Systems, methods, and catalysts for producing a crude product

• US 20060234876A1
• Filed: 04/07/2006
• Published: 10/19/2006
• Est. Priority Date: 04/11/2005
• Status: Abandoned Application

• Current Assignee: Shell Oil Company (Shell Plc)
• Original Assignee: Shell Oil Company (Shell Plc)
• Inventors: Bhan, Opinder Kishan
• Application Number:
  US11/399,843
• Publication Number:
  US 20060234876A1
• Time in Patent Office: Days
• US Class Current: 507/270
• CPC Class Codes: C10G 2300/107 Atmospheric residues having a boiling point of at least about 538 °C
• CPC Class Codes: C10G 45/00 Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
• CPC Class Codes: C10G 45/04 characterised by the catalyst used
• CPC Class Codes: C10G 45/08 in combination with chromium, molybdenum, or tungsten metals, or compounds thereof
• CPC Class Codes: C10G 47/02 characterised by the catalyst used
• CPC Class Codes: C10G 47/12 Inorganic carriers
• CPC Class Codes: C10G 49/02 characterised by the catalyst used
• CPC Class Codes: C10G 49/04 containing nickel, cobalt, chromium, molybdenum, or tungsten metals, or compounds thereof

Abstract

Methods and systems for contacting of a crude feed with one or more catalysts to produce a total product that includes a crude product are described. At least one of the catalysts is a bulk metal catalyst. The crude product is a liquid mixture at 25° C. and 0.101 MPa. The crude product may have MCR content at most 90% of the MCR content of the crude feed. One or more other properties of the crude product may be changed by at least 10% relative to the respective properties of the crude feed.

Claims

1. A method of producing a crude product, comprising:

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°

C. and 0.101 MPa, the crude feed has a micro-carbon residue (MCR) content of at least 0.0001 grams per gram of crude feed, and at least one of the catalysts is a Columns 6-10 metal catalyst that 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 such that the crude product has a MCR content of at most 90% of the MCR content of the crude feed, wherein MCR content is as determined by ASTM Method D4530.

2. The method as claimed in claim 1, wherein the Columns 6-10 metal catalyst comprises 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.

3. The method as claimed in claims 1 or 2, wherein the Columns 6-10 metal catalyst comprises one or more metals from Columns 7-10 of the Periodic Table and/or one or more compounds of one or more metals from Columns 7-10 of the Periodic Table.

4. The method as claimed in claim 1, wherein the Columns 6-10 metal catalyst comprises molybdenum and/or tungsten

5. The method as claimed in claim 1, wherein the Columns 6-10 metal catalyst comprises nickel and/or cobalt.

6. The method as claimed in claim 1, wherein the binder comprises silica, alumina, silica/alumina, titanium oxide, zirconium oxide, or mixtures thereof.

7. The method as claimed in claim 1, wherein the Columns 6-10 metal catalyst is amorphous.

8. The method as claimed in claim 1, wherein the MCR content of the crude product is at most 50% of the MCR content of the crude feed.

9. The method as claimed in claim 1, wherein the MCR content of the crude product is in a range from 0.1% to 75% of the MCR content of the crude feed.

10. The method as claimed in claim 1, wherein the crude feed has from 0.0001 grams to 0.5 grams of MCR per gram of crude feed.

11. The method as claimed in claim 1, wherein the crude product has from 0.00001 grams to 0.1 grams of MCR per gram of crude product.

12. The method as claimed in claim 1, wherein the crude feed also has a C₅ asphaltenes content, and the crude product has a C₅ asphaltenes content of at most 90% of the C₅ asphaltenes content of the crude feed, wherein C₅ asphaltenes content is as determined by ASTM Method D2007.

13. The method as claimed in claim 1, wherein the crude product has a viscosity at 37.8°

C. (100°

F.) of at most 90% of the viscosity at 37.8°

C. of the crude feed, wherein viscosity is as determined by ASTM Method D445.

14. The method as claimed in claim 1, wherein the crude feed also has a sulfur content, and the crude product has a sulfur content of at most 90% of the sulfur content of the crude feed, wherein sulfur content is as determined by ASTM Method D4294.

15. The method as claimed in claim 1, wherein the crude feed also has a residue content, and the crude product has a residue content of at most 90% of the residue content of the crude feed, wherein residue content is as determined by ASTM Method D5307.

16. The method as claimed in claim 1, wherein the contacting is performed in the presence of a hydrogen source.

17. The method as claimed in claim 1, wherein the contacting conditions comprise:

a temperature within a range from 50°

C. to 500°

C.;

a total pressure within a range from 0.1 MPa to 20 MPa;

a liquid hourly space velocity of at least 0.05 h-1; and

a ratio of a gaseous hydrogen source to the crude feed in a range from 0.1 Nm³/m³ to 100,000 Nm³/m³.

18. The method as claimed in claim 1, wherein the one or more catalysts comprise in addition a first additional catalyst, the first additional catalyst having a median pore diameter of at least 100 Å

.

19. The method as claimed in claim 18, wherein the one or more catalysts comprise in addition a second additional catalyst, the second additional catalyst having a median pore diameter of at least 180 Å

.

20. The method as claimed in claims 19 or 20, wherein the method further comprises contacting the crude feed with the Columns 6-10 metal catalyst after contacting the crude feed with the first additional catalyst and/or the second additional catalyst.

21. The method as claimed in claim 1, wherein the method further comprises combining the crude product with a crude that is the same as or different from the crude feed to form a blend.

22. The method as claimed in claim 1 or claim 21 further comprising the step of processing the crude product or blend to produce transportation fuel, heating fuel, lubricants, or chemicals.