free additives. This goes both for the acid and for
the organic additive.
[0038] A single compound as well as a combination of compounds may
be used as additive.
[0039] The total amount of acid and additive used in the process
according to the invention, and the total amount of acid and
additive present in the catalyst according to the invention is at
least 0.01, preferably at least 0.05, more preferably at least 0.1
mole of total of acid and additive per mole of the total of Group
VIB and Group VIII metals. Generally, the molar ratio will be at
most 3, preferably at most 2.
[0040] If an inorganic acid is used, the amount of acid is
generally between 0.01 and 1 mole per mole of total of Group VIB
and Group VIII metals, preferably between 0.05 and 0.5 mole mole
per mole of total of Group VIB and Group VIII metals.
[0041] If an organic acid is used, the amount of acid is generally
between 0.01 and 1 mole per mole of total of Group VIB and Group
VIII metals, preferably between 0.05 and 0.5 mole per mole of total
of Group VIB and Group VIII metals.
[0042] The amount of organic additive is generally between 0.1 and
2.5 mole per mole of total of Group VIB and Group VIII metals,
preferably between 0.15 and 1 mole per mole of total of Group VIB
and Group VIII metals, more preferably between 0.2 and 1 mole per
mole of total of Group VIB and Group VIII metals.
[0043] The molar ratio between acid and additive is generally
0.01-10:1, preferably 0.1-5:1, more preferably 0.15-3:1.
[0044] In general, if the total amount of acid and additive added
is too low, the advantageous effect of the present invention will
not be obtained. On the other hand, the addition of an
exceptionally large total amount of acid and additive will not
improve the effect of the present invention. As will be clear to
the person skilled in the art, the exact amount of acid and
additive to be used in a specific situation will depend upon a
variety of parameters including the metals content of the catalyst,
the pore volume and pore size distribution of the catalyst, the
nature of the acid and additive, the solvent to be used in the
impregnation solution, the impregnation conditions, etc. It is well
within the scope of the person skilled in the art to determine the
optimum amount of acid and additive to be used in each specific
situation, taking the above-mentioned variables into account.
[0045] The present invention also pertains to the hydrotreating
catalyst which comprises a Group VIII metal oxide and a Group VI
metal oxide on a carrier, which catalyst additionally comprises an
acid and an organic additive as described above.
[0046] The dried additive-containing hydrotreating catalyst of the
present invention may be subjected to a sulfiding step before it is
used in the hydrotreating of hydrocarbon feeds, but, as has been
explained before, this is not necessary. If it is decided to
sulfide the catalyst before use, this can be done in one of the
ways known in the art. For example, it is possible to contact the
catalyst with inorganic or organic sulfur compounds, such as
hydrogen sulfide, elemental sulfur, or organic polysulfides, or to
sulfide the catalyst by contacting it with a hydrocarbon feed to
which a sulfur compound has been added. All of this will be known
to the skilled person as catalyst sulfiding or presulfiding.
[0047] The present catalysts can be used in the hydrotreating of a
wide range of feeds. To effect one or more of hydrodesulfurisation,
hydrodenitrogenation, and hydrodearomatisation. Examples of
suitable feeds include middle distillates, kero, naphtha, vacuum
gas oils, and heavy gas oils. The catalyst is particularly suitable
for use in ultra-deep hydrodesulfurisation, viz.
hydrodesulfurisation to a product suphur content below 200 ppm,
more in particular to product sulfur content below 50 ppm. The
conventional process conditions, such as temperatures in the range
of 250.degree.-450.degree. C., pressures in the range of 5-250 bar,
space velocities in the range of 0.1-10 h-1, and H2/oil ratios in
the range of 50-2000 NI/I, can be applied here.
[0048] As indicated above, the catalyst to be activated in the
process according to the invention is either a fresh hydrotreating
catalyst or used and regenerated hydrotreating catalyst.
