US4534852A
Expired / Lapsed
US
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Single-stage hydrotreating process for converting pitch to conversion process feedstock
Assignee: Shell USA Inc
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Filing: 1984-11-30
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Granted: 1985-08-13
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Expires: 2004-11-30
Abstract
Abstract A process is provided for converting pitch-containing residual hydrocarbon oils containing asphaltenes, sulfur and nitrogen compounds and heavy metals into distillate fuels, which comprises: mixing from about 5-60% v residual oils with catalytic cracking feedstock and with hydrogen and passing said mixture downwardly into a hydrotreating zone over a stackedbed catalyst under conditions suitable to convert from about 45-75% of the sulfur compounds present in the mixture to H 2 S; wherein said stacked bed comprises an upper bed consisting of from about 15-85 % v, basis total catalyst, of a high-activity hydrotreating catalyst which contains from about 2-4% w nickel, from about 8-15% w molybdenum and from about 2-4% w phosphorus supported on a carrier consisting mostly of alumina, and a lower bed of a high-activity, hydrodesulfurization catalyst consisting of from about 2-4% w cobalt and/or nickel, from about 8-15% w molybdenum and less than about 0.5% w phosphorus supported on a carrier consisting mostly of alumina; and separating the reaction product from said hydrotreating zone into a hydrogen-rich gas and a liquid residue-containing oil having reduced heavy metal content and being suitable as a catalytic cracking feedstock.
Inventors
- 👤 Don M. Washecheck
- 👤 Charles T. Adams
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-06 11:58
CPC Classifications
C; C10; C10G; C10G45/00; C10G45/02; C10G45/04; C10G45/06; C10G45/08
Claims Analysis
Total Claims: 20
Claim 1
Independent Claim
217 words
A process for converting residual hydrocarbon oils to catalytic cracking feedstocks which comprises: mixing from about 5-60%v residual oils with catalytic cracking feedstock and hydrogen and passing said mixture downwardly into a hydrotreating zone over a stacked-bed of two hydrotreating catalysts under conditions suitable to convert from about 45-75% of the sulfur compounds present to H 2 S; said stacked bed comprising an upper bed consisting of about 15-85%v, basis total catalyst, of a high-activity hydrotreating catalyst containing from about 2-4%w nickel, from about 8-15%w molybdenum and from about 2-4%w phosphorus supported on a carrier consisting mostly of alumina, said catalyst having a compacted bulk density of about 0.7-0.95 gm/cc and a surface area greater than 140 m 2 /gm; and a lower bed consisting of about 15-85%v, basis total catalyst, of a high-activity desulfurization catalyst which contains from about 2-4%w cobalt and/or nickel and from about 8-15%w molybdenum and less than about 0.5%w phosphorus supported on a carrier consisting mostly of alumina, said catalyst having a compacted bulk density of about 0.6-0.8 gm/cc and a surface area greater than 180 m 2 /gm; and separating the reaction product from said hydrotreating zone into a hydrogen-rich gas and a liquid residue-containing oil having reduced sulfur and/or heavy metal content and being suitable as a catalytic cracking feedstock.
Claim 2
Dependent Claim
217 words
A process for converting residual hydrocarbon oils to catalytic cracking feedstocks which comprises: mixing from about 5-60%v residual oils with catalytic cracking feedstock and hydrogen and passing said mixture downwardly into a hydrotreating zone over a stacked-bed of two hydrotreating catalysts under conditions suitable to convert from about 45-75% of the sulfur compounds present to H 2 S; said stacked bed comprising an upper bed consisting of about 15-85%v, basis total catalyst, of a high-activity hydrotreating catalyst containing from about 2-4%w nickel, from about 8-15%w molybdenum and from about 2-4%w phosphorus supported on a carrier consisting mostly of alumina, said catalyst having a compacted bulk density of about 0.7-0.95 gm/cc and a surface area greater than 140 m 2 /gm; and a lower bed consisting of about 15-85%v, basis total catalyst, of a high-activity desulfurization catalyst which contains from about 2-4%w cobalt and/or nickel and from about 8-15%w molybdenum and less than about 0.5%w phosphorus supported on a carrier consisting mostly of alumina, said catalyst having a compacted bulk density of about 0.6-0.8 gm/cc and a surface area greater than 180 m 2 /gm; and separating the reaction product from said hydrotreating zone into a hydrogen-rich gas and a liquid residue-containing oil having reduced sulfur and/or heavy metal content and being suitable as a catalytic cracking feedstock.
