US3977962A — Heavy crude conversion

Claim 1

Independent Claim 276 words

A process for the demetallization and conversion of the 1050°F.+ materials of a heavy metals containing heavy crude or residua feed to 1050°F.- material comprising contacting said feed, in the presence of added hydrogen with catalyst comprising a composite of a porous inorganic oxide support and an admixture of from about 0.1 to about 10 percent of a Group IVA metal, from about 5 to about 30 percent of a Group VIB metal, and from about 1 to about 12 percent of a Group VIII metal, said catalyst including a combination of properties comprising, when the catalyst is of size ranging from about 1/500 to 1/50 inch average particle size diameter, at least about 20 percent of its total pore volume of absolute diameter within the range of about 100A to about 200A; when the catalyst is of size ranging from about 1/50 inch up to 1/25 inch average particle size diameter, at least about 15 percent of its total pore volume of absolute diameter within the range of about 150A to about 250A; when the catalyst is of size ranging from about 1/25 inch to about 1/8 inch average particle size diameter, at least about 15 percent of its total pore volume of absolute diameter within the range of about 175A to about 275A; a surface area ranging at least abot 200 m 2 /g to about 600 m 2 /g and a pore volume ranging from about 0.8 cc/g to about 3.0 cc/g, at severity sufficient to convert at least about 30 percent of the 1050°F.+ material to 1050°F.- material, while removing at least about 80 percent of the heavy metals from the feed.

Claim 2

Dependent Claim 276 words

A process for the demetallization and conversion of the 1050°F.+ materials of a heavy metals containing heavy crude or residua feed to 1050°F.- material comprising contacting said feed, in the presence of added hydrogen with catalyst comprising a composite of a porous inorganic oxide support and an admixture of from about 0.1 to about 10 percent of a Group IVA metal, from about 5 to about 30 percent of a Group VIB metal, and from about 1 to about 12 percent of a Group VIII metal, said catalyst including a combination of properties comprising, when the catalyst is of size ranging from about 1/500 to 1/50 inch average particle size diameter, at least about 20 percent of its total pore volume of absolute diameter within the range of about 100A to about 200A; when the catalyst is of size ranging from about 1/50 inch up to 1/25 inch average particle size diameter, at least about 15 percent of its total pore volume of absolute diameter within the range of about 150A to about 250A; when the catalyst is of size ranging from about 1/25 inch to about 1/8 inch average particle size diameter, at least about 15 percent of its total pore volume of absolute diameter within the range of about 175A to about 275A; a surface area ranging at least abot 200 m 2 /g to about 600 m 2 /g and a pore volume ranging from about 0.8 cc/g to about 3.0 cc/g, at severity sufficient to convert at least about 30 percent of the 1050°F.+ material to 1050°F.- material, while removing at least about 80 percent of the heavy metals from the feed.

Claim 3

Dependent Claim 39 words

The process of claim 1 wherein from about 40 percent to about 60 percent of the 1050°F.+ material is converted to 1050°F.-, and from about 85 percent to about 90 percent of the metals are removed from the feed.

Claim 4

Dependent Claim 36 words

The process of claim 1 wherein the feed is characterized as follows: ______________________________________ Gravity, °API -5 to 20 Heavy Metals, ppm 5-1000 1050°F. +, Wt.% 10-100 Asphaltenes (C.sub.5 insoluble), Wt.% 5-50 Con Carbon, Wt.% 5-50 ______________________________________

Claim 5

Dependent Claim 38 words

The process of claim 1 wherein the product of the reaction is characterized as follows: ______________________________________ Gravity, °API 0 to 14 Heavy Metals, ppm 200-600 1050°F.+, Wt.% 40-100 Asphaltenes (C.sub.5 insoluble), Wt.% 15-30 Con Carbon, Wt.% 10-30 ______________________________________

Claim 6

Dependent Claim 35 words

The process of claim 1 wherein the conditions of the reaction are characterized as follows: ______________________________________ Temperature, °F. (E.I.T.) Start-of-Run 700 End-of-Run 850 Pressure, Psi 2000-10,000 Hydrogen Rate, SCF/B 3000-20,000 Space Velocity, LHSV 0.25-5.0 ______________________________________

Claim 7

Dependent Claim 45 words

The process of claim 1 wherein the catalyst when of particle size diameter ranging from about 1/500 to 1/50 inch is characterized as follows: ______________________________________ Distribution of Pore Diameters 0-50A <20% 100-200A >20% 300A+ <30% Pore Volume, cc/g 0.8-1.4 Surface Area, m.sup.2 /g 300-450 ______________________________________

Claim 8

Dependent Claim 45 words

The process of claim 1 wherein the catalyst, when of particle size diameter ranging from about 1/500 to 1/50 inch, is characterized as follows: ______________________________________ Distribution of Pore Diameters 0-50A <10% 100-200A >25% 300A+ <25% Pore Volume, cc/g 0.9-1.5 Surface Area, m.sup.2 /g 310-500 ______________________________________