[0049] The fresh oxidic hydrotreating catalyst suitable for use as
starting material in the process according to the invention are
known in the art. They may be obtained, e.g., as follows. A carrier
precursor is prepared, e.g., in the case of alumina, in the form of
an alumina hydrogel (boehmite). After it has been dried or not,
e.g., by means of spray-drying, it is shaped into particles, for
example by extrusion. The shaped particles are calcined at a
temperature in the range of 400.degree. to 850.degree. C.,
resulting, in the case of alumina, in a carrier containing a
transition alumina, e.g., a gamma, theta, or eta-alumina. Then,
suitable amounts of precursors for the hydrogenation metals and the
optional other components, such as phosphorus, are deposited on the
catalyst, for example in the form of an aqueous solution. In the
case of Group VI metals and Group VIII metals, the precursors may
be ammonium molybdate, ammonium tungstenate, cobalt nitrate and/or
nickel nitrate. Suitable phosphorus component precursors include
phosphoric acid and the various ammonium hydrogen phosphates. After
an optional drying step at a temperature in the range of
25.degree.-200.degree. C., the resulting material is calcined at a
temperature in the range of 350.degree.-750.degree. C., more in
particular 425 to 600.degree. C., to convert all metal component
precursors, and the optional other component precursors to form
oxide components.
[0050] It will be clear to the skilled man that there can be a wide
number of variations on this method. Thus, it is possible to apply
a plurality of impregnating steps, the impregnating solutions to be
used containing one or more of the component precursors that are to
be deposited, or a portion thereof. Instead of impregnating
techniques there can be used dipping methods, spraying methods,
etc. With multiple impregnation, dipping, etc. drying and/or
calcining may be carried out in between. Alternatively, one or more
component precursors can be mixed wholly or in part with the
carrier prior to the shaping step being carried out. In such an
embodiment the component precursor material, or a portion thereof,
can be deposited on the not yet shaped carrier material, say, a
powder, by means of, e.g., impregnation, after which the shaping
step is carried out. Alternatively, it is possible to intimately
mix one or more component precursors wholly or in part with the
carrier material during the shaping step rather than prior to it.
Techniques that are suitable for this process are co-pelletisation
and co-extrusion. It is recommended that the group VIB metal
component precursor employed in this process be molybdenum
trioxide.
[0051] Oxidic hydrotreating catalysts and the processes for
preparing them are part of the common general knowledge of the
skilled person and described in, e.g., U.S. Pat. No. 4,738,767,
U.S. Pat. No. 4,062,809, U.S. Pat. No. 4,500,424, GB 1 504 586,
U.S. Pat. No. 4,212,729, U.S. Pat. No. 4,326,995, U.S. Pat. No.
4,051,021, U.S. Pat. No. 4,066,574, EP-A 0 469 675.
[0052] The activation process of the present invention is also
applicable to the catalyst which has been used in the hydrotreating
of hydrocarbon feeds and subsequently regenerated.
[0053] The present invention also pertains to a combined process
for regenerating and activating a used hydrotreating catalyst
wherein a used hydrotreating catalyst comprising a Group VIB metal
oxide and a Group VIII metal oxide is first subjected to a
regeneration step to remove carbonaceous and sulfurous deposits,
followed by activating the thus obtained material by contacting it
with an acid and an organic additive which has a boiling point in
the range of 80-500.degree. C. and a solubility in water of at
least 5 grams per liter (20.degree. C., atmospheric pressure).
[0054] The regeneration step of the process according to the
invention is carried out by contacting the used additive-based
catalyst with an oxygen-containing gas under such conditions that
after regeneration, the carbon content of the catalyst generally is
below 3 wt. %, preferably below 2 wt. %, more preferably below 1
wt. %. After regeneration, the sulfur content of the catalyst
generally is below 2 wt. %, preferably below 1 wt. %. Before the
regeneration step, the carbon content of the catalyst generally is
above 5 wt. %, typically between 5 and 25 wt. %. The sulfur content
of the catalyst before the regeneration step generally is above 5
wt. %, typically between 5 and 20 wt. %.
[0055] The maximum catalyst temperature during the regeneration
step will be governed by the properties of the catalyst to be
regenerated and by process constraints, a higher maximum
temperature being preferred in principle because this makes it
possible to reduce the regeneration time. However, a high
regeneration temperature carries the risk of damaging the catalyst.
