Extending life of demetallization catalyst

Claim 2

A process for the catalytic demetallization of Venezuelan crude oil feedstocks containing organometallic impurities comprising Vanadium and nickel, in a reaction zone wherein demetallization catalyst, hydrogen and crude oil feedstock are brought into intimate contact under operating conditions of temperature, between 700° and 850° F., pressure between, 56 and 245 atmospheres, (800 to 3500 psig) and liquid space velocities between 0.2 to 1.5 V f /hr/V r comprising the steps of: (a) initially feeding the feedstock to the reaction zone containing a fresh initial charge of the demetallization catalyst, under operating conditions of temperature, pressure and space velocity selected within said ranges, such that the initial level of Vanadium removal does not exceed 75 wt. percent; (b) maintaining said operating conditions for a period sufficiently long, such that the level of Vanadium removal decreases by about 10% of the initial level; (c) adjusting said operating conditions to achieve a desired level of metals removal, said level being less than 75 wt. percent; (d) removing a demetallized stream from the reaction zone.

Claim 3

The process of claim 1, wherein the reaction zone contains a fixed bed of catalyst.

Claim 4

The process of claim 1, wherein the reaction zone contains an ebullated bed of catalyst.

Claim 5

The process of claim 1, wherein the crude oil feedstock is selected from the group consisting of Bachaquero residuum, Tia Juana residuum, Lagunillas residuum, Boscan residuum, and Orinoco residuum.

Claim 6

The process of claim 1, wherein the demetallization catalyst is bauxite promoted with Molybdenum.

Claim 7

The process of claim 1, wherein the initial level of demetallization is between 45 and 75 wt. percent.

Claim 8

The process of claim 1 wherein the reaction zone temperature is maintained between 750° F. and 840° F., hydrogen partial pressure between 1,000 and 2,500 psig, and space velocity between 0.3 and 1.3 V f /hr/V r .

Claim 9

A process for the catalytic demetallization of Venezuelan crude oil feedstocks containing organometallic impurities comprising of Vanadium and nickel, in an ebullated bed reaction zone in the presence of demetallization catalyst under operating conditions of temperature between 750° and 850° F., pressures between 56 and 245 atm. (800 to 3500 psig) and catalyst space velocities between 0.01 and 0.4 Bbl/D/lb catalyst, comprising the steps of: (a) initially feeding the feedstock to the reaction zone containing fresh initial charge of demetallization catalyst, under operating conditions of temperature, pressure and space velocity selected within said ranges, such that the initial level of Vanadium removal does not exceed 75 wt. percent; (b) maintaining said operating conditions for a period sufficiently long such that the level of Vanadium removal decreases by about 10 percent of the initial level; (c) adjusting operating conditions to achieve the desired level of metals removal less than 75 wt. percent; and (d) establishing a catalyst replacement rate between 0.15 and 3.0 pounds of catalyst per barrel of feed, such that the demetallization rate is maintained constant below 75%; thereby reducing the rate of catalyst deactivation and extending the life of the catalyst.

Claim 10

A process for the catalytic demetallization of Venezuelan crude oil feedstocks containing organometallic impurities comprising of Vanadium and nickel, in an ebullated bed reaction zone in the presence of demetallization catalyst under operating conditions of temperature between 750° and 850° F., pressures between 56 and 245 atm. (800 to 3500 psig) and catalyst space velocities between 0.01 and 0.4 Bbl/D/lb catalyst, comprising the steps of: (a) initially feeding the feedstock to the reaction zone containing fresh initial charge of demetallization catalyst, under operating conditions of temperature, pressure and space velocity selected within said ranges, such that the initial level of Vanadium removal does not exceed 75 wt. percent; (b) maintaining said operating conditions for a period sufficiently long such that the level of Vanadium removal decreases by about 10 percent of the initial level; (c) adjusting operating conditions to achieve the desired level of metals removal less than 75 wt. percent; and (d) establishing a catalyst replacement rate between 0.15 and 3.0 pounds of catalyst per barrel of feed, such that the demetallization rate is maintained constant below 75%; thereby reducing the rate of catalyst deactivation and extending the life of the catalyst.

Claim 11

Process of claim 8, wherein the initial level of demetallization is between 45 and 75 weight percent.

Claim 12

The process of claim 8 wherein the reaction zone temperature is maintained between 750° F. and 840° F., hydrogen partial pressure between 1,000 and 2,500 psig, catalyst space velocity between 0.03 and 0.114 bbl/day/lb catalyst, and catalyst replacement rate between 0.2 and 1.8 lb/bbl of feed.