Claim 9

Dependent Claim 45 words

The process of claim 1 wherein the catalyst, when of particle size diameter ranging from about 1/500 to 1/50 inch, is characterized as follows: ______________________________________ Distribution of Pore Diameters 0-50A <2% 100-200A >70% 300A+ <1% Pore Volume, cc/g 1.1-1.7 Surface Area, m.sup.2 /g 325-550 ______________________________________

Claim 10

Dependent Claim 45 words

The process of claim 1 wherein the catalyst, when of particle size diameter ranging from about 1/50 to 1/25 inch, is characterized as follows: ______________________________________ Distribution of Pore Diameters 0-50A <10% 150-250A >15% 350A+ <35% Pore Volume, cc/g 1.1-1.7 Surface Area, m.sup.2 /g 320-475 ______________________________________

Claim 11

Dependent Claim 45 words

The process of claim 1 wherein the catalyst, when of particle size diameter ranging from about 1/50 to 1/25 inch, is characterized as follows: ______________________________________ Distribution of Pore Diameters 0-50A <5% 150-250A >20% 350A+ <30% Pore Volume, cc/g 1.3-1.9 Surface Area, m.sup.2 /g 340-575 ______________________________________

Claim 12

Dependent Claim 45 words

The process of claim 1 wherein the catalyst, when of particle size diameter ranging from about 1/50 to 1/25 inch, is characterized as follows: ______________________________________ Distribution of Pore Diameters 0-50A <1% 150-250A >45% 350A+ <7% Pore Volume, cc/g 1.5-2.1 Surface Area, m.sup.2 /g 360-600 ______________________________________

Claim 13

Dependent Claim 45 words

The process of claim 1 wherein the catalyst, when of particle size diameter ranging from about 1/25 to 1/8 inch, is characterized as follows: ______________________________________ Distribution of Pore Diameters 0-50A <5% 175-275A >15% 350A+ <40% Pore Volume, cc/g 1.3-1.9 Surface Area, m.sup.2 /g 340-500 ______________________________________

Claim 14

Dependent Claim 45 words

The process of claim 1 wherein the catalyst, when of particle size diameter ranging from about 1/25 to 1/8 inch, is characterized as follows: ______________________________________ Distribution of Pore Diameters 0-50A <4% 175-275A >20% 350A+ <35% Pore Volume, cc/g 1.5-2.1 Surface Area, m.sup.2 /g 350-600 ______________________________________

Claim 15

Dependent Claim 45 words

The process of claim 1 wherein the catalyst, when of particle size diameter ranging from about 1/25 to 1/8 inch, is characterized as follows: ______________________________________ Distribution of Pore Diameters 0-50A <3% 175-275A >30% 350A+ <25% Pore Volume, cc/g 1.8-2.3 Surface Area, m.sup.2 /g 370-650 ______________________________________

Claim 16

Dependent Claim 49 words

The process of claim 1 wherein said catalyst comprises an admixture of from about 2 to about 5 percent of a Group IVA metal, from about 10 to about 20 percent of a Group VIB metal, and from about 4 to about 8 percent of a Group VIII metal.

Claim 17

Dependent Claim 39 words

The process of claim 15 wherein the product of the reaction is characterized as follows: ______________________________________ Gravity, °API 14 to 30 Heavy Metals, ppm 10-100 1050°F.+, Wt.% 10-50 Asphaltenes, (C.sub.5 insoluble), Wt.% 3-20 Con Carbon, Wt. % 3-20 ______________________________________

Claim 18

Dependent Claim 41 words

The process of claim 15 wherein the product of the reaction is characterized as follows: ______________________________________ Gravity, °API 15 to 25 Heavy Metals, ppm 40-80 1050°F.+, Wt. % 25-40 Asphaltenes (C.sub.5 insoluble), Wt. % 5-15 Con Carbon, Wt. % 5-10 ______________________________________

Claim 19

Dependent Claim 226 words

A process for the demetallization, conversion and reduction of the Con carbon content of the 1050°F. materials of a heavy metals containing heavy crude or residua feed to 1050°F.- material comprising contacting said feed, in the presence of added hydrogen, with a catalyst comprising a composite of a porous inorganic oxide support and an admixture of from about 0.1 to about 10 percent of a Group IVA metal, from about 5 to about 30 percent of a Group VIB metal, and from about 1 to about 12 percent of a Group VIII metal, said catalyst including a combination of properties comprising at least about 55 percent of its total pore volume of absolute pore diameters ranging from about 100A to about 200A, less than 10 percent of its total pore volume are of absolute pore diameters ranging from 0 to about 50A, less than about 25 percent of its total pore volume of absolute pore diameters ranging 300A+, surface area ranges at least about 200 m 2 to about 600 m 2 and pore volume ranges from about 0.6 cc/g to about 1.5 cc/g, at severity sufficient to convert at least about 50 percent of the 1050°F+ material to 1050°F.- material, remove at least about 90 percent of the heavy metals from the feed, and reduce Con carbon from about 50 percent to about 100 percent.