Catalysts with a higher metal content will generally require a
lower maximum catalyst temperature than catalysts with a lower
metal content. Generally, the maximum catalyst temperature during
the regeneration process is at most 650.degree. C., preferably at
most 575.degree. C., more preferably at most 550.degree. C., still
more preferably at most 525.degree. C.
[0056] The maximum catalyst temperature during the regeneration
process generally is at least 300.degree. C., preferably at least
350.degree. C., more preferably at least 400.degree. C., still more
preferably at least 450.degree. C.
[0057] It is noted that in this specification any temperature given
relates to the temperature of the catalyst, except when explicitly
indicated otherwise. The catalyst temperature can be determined in
any way known to the skilled person, e.g., by way of appropriately
placed thermocouples.
[0058] It is preferred for the regeneration step in the presence of
oxygen to be carried out in two steps, namely a first
lower-temperature step and a second higher-temperature step. In the
first, lower-temperature step, the catalyst is contacted with an
oxygen-containing gas at a temperature of 100 to 370.degree. C.,
preferably 175 to 370.degree. C. In the second, higher-temperature
regeneration step, the catalyst is contacted with an
oxygen-containing gas at a temperature of In the second,
higher-temperature regeneration step, the catalyst is contacted
with an oxygen-containing gas at a temperature of 300 to
650.degree. C., preferably 320 to 550.degree. C., still more
preferably 350-525.degree. C. The temperature during the second
step is higher than the temperature of the first step discussed
above, preferably by at least 10.degree. C., more preferably by at
least 20.degree. C. The determination of appropriate temperature
ranges is well within the scope of the skilled person, taking the
above indications into account.
[0059] It is preferred for the catalyst to be regenerated in a
moving bed process, preferably, if applicable, at a bed thickness
of 1-15 cm. In the context of the present specification, the term
"moving bed" is intended to refer to all processes wherein the
catalyst is in movement as compared to the unit, including
ebullated bed processes, fluidised processes, processes in which
the catalyst is rotated through a unit, and all other processes
wherein the catalyst is in movement. The duration of the
regeneration process including stripping will depend on the
properties of the catalyst and the exact way in which the process
is carried out, but will generally be between 0.25 and 24 hours,
preferably between 2 and 16 hours.
[0060] The regenerated catalyst will be contacted with the acid and
additive in the process according to the invention as has been
described above.
[0061] The invention will be illustrated by the following examples,
but is not intended to be limited thereto or thereby.
EXAMPLE 1
Activating Used Catalyst with Citric Acid and Polyethylene
Glycol
[0062] A hydroprocessing catalyst that had been used for 12 months
on the hydrotreating of a LGO feedstock was regenerated as follows.
The catalyst contained 23.2 wt. % of carbon, 9 wt. % of sulfur, and
22.4 wt. % of hydrocarbon.
[0063] In a first step, the hydrocarbon was removed from the
catalyst by stripping. Then, the catalyst was regenerated by
contacting it with air at a temperature of 490-500.degree. C. for a
period of 24 hours. The regenerated starting material thus obtained
contained molybdenum, cobalt, and phosphorus on an alumina
carrier.
[0064] The regenerated catalyst was impregnated via pore volume
impregnation with an impregnation solution containing citric acid
and polyethylene glycol in an amount of 0.1 mole acid per mole of
hydrogenation metals and 0.5 mole polyethylene glycol per mole of
hydrogenation metals, respectively, and subsequently dried
overnight at a temperature of 120.degree. C.
[0065] The catalyst was tested on a LGO feedstock having the
following properties:
TABLE-US-00001 S (wt. %) 1.4837 N (wt. ppm) 170 density (15.degree.
C., g/ml) 0.8609 viscosity (50.degree. C., cSt) 4.11 H (wt. %)
12.90 Distillation Data (ASTM D 86, .degree. C.) Initial boiling
point 182 10 vol. % 288 50 vol. % 325 90 vol. % 364 Final boiling
point 375
[0066] The catalyst was tested at a liquid hourly space velocity
(LHSV) of 1.5 h-1 and a hydrogen to oil ratio of 200 NI/I at
various conditions with varying temperature and pressure. Each
condition was maintained for two days. The catalyst was tested side
by side with a fresh catalyst. The test conditions and activities
of the two catalysts are given below.
