Two-stage hydrodesulfurization of oil utilizing a narrow pore size distribution catalyst

Claim 2

A process for hydrodesulfurizing a sulfur and metal-containing heavy hydrocarbon feed, which comprises: a. contacting said feed in a first hydrodesulfurization zone with hydrogen and a first catalyst under hydrodesulfurization conditions to produce a first hydrodesulfurized hydrocarbon product, said first catalyst comprising an oxide or a sulfide of a Group VIB metal and an oxide or a sulfude of a Group VIII metal deposited on an alumina support, said first catalyst having a median pore radius being in the range from about 30 to about 60 Angstroms, and b. contacting at least a portion of said first hydrodesulfurized hydrocarbon product in a second hydrodesulfurization zone with hydrogen and a second catalyst under hydrodesulfurization conditions, said second catalyst having a median pore radius greater than said first catalyst, the median pore radius of said second catalyst being in the range from about 70 to about 95 Angstroms, said second catalyst comprising a hydrogenation component selected from the group consisting of at least one elemental metal, metal oxide or metal sulfide of a Group VIB metal and at least one elemental metal, metal oxide or metal sulfide of a Group VIII non-noble metal, said hydrogenation component being composited with an alumina support, said second catalyst having the following physical characteristics: a total pore volume between 0.45 and 1.50 ml/g; less than 0.05 ml/g pore volume in pores with radii greater than 100 Angstroms; at least 0.40 ml/g pore volume having a narrowness index in pores with radii between said median pore radius of said second catalyst and from about 10 Angstroms above and 10 Angstroms below said median pore radius of said second catalyst, at least 75% of the pore volume of said second catalyst having said narrowness index with radii between the median pore radius and 10 Angstroms above and 10 Angstroms below said median pore radius of said second catalyst; less than 0.05 ml/g of the pore volume in pores with radii below 60 Angstroms, and a total surface area ranging between 130 and 500 square meters per gram.

Claim 3

The process of claim 1 wherein said second catalyst has the following physical characteristics: Surface Area, m 2 /g: 130 to 500 Pore Volume, ml/g: 0.45 to 1.50 Median Pore Radius, A: 70 to 95 Pore Volume Distribution: Pv above 100A radius, ml/g: 0 to 0.05 Pv between RM +10A above and 10A below, ml/g: 0.40 to 1.00 % PV between R m + 10A above and 10A below, %: 75 to 99 Pv below 60A radius, ml/g: 0 to 0.050

Claim 4

The process of claim 1 wherein said second catalyst has the following physical characteristics: Surface Area, m 2 /g: 132 to 200 Pore Volume, ml/g: 0.48 to 1.00 Median Pore Radius, A: 75 to 90 Pore Volume Distribution: Pv above 100A radius, ml/g: 0 to 0.04 Pv between R m + 10A above and 10A below, ml/g: 0.41 to 0.80 % PV between R m + 10A above and 10A below, %: 80 to 98 Pv below 60A radius, ml/g; 0 to 0.04.

Claim 5

The process of claim 1 wherein said second catalyst has the following physical characteristics: Surface Area, m 2 /g: 135 to 175 Pore Volume, ml/g: 0.50 to 0.60 Median Pore Radius, A: 78 to 86 Pore Volume Distribution: Pv above 100A radius, ml/g: 0 to 0.035 Pv between R m +10A above and 10A below, ml/g: 0.42 to 0.60 % PV between R m +10A above and 10A below, %: 81 to 96 Pv below 60A radius, ml/g: 0 to 0.035.

Claim 6

The process of claim 1 wherein in said second catalyst said Group VIB metal, calculated as the oxide thereof, comprises at least 8 weight percent of the total second catalyst and wherein said Group VIII metal, calculated as the oxide thereof, comprises at least 2.5 weight percent of the total second catalyst.

Claim 7

The process of claim 1 wherein in said second catalyst said Group VIB metal, calculated as the oxide thereof, comprises at least 14 weight percent of the total second catalyst and wherein said Group VIII metal, calculated as the oxide thereof, comprises at least 3.5 weight percent of the total second catalyst.

Claim 8

The process of claim 1 wherein in said second catalyst said Group VIB metal is selected from the group consisting of molybdenum oxide, molybdenum sulfide, tungsten oxide, tungsten sulfide and mixtures thereof and wherein said Group VIII is selected from the group consisting of nickel oxide, cobalt oxide, nickel sulfide, cobalt sulfide and mixtures thereof.

Claim 9

The process of claim 1 wherein said first catalyst has more than 75 percent of its pore volume in pores having radii ranging between said median pore radius of the first catalyst and 10 Angstroms above and 10 Angstroms below the median pore radius of the first catalyst, and wherein said first catalyst has less than 0.05 ml/g pore volume in pores with radii greater than 100 Angstroms.

Claim 10

The process of claim 1 wherein said first catalyst has a surface area of at least 150 square meters per gram and more than 80 percent of its pore volume being in pores having radii ranging from about 25 to about 45 Angstroms.