Claim 3
Dependent Claim
22 words
The process of claim 1 wherein the lower bed catalyst contains from about 2-4%w cobalt, and essentially no nickel and no phosphorus.
Claim 4
Dependent Claim
30 words
The process of claim 1 wherein the carrier has been extruded, dried and impregnated with an aqueous solution containing the desired catalytically active metals by the dry pore volume method.
Claim 5
Dependent Claim
17 words
The process of claim 3 wherein the carrier has been extruded into a trilobe shape before impregnation.
Claim 6
Dependent Claim
14 words
The process of claim 3 wherein the carrier comprises more than 95%w gamma alumina.
Claim 7
Dependent Claim
30 words
The process of claim 5 wherein the upper bed catalyst has a compacted bulk density of about 0.76-0.88 gm/cc and a surface area greater than about 150 m 2 /gm.
Claim 8
Dependent Claim
31 words
The process of claim 5 wherein in the lower bed catalyst has a compacted bulk density of about 0.67-0.79 gm/cc and a surface area greater than about 200 m 2 /gm.
Claim 9
Dependent Claim
30 words
The process of claim 1 wherein the hydrotreating zone is contained in a single reactor and the upper bed of catalyst consists of about one-third of the total catalyst volume.
Claim 10
Dependent Claim
156 words
A single stage process for hydrofining heavy oils containing 5-60%v residual oils over stacked catalyst beds, which comprises: (a) contacting said oils in a hydrofining zone under hydrodesulfurizing conditions by mixing same with hydrogen and passing the mixture downwardly over an upper bed containing a catalyst comprising a carrier, at least 95%w of which is gamma alumina, having supported thereon from about 2-4%w nickel, from about 8-15% molybdenum and from about 2-4%w phosphorus, said bed volume constituting about 15-85% of the total catalyst; (b) thence downwardly over a lower bed containing a catalyst comprising a carrier, at least 95%w of which is gamma alumina having supported thereon from about 2-4%w cobalt and/or nickel, from about 8-15%w molybdenum and less than 0.5%w phosphorus; and (c) separating the reaction product from the hydrofining zone into a hydrogen-rich gas and a desulfurized, demetallized liquid oil product all or part of which is suitable for inclusion in a conversion process.
Claim 11
Dependent Claim
156 words
A single stage process for hydrofining heavy oils containing 5-60%v residual oils over stacked catalyst beds, which comprises: (a) contacting said oils in a hydrofining zone under hydrodesulfurizing conditions by mixing same with hydrogen and passing the mixture downwardly over an upper bed containing a catalyst comprising a carrier, at least 95%w of which is gamma alumina, having supported thereon from about 2-4%w nickel, from about 8-15% molybdenum and from about 2-4%w phosphorus, said bed volume constituting about 15-85% of the total catalyst; (b) thence downwardly over a lower bed containing a catalyst comprising a carrier, at least 95%w of which is gamma alumina having supported thereon from about 2-4%w cobalt and/or nickel, from about 8-15%w molybdenum and less than 0.5%w phosphorus; and (c) separating the reaction product from the hydrofining zone into a hydrogen-rich gas and a desulfurized, demetallized liquid oil product all or part of which is suitable for inclusion in a conversion process.
Claim 12
Dependent Claim
24 words
The process of claim 9 wherein the catalyst in the lower bed contains from about 2-4%w cobalt, and essentially no nickel and no phosphorus.
Claim 13
Dependent Claim
16 words
The process of claim 9 wherein the hydrofined oil is passed to a catalytic cracking process.