TABLE-US-00002 fresh catalyst reactivated catalyst T (.degree. C.)
PpH2 (MPa) RVA-HDS (ppm S) RVA-HDS (ppm S) 1 345 5.1 100 (42) 93
(50) 2 350 5.1 100 (28) 93 (33) 3 350 3.0 100 (159) 98 (165) 4 350
5.1 100 (55) 103 (52)
[0067] As can be seen from the above table, the activity of the
spent and reactivated catalyst had been brought back to an activity
which is substantially as high as the activity of the fresh
catalyst. In comparison, the activity of the spent catalyst after
regeneration was 70% as compared with its initial activity.
EXAMPLE 2
Activating Used Catalyst with Phosphoric Acid and Polyethylene
Glycol
[0068] A hydroprocessing catalyst that had been used for 24 months
on the hydrotreating of a LGO feedstock was regenerated as follows.
The catalyst contained 25.4 wt. % of carbon, 8.8 wt. % of sulfur,
and 18.3 wt. % of hydrocarbon. In a first step, the hydrocarbon was
removed from the catalyst by stripping. Then, the catalyst was
regenerated by contacting it with air at a temperature of
450.degree. C. for a period of 24 hours. The regenerated starting
material thus obtained contained molybdenum, cobalt, and phosphorus
on an alumina carrier.
[0069] The regenerated catalyst was impregnated via pore volume
impregnation with an impregnation solution containing phosphoric
acid and polyethylene glycol in an amount of 0.2 mole polyethylene
glycol per mole of hydrogenation metals, and subsequently dried
overnight at a temperature of 120.degree. C. The final catalyst
contained 4.8 wt. % of phosphorus, calculated as P.sub.2O.sub.5
while the original catalyst contained 1.6 wt. %.
[0070] The catalyst was tested on a LGO feedstock having the
following properties:
TABLE-US-00003 S (wt. %) 1.323 N (wt. ppm) 110 density (15.degree.
C., g/ml) 0.8574 Distillation Data (ASTM D 86, .degree. C.) Initial
boiling point 183 10 vol. % 253 50 vol. % 298 90 vol. % 360 Final
boiling point 380
[0071] The catalyst was tested at a hydrogen partial pressure of
3.92 MPa, a liquid hourly space velocity (LHSV) of 1.5 h-1, and a
hydrogen to oil ratio of 200 NI/I at various conditions with
varying temperatures. Each condition was maintained for two days.
The catalyst was tested side by side with a fresh catalyst. The
test conditions and activities of the two catalysts are given
below.
TABLE-US-00004 fresh catalyst reactivated catalyst T (.degree. C.)
RVA-HDS (ppm S) RVA-HDS (ppm S) 1 340 100 (114) 98 (120) 2 350 100
(39) 99 (41) 3 330 100 (406) 101 (398)
[0072] As can be seen from the above table, the activity of the
spent and reactivated catalyst had been brought back to an activity
which is substantially as high as the activity of the fresh
catalyst. In comparison, the relative volume activity for HDS of
the spent catalyst after having been used for 24 months in the
hydrotreating of a hydrocarbon oil had decreased to 53% as compared
with its is initial relative volume activity.
EXAMPLE 3
Activating Used Catalyst with Citric Acid and Polyethylene
Glycol
[0073] A hydroprocessing catalyst that had been used in the
hydrotreating of a hydrocarbon feedstock was regenerated as
follows. The catalyst contained 17.9 wt. % of carbon and 10.7 wt %
of sulfur. The catalyst was regenerated by contacting it with air
at a temperature of 500-530.degree. C. The regenerated starting
material thus obtained contained molybdenum, nickel, and phosphorus
on an alumina carrier.
[0074] The regenerated catalyst was impregnated via pore volume
impregnation with an impregnation solution containing citric acid
and polyethylene glycol in an amount of 0.09 mole acid per mole of
hydrogenation metals and 0.22 mole polyethylene glycol per mole of
hydrogenation metals, respectively, and subsequently aged for 24
hours while wet and dried overnight at a temperature of 90.degree.
