SLURRY HYDROCRACKING PROCESS USING SPENT HYDROPROCESSING CATALYST

• US 20160137930A1
• Filed: 11/18/2014
• Published: 05/19/2016
• Est. Priority Date: 11/18/2014
• Status: Abandoned Application

• Current Assignee: UOP Llc (Honeywell International Inc.)
• Original Assignee: UOP Llc (Honeywell International Inc.)
• Inventors: Jeanneret, John J., Baird, Lance A.
• Application Number:
  US14/546,735
• Publication Number:
  US 20160137930A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B01J 2229/186 not in framework positions
• CPC Class Codes: B01J 23/882 and cobalt
• CPC Class Codes: B01J 23/883 and nickel
• CPC Class Codes: B01J 23/888 Tungsten
• CPC Class Codes: B01J 23/90 Regeneration or reactivation
• CPC Class Codes: B01J 23/92 of catalysts comprising metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
• CPC Class Codes: B01J 23/94 of catalysts comprising metals, oxides or hydroxides of the iron group metals or copper
• CPC Class Codes: B01J 29/064 containing iron group metals, noble metals or copper
• CPC Class Codes: B01J 29/076 containing arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
• CPC Class Codes: B01J 29/106 Y-type faujasite
• CPC Class Codes: B01J 29/166 Y-type faujasite
• CPC Class Codes: B01J 29/7215 Zeolite Beta
• CPC Class Codes: B01J 29/7815 Zeolite Beta
• CPC Class Codes: B01J 29/90 Regeneration or reactivation
• CPC Class Codes: B01J 35/40 characterised by dimensions, e.g. grain size in a colloidal state B01J35/23; crystallite size B01J35/77
• CPC Class Codes: B01J 37/0036 Grinding
• CPC Class Codes: B01J 38/00 Regeneration or reactivation of catalysts, in general
• CPC Class Codes: C10G 47/20 the catalyst containing other metals or compounds thereof
• CPC Class Codes: C10G 47/26 suspended in the oil, e.g. slurries
• CPC Class Codes: C10G 65/12 including cracking steps and other hydrotreatment steps

Abstract

A slurry hydrocracking process using spent hydroprocessing catalyst is described. The process includes obtaining the spent hydroprocessing catalyst from a hydroprocessing zone; reducing the size of the spent hydroprocessing catalyst; and introducing a heavy hydrocarbon feed and a hydrogen stream into a slurry hydrocracking zone in the presence of the reduced size spent hydroprocessing catalyst under slurry hydrocracking conditions to form a slurry hydrocracking effluent.

Claims

1. A slurry hydrocracking process using spent hydroprocessing catalyst comprising:

obtaining the spent hydroprocessing catalyst from a hydroprocessing zone;

reducing the size of the spent hydroprocessing catalyst; and

introducing a heavy hydrocarbon feed and a hydrogen stream into a slurry hydrocracking zone in the presence of the reduced size spent hydroprocessing catalyst under slurry hydrocracking conditions to form a slurry hydrocracking effluent.

2. The process of claim 1 wherein the spent hydroprocessing catalyst comprises at least one Group VIII metal and at least one Group VI metal on a support.

3. The process of claim 2 wherein the at least one Group VIII metal comprises iron, cobalt, and nickel, wherein the Group VI metal comprises molybdenum and tungsten, and wherein the support comprises a metal oxide.

4. The process of claim 1 wherein the spent hydroprocessing catalyst comprises at least one Group VIII or Group VI metals on an amorphous base or a zeolite base.

5. The process of claim 4 wherein the at least one Group VIII metal comprises iron, cobalt, and nickel, wherein the Group VI metal comprises molybdenum and tungsten, and wherein the zeolite base comprises alumina and silica.

6. The process of claim 1 wherein the reduced size spent hydroprocessing catalyst is present in an amount of about 200 wppm to about 1 wt %.

7. The process of claim 1 wherein reducing the size of the spent hydroprocessing catalyst comprises one or more of grinding the spent hydroprocessing catalyst, ball milling the spent hydroprocessing catalyst, and jet milling the spent hydroprocessing catalyst.

8. The process of claim 1 wherein the reduced size spent hydroprocessing catalyst has an average size of less than 500 μ

m.

9. The process of claim 1 wherein the reduced size spent hydroprocessing catalyst has an average size of less than 100 μ

m.

10. The process of claim 1 further comprising recovering the reduced size spent hydroprocessing catalyst from the slurry hydrocracking effluent.

11. The process of claim 10 further comprising recycling the recovered catalyst.

12. A slurry hydrocracking process using spent hydroprocessing catalyst comprising:

obtaining the spent hydroprocessing catalyst from a hydroprocessing zone, the spent hydroprocessing catalyst comprising at least one Group VIII metal and at least one Group VI metal on a support or at least one Group VIII or Group VI metals on an amorphous base or a zeolite base;

grinding the spent hydroprocessing catalyst to reduce the size of the spent hydroprocessing catalyst to less than 500 μ

m; and

introducing a heavy hydrocarbon feed and a hydrogen stream into a slurry hydrocracking zone in the presence of the ground spent hydroprocessing catalyst under slurry hydrocracking conditions to form a slurry hydrocracking effluent.

13. The process of claim 12 wherein the at least one Group VIII metal comprises iron, cobalt, and nickel and wherein the Group VI metal comprises molybdenum and tungsten, and wherein the support comprises a metal oxide.

14. The process of claim 13 wherein the metal oxide comprises alumina, silica, titania, zirconia, or mixtures thereof.

15. The process of claim 12 wherein the at least one Group VIII metal comprises iron, cobalt, and nickel, wherein the Group VI metal comprises molybdenum and tungsten, and wherein the zeolite base comprises alumina and silica.

16. The process of claim 12 wherein the reduced size spent hydroprocessing catalyst is present in an amount of about 30 wppm to about 100 wppm.

17. The process of claim 12 wherein the ground spent hydroprocessing catalyst has an average size of less than 500 μ

m.

18. The process of claim 12 wherein the ground spent hydroprocessing catalyst has an average size of less than 100 μ

m.

19. The process of claim 12 further comprising recovering the ground spent hydroprocessing catalyst from the slurry hydrocracking effluent.

20. A slurry hydrocracking process using spent hydroprocessing catalyst comprising:

obtaining the spent hydroprocessing catalyst from a hydroprocessing zone, wherein the spent hydroprocessing catalyst has at least one of;

a metals content of at least about 10 wt %;

a crushing strength after regeneration of less than about 20 N;

a weight activity after regeneration of less than about 80% of a weight activity of an initial hydroprocessing catalyst or a volume activity after regeneration of less than about 80% of a volume activity of the initial hydroprocessing catalyst;

or

a surface area after regeneration of less than about 80% of a surface area of the initial hydroprocessing catalyst; and

introducing a heavy hydrocarbon feed and a hydrogen stream into a slurry hydrocracking zone in the presence of the spent hydroprocessing catalyst under slurry hydrocracking conditions to form a slurry hydrocracking effluent.