Claim 14
Dependent Claim
19 words
The process of claim 9 wherein the upper bed of catalyst constitutes about 1/3 of the total catalyst volume.
Claim 15
Dependent Claim
19 words
The process of claim 11 wherein all of the desulfurized liquid oil is employed as the catalytic cracking feedstock.
Claim 16
Dependent Claim
60 words
The process of claim 9 wherein the upper bed hydrofining catalyst has a compacted bulk density of about from 0.7 to 0.95 gm/cc and a surface area of more than 140 m 2 /gm and wherein the lower bed of hydrofining catalyst has a compacted bulk density of 0.6-0.8 gm/cc and a surface area greater than 180 m 2 /gm.
Claim 17
Dependent Claim
56 words
The process of claim 14 wherein the upper bed catalyst has a compacted bulk density of about 0.76-0.88 gm/cc and a surface area greater than about 150 m 2 /gm and wherein the lower bed catalyst has a compacted bulk density of about 0.67-0.79 gm/cc and a surface area greater than about 200 m 2 /gm.
Claim 18
Dependent Claim
202 words
A single stage hydrotreating process for converting residual oils containing sulfur and nitrogen compounds and metals into distillate fuels, which comprises: (a) preparing an oil mixture which contains about 2-50%v of hydrocarbons boiling above 1000° F.; (b) passing said mixture along with hydrogen into a hydrotreating zone under hydrodesulfurization conditions suitable to convert from about 30-80% of the sulfur compounds present in the mixture to H 2 S; (c) passing said hydrogen and oil mixture downwardly over a stacked-bed of hydrotreating catalysts wherein an upper bed contains a catalyst comprising a carrier consisting essentially of gamma alumina and having supported thereon from about 2-4%w nickel, from about 8-15%w molybdenum and from about 2-4%w phosphorus, said upper bed constituting 15-85% of the total catalyst volume; and wherein a lower bed contains a catalyst comprising a gamma alumina carrier having supported thereon from 2-4%w cobalt and/or nickel from about 8-15%w molybdenum and less than 0.5%w phosphorus; (d) separating the reaction product from said hydrotreating zone into a hydrogen-rich gas and a partially desulfurized liquid heavy oil having reduced metal content; and (e) passing all or a portion of said desulfurized liquid heavy oil into a catalytic cracking process and converting same into distillate oils.
Claim 19
Dependent Claim
202 words
A single stage hydrotreating process for converting residual oils containing sulfur and nitrogen compounds and metals into distillate fuels, which comprises: (a) preparing an oil mixture which contains about 2-50%v of hydrocarbons boiling above 1000° F.; (b) passing said mixture along with hydrogen into a hydrotreating zone under hydrodesulfurization conditions suitable to convert from about 30-80% of the sulfur compounds present in the mixture to H 2 S; (c) passing said hydrogen and oil mixture downwardly over a stacked-bed of hydrotreating catalysts wherein an upper bed contains a catalyst comprising a carrier consisting essentially of gamma alumina and having supported thereon from about 2-4%w nickel, from about 8-15%w molybdenum and from about 2-4%w phosphorus, said upper bed constituting 15-85% of the total catalyst volume; and wherein a lower bed contains a catalyst comprising a gamma alumina carrier having supported thereon from 2-4%w cobalt and/or nickel from about 8-15%w molybdenum and less than 0.5%w phosphorus; (d) separating the reaction product from said hydrotreating zone into a hydrogen-rich gas and a partially desulfurized liquid heavy oil having reduced metal content; and (e) passing all or a portion of said desulfurized liquid heavy oil into a catalytic cracking process and converting same into distillate oils.
Claim 20
Dependent Claim
20 words
The process of claim 16 wherein the upper bed of catalyst constitutes about one third of the total catalyst volume.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1988-08-12 | 1989-02-11 | 1989-08-13 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1992-08-12 | 1993-02-11 | 1993-08-13 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1996-08-12 | 1997-02-11 | 1997-08-13 | $7700.00 | Window Closed / Lapsed |