Integrated process for catalytic dewaxing

Abstract

An integrated process is disclosed for dewaxing hydrocarbon feedstocks in a sour environment. The process includes hydrotreating, dewaxing, hydrofinishing or combination thereof wherein there is no disengagement between any of the process steps.

1 . An integrated process for dewaxing a raffinate feedstock containing up to 20,000 ppmw sulfur and up to 1000 ppmw nitrogen which comprises: (a) contacting the feedstock with a hydrotreating catalyst under hydrotreating conditions to produce a hydrotreated feedstock and gaseous nitrogen- and sulfur-containing contaminants, and (b) passing at least a portion of the hydrotreated feedstock and gaseous components from step (a) without disengagement to a hydrodewaxing zone containing a dewaxing catalyst including at least one of ZSM-48, ZSM-22, ZSM-23, ZSM-5, ZSM-35, Beta, SSZ-31,SAPO-11, SAPO-31, SAPO-41, MAPO-11, ECR-42, synthetic ferrierites, mordenite, offretite, erionite, and chabazite and hydrodewaxing the hydrotreated feedstock under hydrodewaxing conditions, said dewaxing catalyst including a metal hydrogenation component which is at least one Group 6 metal, at least one Group 8-10 metal, or mixtures of Group 6 and Group 8-10 metals, to form a hydrodewaxed product.  
     
     
         2 . The process of  claim 1  wherein the hydrotreating conditions temperatures of 315-425° C., pressures of 2170-20786 kPa, Liquid Hourly Space Velocities (LHSV) of 0.1-10 and hydrogen treat rates of 89-1780 m 3 /m 3 .  
     
     
         3 . The process of  claim 1  wherein the metal hydrogenation component is Pt, Pd or mixtures thereof.  
     
     
         4 . The process of  claim 1  wherein the hydrodewaxing conditions include a temperature of 360 to 425° C., hydrogen pressures of from 2859-20786 kPa, liquid hourly space velocities of 0.1 to 10 LHSV and hydrogen treat gas rates of from 53.4-1780 m 3 /m 3 .  
     
     
         5 . The process of  claim 1  further comprising a hydrofinishing step following step (b).  
     
     
         6 . The process of  claim 1  wherein the dewaxing catalyst contains ZSM-48.  
     
     
         7 . The process of  claim 1  wherein the dewaxing catalyst further comprises a second dewaxing catalyst.  
     
     
         8 . An integrated process for dewaxing a raffinate feedstock containing up to 20,000 ppmw sulfur and up to 1000 ppmw nitrogen which comprises: (a) contacting the feedstock with a hydrotreating catalyst under hydrotreating conditions to produce a hydrotreated feedstock and gaseous nitrogen- and sulfur-containing contaminants, (b) passing at least a portion of the hydrotreated feedstock and gaseous sulfur- and nitrogen-containing contaminants from step (a) without disengagement to a hydrodewaxing zone containing a dewaxing catalyst including at least one of ZSM-48, ZSM-22, ZSM-23, ZSM-5, ZSM-35, Beta, SSZ-31, SAPO-11, SAPO-31, SAPO-41, MAPO-11, ECR-42, synthetic ferrierites, mordenite, offretite, erionite, and chabazite and hydrodewaxing the hydrotreated feedstock under hydrodewaxing conditions, said dewaxing catalyst including a metal hydrogenation component which is at least one Group 6 metal, at least one Group 8-10 metal, or mixtures of Group 6 and Group 8-10 metals, said hydrodewaxing zone also containing a second dewaxing catalyst wherein the second dewaxing catalyst is tolerant of the sulfur- and nitrogen-containing contaminants.  
     
     
         9 . The process of  claim 8  wherein the hydrotreating conditions temperatures of 315-425° C., pressures of 2170-20786 kPa, Liquid Hourly Space Velocities (LHSV) of 0.1-10 and hydrogen treat rates of 89-1780 m 3 /m 3 .  
     
     
         10 . The process of  claim 8  wherein the metal hydrogenation component is Pt, Pd or mixtures thereof.  
     
     
         11 . The process of  claim 8  wherein the hydrodewaxing conditions include a temperature of 360 to 425° C., hydrogen pressures of from 2859-20786 kPa, liquid hourly space velocities of 0.1 to 10 LHSV and hydrogen treat gas rates of from 53.4-1780 m 3 /m 3 .  
     
     
         12 . The process of  claim 8  further comprising a hydrofinishing step following step (b).  
     
     
         13 . The process of  claim 8  wherein the second dewaxing catalyst is ZSM-5 or zeolite beta.  
     
     
         14 . The process of  claim 8  wherein the dewaxing catalyst contains ZSM-48.  
     
     
         15 . An integrated process for dewaxing a raffinate feedstock containing up to 20,000 ppmw sulfur and up to 1000 ppmw nitrogen which comprises: (a) contacting the feedstock with a dewaxing catalyst including at least one of ZSM-48, ZSM-22, ZSM-23, ZSM-5, ZSM-35, Beta, SSZ-31,SAPO-11, SAPO-31, SAPO-41, MAPO-11, ECR-42, synthetic ferrierites, mordenite, offretite, erionite, and chabazite under hydrodewaxing conditions, said dewaxing catalyst including a metal hydrogenation component which is at least one Group 6 metal, at least one Group 8-10 metal, or mixtures of Group 6 and Group 8-10 metals, to form a hydrodewaxed product, and (b) passing at least a portion of the hydrodewaxed product and gaseous components from step (b) to a hydrofinishing zone and hydrofinishing the hydrodewaxed product under hydrofinishing conditions.  
     