Claim 20

Dependent Claim 226 words

A process for the demetallization, conversion and reduction of the Con carbon content of the 1050°F. materials of a heavy metals containing heavy crude or residua feed to 1050°F.- material comprising contacting said feed, in the presence of added hydrogen, with a catalyst comprising a composite of a porous inorganic oxide support and an admixture of from about 0.1 to about 10 percent of a Group IVA metal, from about 5 to about 30 percent of a Group VIB metal, and from about 1 to about 12 percent of a Group VIII metal, said catalyst including a combination of properties comprising at least about 55 percent of its total pore volume of absolute pore diameters ranging from about 100A to about 200A, less than 10 percent of its total pore volume are of absolute pore diameters ranging from 0 to about 50A, less than about 25 percent of its total pore volume of absolute pore diameters ranging 300A+, surface area ranges at least about 200 m 2 to about 600 m 2 and pore volume ranges from about 0.6 cc/g to about 1.5 cc/g, at severity sufficient to convert at least about 50 percent of the 1050°F+ material to 1050°F.- material, remove at least about 90 percent of the heavy metals from the feed, and reduce Con carbon from about 50 percent to about 100 percent.

Claim 21

Dependent Claim 39 words

The process of claim 18 wherein from about 60 percent to about 75 percent of the 1050°F.+ material is converted to 1050°F.-, and from about 97 percent to about 100 percent of the metals are removed from the feed.

Claim 22

Dependent Claim 18 words

The process of claim 18 wherein Con carbon is reduced from about 75 percent to about 90 percent.

Claim 23

Dependent Claim 37 words

The process of claim 18 wherein the feed is characterized as follows: ______________________________________ Gravity, °API 14-30 Heavy Metals (Ni & V), ppm 10-100 1050°F.+, Wt.% 10-50 Asphaltenes (C.sub.5 insoluble), Wt.% 3-20 Con Carbon, Wt. % 3-20 ______________________________________

Claim 24

Dependent Claim 39 words

The process of claim 18 wherein the feed is characterized as follows: ______________________________________ Gravity, °API 15-25 Heavy Metals (Ni & V), ppm 40-80 1050°F.+, Wt. % 25-40 Asphaltenes (C.sub.5 insoluble), Wt. % 5-15 Con Carbon, Wt. % 5-10 ______________________________________

Claim 25

Dependent Claim 42 words

The process of claim 18 wherein the product of the reaction is characterized as follows: ______________________________________ Gravity, °API 18-30 Heavy Metals (Ni & V), ppm <50 1050°F.+, Wt. % 5-30 Asphaltenes (C.sub.5 insoluble), Wt. % <3 Con Carbon, Wt. % <5 ______________________________________

Claim 26

Dependent Claim 42 words

The process of claim 18 wherein the product of the reaction is characterized as follows: ______________________________________ Gravity, °API 20-28 Heavy Metals (Ni & V), ppm <5 1050°F.+, Wt. % 10-25 Asphaltenes (C.sub.5 insoluble), Wt. % <1 Con Carbon, Wt. % <3 ______________________________________

Claim 27

Dependent Claim 35 words

The process of claim 18 wherein the conditions of the reaction are characterized as follows: ______________________________________ Temperature, °F. (E.I.T.) Start-of-Run 600 End-of-Run 850 Pressure, Psi 2000-10,000 Hydrogen Rate, SCF/B 3000-20,000 Space Velocity, LHSV 0.25-5.0 ______________________________________

Claim 28

Dependent Claim 35 words

The process of claim 18 wherein the conditions of the reaction are characterized as follows: ______________________________________ Temperature, °F. (E.I.T.) Start-of-Run 650 End-of-Run 775 Pressure, Psi 2000-5000 Hydrogen Rate, SCF/B 3000-10,000 Space Velocity, LHSV 0.25-2.0 ______________________________________

Claim 29

Dependent Claim 37 words

The process of claim 18 wherein the catalyst is of particle size diameter ranging from about 1/500 to 1/8 inch and characterized as follows: ______________________________________ Distribution of Pore Diameters ______________________________________ 0-50A <1% 100-200A >70% -300A <1% ______________________________________

Claim 30

Dependent Claim 15 words

The process of claim 1 wherein the Group IVA metal of the catalyst is germanium.

Claim 31

Dependent Claim 15 words

The process of claim 18 wherein the Group IVA metal of the catalyst is germanium.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1979-08-31	1980-03-01	1980-08-31	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1983-08-31	1984-03-01	1984-08-31	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1987-08-31	1988-03-01	1988-08-31	$7700.00	Window Closed / Lapsed

Heavy crude conversion

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