SYSTEMS AND METHODS FOR PRODUCING A CRUDE PRODUCT AND COMPOSITIONS THEREOF

• US 20080087575A1
• Filed: 10/03/2007
• Published: 04/17/2008
• Est. Priority Date: 10/06/2006
• Status: Abandoned Application

• Current Assignee: Shell Oil Company (Shell Plc)
• Original Assignee: Shell Oil Company (Shell Plc)
• Inventors: BHAN, Opinder, Wellington, Scott
• Application Number:
  US11/866,916
• Publication Number:
  US 20080087575A1
• Time in Patent Office: Days
• US Class Current: 208/72
• CPC Class Codes: B01J 21/04 Alumina
• CPC Class Codes: B01J 23/22 Vanadium
• CPC Class Codes: B01J 23/28 Molybdenum
• CPC Class Codes: B01J 23/882 and cobalt
• CPC Class Codes: B01J 23/883 and nickel
• CPC Class Codes: B01J 35/002 Catalysts characterised by their physical properties
• CPC Class Codes: B01J 35/1019 100-500 m2/g
• CPC Class Codes: B01J 35/1042 0.5-1.0 ml/g
• CPC Class Codes: B01J 35/1061 2-50 nm
• CPC Class Codes: B01J 35/108 Pore distribution
• CPC Class Codes: B01J 35/30 characterised by their physical properties
• CPC Class Codes: B01J 35/615 100-500 m2/g
• CPC Class Codes: B01J 35/635 0.5-1.0 ml/g
• CPC Class Codes: B01J 35/647 2-50 nm
• CPC Class Codes: B01J 35/66 Pore distribution
• CPC Class Codes: B01J 37/0009 Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
• CPC Class Codes: B01J 37/0203 the impregnation liquid containing organic compounds
• CPC Class Codes: C10G 2300/206 Asphaltenes
• CPC Class Codes: C10G 2300/208 Sediments, e.g. bottom sediment and water or BSW
• CPC Class Codes: C10G 2300/302 Viscosity
• CPC Class Codes: C10G 2300/308 : Gravity, density, e.g. API
• CPC Class Codes: C10G 2300/4006 : Temperature
• CPC Class Codes: C10G 2300/4012 : Pressure
• CPC Class Codes: C10G 2300/4018 : Spatial velocity, e.g. LHSV, WHSV
• 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 47/00 : Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions C10G15/00 takes precedence; destructive hydrogenation of non-melting solid carbonaceous or similar materials C10G1/06
• CPC Class Codes: C10G 47/10 : with catalysts deposited on a carrier
• CPC Class Codes: C10G 47/12 : Inorganic carriers
• CPC Class Codes: C10G 49/04 : containing nickel, cobalt, chromium, molybdenum, or tungsten metals, or compounds thereof
• CPC Class Codes: C10G 65/12 : including cracking steps and other hydrotreatment steps

Abstract

Systems and methods for producing a crude product are described herein. Systems include an upstream contacting zone and a downstream contacting zone coupled to the upstream contacting zone. The upstream contacting zone and the downstream contacting zone include one or more catalysts. Contact of a hydrocarbon feed with the one or more of the catalysts produces a hydrocarbon feed/total product mixture having a molybdenum content of at most 90% of the molybdenum of the hydrocarbon feed. Contact of the hydrocarbon feed/total product mixture in downstream with one or more downstream catalysts produces a crude product having 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. Methods of producing a crude product using said systems are described herein. Compositions of said crude product produced from said systems and methods are described herein.

Claims

1. A method of treating a hydrocarbon feed, comprising:

contacting a hydrocarbon feed with one or more catalysts in an upstream contacting zone at a temperature of at most 450°

C. and a partial pressure of hydrogen of at most 7 MPa, the 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, and the one or more catalysts comprising at least one catalyst having, per gram of first catalyst, 0.0001 grams to 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;

producing an intermediate product in the upstream contacting zone having a molybdenum content of at most 90% of the molybdenum content of the hydrocarbon feed;

providing the intermediate product to a downstream contacting zone;

contacting the intermediate product with the one or more additional catalysts positioned in the downstream contacting zone at a temperature of at most 450°

C. and a partial pressure of hydrogen of at most 7 MPa, at least one of the additional catalysts having, per gram of additional 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; and

producing a total product that includes the crude product, wherein the crude product is a liquid mixture at 25°

C. and 0.101 MPa and the crude product has a residue content of at most 90% of the residue content of the hydrocarbon feed and a molybdenum content of at most 90% of the molybdenum content of the hydrocarbon feed, wherein molybdenum content is as determined by ASTM Method D5708 and residue content is as determined by ASTM Method D5307.

2. The method of claim 1, wherein the hydrocarbon feed has an API gravity of at least 5.

3. 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.

4. The method of claim 1, wherein the hydrocarbon feed has at least 0.01 grams of C₅ asphaltenes per gram of hydrocarbon feed, and wherein the crude product has a C₅ asphaltenes content of at most 90% of the hydrocarbon feed C₅ asphaltenes content.

5. 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.

6. 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.

7. The method of claim 1, wherein the hydrocarbon feed has at least 0.01 grams of C₅ asphaltenes per gram of hydrocarbon feed, and wherein the crude product has a C₅ asphaltenes content of at most 90% of the hydrocarbon feed C₅ asphaltenes content.

8. 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.

9. The method of claim 1, wherein the Columns 6-10 metals catalyst comprises molybdenum.

10. The method of claim 1, wherein the Columns 6-10 metals catalyst comprises at most 0.1 grams of molybdenum per gram of catalyst.

11. The method of claim 1, wherein the Columns 6-10 metals catalyst is a supported catalyst, and wherein the support comprises alumina, silica, silica-alumina, titanium oxide, zirconium oxide, magnesium oxide, or mixtures thereof.