C.
[0075] The catalyst was tested on a CGO feedstock having the
following properties:
TABLE-US-00005 S (wt. %) 2.44 N (wt. ppm) 3546 density (15.degree.
C., g/ml) 0.9173 H (wt. %) 11.7 Distillation Data (ASTM D 1160,
.degree. C.) Initial boiling point 176.degree. C. 10 vol. %
250.degree. C. 50 vol. % 332.degree. C. 90 vol. % 412.degree. C.
Final boiling point 503.degree. C.
[0076] The catalyst was tested at a temperature of 387.degree. C.,
a pressure of 100 bar, a is liquid hourly space velocity (LHSV) of
2.1 h-1, and a hydrogen to oil ratio of 1000 NI/I. The
hydrodenitrogenation activity of the regenerated and reactivated
catalyst was 90% of the hydrodenitrogenation activity of the fresh
catalyst. In comparison, the activity of the spent catalyst after
regeneration but before reactivation was about 60% of the activity
of the fresh catalyst.
COMPARATIVE EXPERIMENTS 1 TO 3 AND EXAMPLES 4 TO 8
[0077] In Comparative experiments 1 to 3 and Examples 4 to 8,
different catalysts were prepared as described below. The catalysts
were tested on liquid gas oil (LGO) at a temperature of 340.degree.
C., a pressure of 45 bar, a liquid hourly space velocity (LHSV) of
2.5 h-1, and a hydrogen to oil ratio of 200 NI/I. The
hydrodesulphurisation activity was measured. The measured relative
volume activity values (RVA) are indicated in the table below.
[0078] The crystalline fraction (CRYS) of cobalt molybdate was
measured using x-ray diffraction. The crystalline fraction
(expressed as weight percentage relative to the catalyst weight) is
evaluated from the x-ray diffractogram by evaluating peak aera of
the .alpha.-cobalt molybdate crystal reflections against a
calibration curve determined from a hundred percent crystalline
a-cobalt molybdate.
[0079] All reactivations were carried out by pore volume
impregnation with a solution containing the organic additive and/or
the acid, followed by ageing for 2 hours at 60.degree. C., followed
by drying at 120.degree. C.
[0080] Comparative experiment 1 (CE1) is the regenerated catalyst
described in example 1. In comparative experiment 2 (CE2), the
catalyst of CE1 is reactivated using only citric acid (CA) in
amount of 5 w % (relative to the catalyst weight). In comparative
experiment 3 (CE3), the catalyst of CE1 is activated using only
polyethylene glycol (PEG) in amount of 10 w % (relative to the
catalyst weight). In example 4 according to the invention (Ex4) the
catalyst of CE1 is activated with 4 w % CA and 10 wt % PEG. In
example 5 (Ex5), the catalyst of CE1 is activated with 10 w % CA
and 10 wt % PEG. In example 6 (Ex6), the catalyst of CE1 is
activated with 3.75 w % acetic acid (HAC) and 10 wt % PEG. In
example 7 (Ex7), the catalyst of CE1 is activated with 4 w % CA and
5 wt % glycerol (GLY).
[0081] It can be concluded that the process according to the
invention results in an almost complete recovery of the catalytic
activity of the used and regenerated catalyst, in particular at
higher citric acid contents. The examples show a synergistic effect
of the acid and the organic additive.
[0082] Comparative experiment 4 (CE4) concerns a fresh catalyst
comprising cobalt and molybdenum on a silica/alumina carrier, which
has been calcined at a temperature of 500.degree. C. Example 8
according to the invention (Ex8) is the catalyst of CE4 reactivated
with 4 wt % CA and 10 w % PEG. Example 8 shows that significant
activity improvement can also be obtained by reactivating fresh
catalyst.
TABLE-US-00006 Exp Acid Additive RVA CRYS CE1 -- -- 42 8.4 CE2 CA
-- 46 CE3 -- PEG 50 Ex4 CA PEG 61 2.4 Ex5 CA 10% PEG 97 <0.5 Ex6
HAC PEG 55 Ex7 CA GLY 54 CE4 -- -- 70 2.1 Ex8 CA PEG 76
* * * * *