Claim 11

The process of claim 1 wherein said hydrocarbon feed is a sulfur-containing feed and wherein said feed in said first hydrodesulfurization zone is desulfurized to a level ranging between about 35 to about 90 percent relative to the feed sulfur.

Claim 12

The process of claim 10 wherein the desulfurization level in said first hydrodesulfurization zone is limited to not more than 88 weight percent desulfurization based on the feed sulfur.

Claim 13

The process of claim1 wherein the hydrodesulfurization conditions in each of said hydrodesulfurization zones include a temperature ranging from about 600° to about 850° F., a pressure ranging from about 600 to about 3500 psig, a liquid hourly space velocity ranging from about 0.05 to about 5 volumes of hydrocarbon feed per hour per volume of catalyst, a hydrogen rate ranging from about 300 to about 20,000 standard cubic feet per barrel, and a hydrogen partial pressure ranging from about 500 to about 3000 psig.

Claim 14

A process for hydrodesulfurizing and hydrodemetallizing a sulfur and metal-containing heavy hydrocarbon feed, which comprises: a. contacting said feed in a first hydrodesulfurization zone with hydrogen and a first hydrodesulfurization catalyst under hydrodesulfurization conditions to effect a 35 to about 85 percent desulfurization of said feed and thereby produce a partially desulfurized hydrocarbon product; b. contacting at least a portion of said partially desulfurized hydrocarbon product in a second hydrodesulfurization zone with hydrogen and a second catalyst under hydrodesulfurization conditions, said second catalyst comprising a hydrogenation component composited with an alumina support, said hydrogenation component being selected from the group consisting of at least one elemental metal, metal oxide or metal sulfide of a Group VIB metal and at least one elemental metal, metal oxide or metal sulfide of a Group VIII non-noble metal, said second catalyst having a median pore radius ranging from about 70 to about 95 Angstroms and having the following physical characteristics: a total pore volume between 0.45 and 1.50 ml/g; less than 0.05 ml/g pore volume in pores with radii greater than 100 Angstroms; at least 0.40 ml/g pore volume in pores with radii between said median pore radius of said second catalyst and from 10 Angstroms above and 10 Angstroms below said median pore radius of said second catalyst; at least 75 percent of the pore volume in pores with radii between the median pore radius of said second catalyst and 10 Angstroms above and 10 Angstroms below the median pore radius of said second catalyst; less than 0.05 ml/g of the pore volume in pores with radii below 60 Angstroms, and a total surface area ranging between 130 and 500 square meters per gram.

Claim 15

A process for hydrodesulfurizing and hydrodemetallizing a sulfur and metal-containing heavy hydrocarbon feed, which comprises: a. contacting said feed in a first hydrodesulfurization zone with hydrogen and a first hydrodesulfurization catalyst under hydrodesulfurization conditions to effect a 35 to about 85 percent desulfurization of said feed and thereby produce a partially desulfurized hydrocarbon product; b. contacting at least a portion of said partially desulfurized hydrocarbon product in a second hydrodesulfurization zone with hydrogen and a second catalyst under hydrodesulfurization conditions, said second catalyst comprising a hydrogenation component composited with an alumina support, said hydrogenation component being selected from the group consisting of at least one elemental metal, metal oxide or metal sulfide of a Group VIB metal and at least one elemental metal, metal oxide or metal sulfide of a Group VIII non-noble metal, said second catalyst having a median pore radius ranging from about 70 to about 95 Angstroms and having the following physical characteristics: a total pore volume between 0.45 and 1.50 ml/g; less than 0.05 ml/g pore volume in pores with radii greater than 100 Angstroms; at least 0.40 ml/g pore volume in pores with radii between said median pore radius of said second catalyst and from 10 Angstroms above and 10 Angstroms below said median pore radius of said second catalyst; at least 75 percent of the pore volume in pores with radii between the median pore radius of said second catalyst and 10 Angstroms above and 10 Angstroms below the median pore radius of said second catalyst; less than 0.05 ml/g of the pore volume in pores with radii below 60 Angstroms, and a total surface area ranging between 130 and 500 square meters per gram.

Claim 16

The process of claim 13 wherein said first catalyst has a median pore radius ranging from about 30 to about 60 Angstroms; more than 75 percent of its pore volume being in pores having radii ranging between said median pore radius of the first catalyst and about 10 Angstroms above and 10 Angstroms below said median pore radius of the first catalyst, and said first catalyst having less than 0.05 ml/g pore volume in pores with radii greater than 100 Angstroms.

Claim 17

The process of claim 13 wherein the total effluent of the first hydrodesulfurization zone is passed to said second hydrodesulfurization zone.

Claim 18

The process of claim 13 wherein the effluent of said first hydrodesulfurization zone comprises hydrogen sulfide and a partially desulfurized hydrocarbon product and wherein the hydrogen sulfide is separated from said partially desulfurized hydrocarbon product prior to said contacting step (b).