12. The method of claim 1, wherein the Columns 6-10 metals catalyst has a pore size distribution with a median pore diameter from 50 angstroms to 150 angstroms, from 60 angstroms to 135 angstroms, or from 70 angstroms to 120 angstroms.

13. The method of claim 1, wherein the Columns 6-10 metals catalyst has a surface area of at least 200 m²/g.

14. The method of claim 1, wherein the Columns 6-10 metals catalyst comprises molybdenum, nickel, cobalt or mixtures thereof.

15. The method of claim 1, wherein the Columns 6-10 metals 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.

16. The method of claim 1, wherein the catalyst having the pore size distribution has a molybdenum content of at least 0.1 grams per gram of catalyst.

17. The method of claim 1, wherein the catalyst having the pore size distribution at least 0.1 grams of molybdenum per gram of catalyst.

18. The method of claim 1, wherein the catalyst having the pore size distribution is a supported catalyst, and wherein the support comprises alumina, silica, silica-alumina, titanium oxide, zirconium oxide, magnesium oxide, or mixtures thereof.

19. The method of claim 1, wherein the catalyst having the pore size distribution has a pore size distribution with a median pore diameter from 50 angstroms to 130 angstroms.

20. The method of claim 1, wherein the catalyst having the pore size distribution comprises molybdenum, nickel, cobalt or mixtures thereof.

21. The method of claim 1, wherein the hydrocarbon feed is contacted with one or more catalysts in a fixed bed reactor.

22. The method of claim 1, further comprising heating the one or more catalysts to a temperature of at least 400°

C. in a time period of less than three weeks.

23. The method of claim 22, wherein the one or more catalysts are heated prior to contacting the hydrocarbon feed with the one or more catalyst.

24. The method of claim 1, further comprising providing the intermediate product to an additional contacting zone positioned between the upstream and downstream contacting zones, the additional contacting zone comprising one or more catalysts and contacting the additional intermediate product with the one or more catalysts to produce the intermediate product, wherein the intermediate product has Ni/V/Fe of at most 50% of the hydrocarbon feed Ni/V/Fe content, wherein Ni/V/Fe content is as determined by ASTM Method D5708.

25. The method of claim 1, further comprising producing an additional intermediate product and providing the additional intermediate product to an additional contacting zone positioned downstream of the downstream contacting zone, the additional contacting zone comprising one or more zeolite catalysts and contacting the additional intermediate product with the one or more zeolite catalysts to produce the total product, wherein the crude product has at least 0.3 grams of naphtha per gram of crude product, wherein naphtha content is as determined by ASTM Method D5307.

26. The method of claim 25, further comprising separating the naphtha from the crude product and blending the naphtha with one or more hydrocarbon feeds.

27. 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.

28. A system for treating a hydrocarbon feed, 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°

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°

C. and 7 MPa produces a total product that includes a crude product, wherein the crude product is a liquid mixture at 25°

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, wherein molybdenum content is as determined by ASTM Method D5708 and residue content is as determined by ASTM Method D5307.

29. The system of claim 28, wherein the Columns 6-10 metals catalyst comprises molybdenum.

30. The system of claim 28, wherein the Columns 6-10 metals catalyst comprises at most 0.1 grams of molybdenum per gram of catalyst.

31. The system of claim 28, wherein the Columns 6-10 metals catalyst is a supported catalyst, and wherein the support comprises alumina, silica, silica-alumina, titanium oxide, zirconium oxide, magnesium oxide, or mixtures thereof.

32. The system of claim 28, wherein the Columns 6-10 metals catalyst has a pore size distribution with a median pore diameter from 60 angstroms to 135 angstroms or from 70 angstroms to 120 angstroms.

33. The system of claim 28, wherein the Columns 6-10 metals catalyst has a surface area of at least 200 m²/g.

34. The system of claim 28, wherein the Columns 6-10 metals catalyst comprises molybdenum, nickel, cobalt or mixtures thereof.

35. The system of claim 28, wherein the Columns 6-10 metals 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.

36. The system of claim 28, wherein the Columns 6-10 metals catalyst having the pore size distribution has a molybdenum content of at least 0.1 grams per gram of catalyst.

37. The system of claim 28, wherein Columns 6-10 metals catalyst having the pore size distribution at least 0.1 grams of molybdenum per gram of catalyst.

38. The system of claim 28, wherein Columns 6-10 metals catalyst having the pore size distribution is a supported catalyst, and wherein the support comprises alumina, silica, silica-alumina, titanium oxide, zirconium oxide, magnesium oxide, or mixtures thereof.

39. The system of claim 28, wherein Columns 6-10 metals catalyst having the pore size distribution has a pore size distribution with a median pore diameter from 50 angstroms to 130 angstroms.

40. The system of claim 28, wherein Columns 6-10 metals catalyst having the pore size distribution comprises molybdenum, nickel, cobalt or mixtures thereof.

41. The system of claim 28, wherein the hydrocarbon feed is contacted with one or more catalysts in a fixed bed reactor.

42. The system of claim 28, 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.

43. A hydrocarbon composition comprising:

at least 0.1 wtppm of molybdenum;

at least 0.01 grams of hydrocarbons having a boiling range distribution between 38°

C. and 200°

C. per gram of hydrocarbon composition; and

at least 0.1 grams of hydrocarbons having a boiling range distribution between 343°

C. and 650°

C. per gram of hydrocarbon composition, wherein the hydrocarbon composition is produced by contacting a hydrocarbon feed with one or more catalysts, at least one of the one or more 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 wherein molybdenum content is as determined by ASTM Method D5708 and boiling range distributions are as determined ASTM Method D2007.