METHODS FOR PRODUCING A CRUDE PRODUCT

• US 20090188836A1
• Filed: 10/03/2007
• Published: 07/30/2009
• 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 Kishan, Wellington, Scott Lee
• Application Number:
  US11/866,921
• Publication Number:
  US 20090188836A1
• Time in Patent Office: Days
• US Class Current: 208/121
• CPC Class Codes: B01J 21/04 Alumina
• CPC Class Codes: B01J 2235/00 Indexing scheme associated with group B01J35/00, related to the analysis techniques used to determine the catalysts form or properties
• CPC Class Codes: B01J 2235/15 X-ray diffraction
• CPC Class Codes: B01J 2235/30 Scanning electron microscopy; Transmission electron microscopy
• 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 35/30 characterised by their physical properties
• CPC Class Codes: B01J 35/37 Crush or impact strength
• 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 35/70 characterised by their crystalline properties, e.g. semi-crystalline catalysts comprising carbon B01J21/18; molecular sieves B01J29/00
• 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, methods, and catalysts for conversion of a hydrocarbon feed to a total product are described. Contact of the hydrocarbon feed with one or more catalysts produces the total product. The total product includes a crude product that is a liquid mixture at 25° C. and 0.101 MPa having a residue content of at most 90% of the residue content of the hydrocarbon feed. At least one of the catalysts includes a metal from Column 6 of the Periodic Table, mineral oxide fines and a support.

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°

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 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 least 3 MPa and a temperature of least 200°

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

2. The method of claim 1, wherein the Column 6 metal comprises molybdenum.

3. The method of claim 1, wherein obtaining the catalyst comprises combining the mineral oxide fines, the Column 6 metal, the support 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.

4. The method of claim 1, 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 obtained catalyst comprises molybdenum, nickel, cobalt or mixtures thereof.

6. The method of claim 1, wherein the hydrocarbon feed has an API gravity of at most 15.

7. 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.

8. 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.

9. 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.

10. The method of claim 1, wherein the hydrocarbon feed has a viscosity of at least 10 cSt at 37.8°

C., and wherein the crude product has a viscosity at 37.8°

C. of at most 50% of the viscosity of the hydrocarbon feed at 37.8°

C.

11. 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.

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

13. 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.

14. 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°

C. and 0.101 MPa;

the hydrocarbon feed has a viscosity of at least 10 cSt at 37.8°

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°

C. to produce the crude product;

the crude product having a viscosity content of at most 50% of the viscosity content of the hydrocarbon feed, wherein viscosity is as determined by ASTM Method D445.

15. A catalyst for treating a hydrocarbon feed comprising:

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 Å 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.

17. The catalyst of claim 16, wherein the catalyst has at most 0.1 grams, or at most 0.06 of Columns 6 metal per gram of catalyst.

18. The catalyst of claim 16, wherein the catalyst has from 1% to 10% of pores having a pore size between 1000 angstroms and 5000 angstroms, wherein pore size is as measured by ASTM Method D4284.

19. The catalyst of claim 16, wherein the catalyst has a surface area of at least 200 m²/g, wherein surface area is as determined by ASTM Method D3663.

20. The catalyst of claim 16, wherein the mineral oxide fines comprise alumina.

21. The catalyst of claim 16, further comprising one or more metals from Columns 9 and 10 of the Periodic Table and/or one or more compounds of one or more metals from Columns 9 and 10 of the Periodic Table.