Claim 19

A process for hydrodesulfurizing a heavy hydrocarbon feed, which comprises: a. contacting said feed in a first hydrodesulfurization zone with hydrogen and a first catalyst under hydrodesulfurization conditions to produce a first hydrodesulfurized hydrocarbon product, said first catalyst comprising an oxide or sulfide of a Group VIB metal and an oxide or sulfide of a Group VIII metal composited with an alumina support material containing 1 to 6 weight percent silica, said first catalyst having a surface area of at least 150 square meters per gram and more than 80 percent of its pore volume in pores having radii ranging from about 25 to about 45 Angstroms; a median pore radius ranging from about 30 to about 60 Angstroms; more than 75 percent of its pore volume in pores having radii ranging between said median pore radius and about 10 Angstroms above and 10 Angstroms below said median pore radius, and less than 0.05 ml/g pore volume in pores with radii greater than 100 Angstroms, and b. contacting at least a portion of said first hydrodesulfurized hydrocarbon product in a second hydrodesulfurization zone with hydrogen and a second catalyst, said second catalyst comprising a hydrogenation component composited with an alumina support, said second catalyst having a median pore radius ranging from about 70 to about 95 Angstroms, a total pore volume between 0.45 and 1.5 ml/g; less than 0.05 ml/g pore volume in pores with radii greater than 100 Angstroms, at least 0.40 ml/g pore volume in pores with radii between the median pore radius of the second catalyst and from about 10 Angstroms above and 10 Angstroms below said median pore radius of said second catalyst, said second catalyst having at least 75 percent of the pore volume in pores with radii between the median pore radius of said second catalyst and 10 Angstroms above and 10 Angstroms below the median pore radius of said second catalyst, said second catalyst having less than 0.05 ml/g of the pore volume in pores with radii below 60 Angstroms and a total surface area ranging between 130 and 500 square meters per gram, the hydrogenation component of said second catalyst being selected from the group consisting of at least one elemental metal, metal oxide or metal sulfide of a Group VIB metal and at least one elemental metal or metal oxide or metal sulfide of a group VIII non-noble metal, said Group VIB metal being present in an amount of at least 14 weight percent, calculated as the metal oxide, based on the total catalyst and said Group VIII metal being present in an amount of at least 3.5 weight percent, calculated as the metal oxide, based on the total catalyst.

Claim 20

A process for hydrodesulfurizing a heavy hydrocarbon feed, which comprises: a. contacting said feed in a first hydrodesulfurization zone with hydrogen and a first catalyst under hydrodesulfurization conditions to produce a first hydrodesulfurized hydrocarbon product, said first catalyst comprising an oxide or sulfide of a Group VIB metal and an oxide or sulfide of a Group VIII metal composited with an alumina support material containing 1 to 6 weight percent silica, said first catalyst having a surface area of at least 150 square meters per gram and more than 80 percent of its pore volume in pores having radii ranging from about 25 to about 45 Angstroms; a median pore radius ranging from about 30 to about 60 Angstroms; more than 75 percent of its pore volume in pores having radii ranging between said median pore radius and about 10 Angstroms above and 10 Angstroms below said median pore radius, and less than 0.05 ml/g pore volume in pores with radii greater than 100 Angstroms, and b. contacting at least a portion of said first hydrodesulfurized hydrocarbon product in a second hydrodesulfurization zone with hydrogen and a second catalyst, said second catalyst comprising a hydrogenation component composited with an alumina support, said second catalyst having a median pore radius ranging from about 70 to about 95 Angstroms, a total pore volume between 0.45 and 1.5 ml/g; less than 0.05 ml/g pore volume in pores with radii greater than 100 Angstroms, at least 0.40 ml/g pore volume in pores with radii between the median pore radius of the second catalyst and from about 10 Angstroms above and 10 Angstroms below said median pore radius of said second catalyst, said second catalyst having at least 75 percent of the pore volume in pores with radii between the median pore radius of said second catalyst and 10 Angstroms above and 10 Angstroms below the median pore radius of said second catalyst, said second catalyst having less than 0.05 ml/g of the pore volume in pores with radii below 60 Angstroms and a total surface area ranging between 130 and 500 square meters per gram, the hydrogenation component of said second catalyst being selected from the group consisting of at least one elemental metal, metal oxide or metal sulfide of a Group VIB metal and at least one elemental metal or metal oxide or metal sulfide of a group VIII non-noble metal, said Group VIB metal being present in an amount of at least 14 weight percent, calculated as the metal oxide, based on the total catalyst and said Group VIII metal being present in an amount of at least 3.5 weight percent, calculated as the metal oxide, based on the total catalyst.

Claim 21

The process of claim 17 wherein said alumina support of said second catalyst additionally contains a minor amount of silica.

Claim 22

The process of claim 17 wherein the support of said second catalyst consists essentially of alumina.

Claim 23

The process of claim 1 wherein said alumina support of said first catalyst additionally contains from about 1 to about 6 weight percent silica.

Claim 24

The process of claim 1 wherein said alumina support of said second catalyst additionally contains a minor amount of silica.

Claim 25

The process of claim 1 wherein the temperature in said second hydrodesulfurization zone ranges from about 600° to about 850° F.

Claim 26

The process of claim 17 wherein the temperature in said second hydrodesulfurization zone ranges from about 600° to about 850° F.