     
         16 . The process of  claim 15  wherein the metal hydrogenation component is Pt, Pd or mixtures thereof.  
     
     
         17 . The process of  claim 15  wherein the hydrodewaxing conditions include a temperature of 360 to 425° C., hydrogen pressures of from 2859-20786 kPa, liquid hourly space velocities of 0.1 to 10 LHSV and hydrogen treat gas rates of from 53.4-1780 m 3 /m 3 .  
     
     
         18 . The process of  claim 15  wherein the hydrofinishing conditions include temperatures of 150-350° C., pressures of 100-3000 psig (790-20786 kPa), LHSV of 0.1-20, and treat gas rates of 300-10000 scf/bbl (53-1780 m 3 /m 3 ).  
     
     
         19 . The process of  claim 15  wherein the dewaxing catalyst includes ZSM-48.  
     
     
         20 . An integrated process for dewaxing a raffinate feed which comprises: (a) solvent dewaxing the raffinate to form a raffinate and a slack wax, (b) deoiling the slack wax to produce a foots oil, (c) contacting the foots oil with a hydrotreating catalyst under hydrotreating conditions to produce a hydrotreated foots oil and gaseous nitrogen- and sulfur-containing contaminants and (d) passing at least a portion of the hydrotreated foots oil and gaseous sulfur- and nitrogen-containing contaminants from step (c) without disengagement to a hydrodewaxing zone containing a dewaxing catalyst including at least one of ZSM-48, ZSM-22, ZSM-23, ZSM-5, ZSM-35, Beta, SSZ-31,SAPO-11, SAPO-31, SAPO-41, MAPO-11, ECR-42, synthetic ferrierites, mordenite, offretite, erionite, and chabazite and hydrodewaxing the hydrotreated foots oil under hydrodewaxing conditions, said dewaxing catalyst including a metal hydrogenation component which is at least one Group 6 metal, at least one Group 8-10 metal, or mixtures of Group 6 and Group 8-10 metals to from a hydrodewaxed product.  
     
     
         21 . The process of  claim 20  wherein the hydrotreating conditions temperatures of 315-425° C., pressures of 2170-20786 kPa, Liquid Hourly Space Velocities (LHSV) of 0.1-10 and hydrogen treat rates of 89-1780 m 3 /m 3 .  
     
     
         22 . The process of  claim 20  wherein the metal hydrogenation component is Pt, Pd or mixtures thereof.  
     
     
         23 . The process of  claim 20  wherein the hydrodewaxing conditions include a temperature of 360 to 425° C., hydrogen pressures of from 2859-20786 kPa, liquid hourly space velocities of 0.1 to 10 LHSV and hydrogen treat gas rates of from 53.4-1780 m 3 /m 3 .  
     
     
         24 . The process of  claim 20  further comprising a hydrofinishing step following step (c).  
     
     
         25 . The process of  claim 20  wherein the dewaxing catalyst includes ZSM-48.  
     
     
         26 . An integrated process for dewaxing a feedstock containing up to 20,000 ppmw sulfur and up to 1000 ppmw nitrogen comprises: (a) blending a raffinate feedstock and at least one of a slack wax or foots oil to form a blended feedstock, (b) contacting the blended feedstock with a hydrotreating catalyst under hydrotreating conditions to produce a hydrotreated feedstock and gaseous nitrogen- and sulfur-containing contaminants, and (c) passing at least a portion of the hydrotreated feedstock and gaseous components from step (b) without disengagement to a hydrodewaxing zone containing a dewaxing catalyst including at least one of ZSM-48, ZSM-22, ZSM-23, ZSM-5, ZSM-35, Beta, SSZ-31,SAPO-11, SAPO-31, SAPO-41, MAPO-11, ECR-42, synthetic ferrierites, mordenite, offretite, erionite, and chabazite and hydrodewaxing the hydrotreated feedstock under hydrodewaxing conditions, said dewaxing catalyst including a metal hydrogenation component which is at least one Group 6 metal, at least one Group 8-10 metal, or mixtures of Group 6 and Group 8-10 metals, to form a hydrodewaxed product.  
     
     
         27 . The process of  claim 26  wherein the hydrotreating conditions temperatures of 315-425° C., pressures of 2170-20786 kPa, Liquid Hourly Space Velocities (LHSV) of 0.1-10 and hydrogen treat rates of 89-1780 m 3 /m 3 .  
     
     
         28 . The process of  claim 26  wherein the metal hydrogenation component is Pt, Pd or mixtures thereof.  
     
     
         29 . The process of  claim 26  wherein the hydrodewaxing conditions include a temperature of 360 to 425° C., hydrogen pressures of from 2859-20786 kPa, liquid hourly space velocities of 0.1 to 10 LHSV and hydrogen treat gas rates of from 53.4-1780 m 3 /m 3 .  
     
     
         30 . The process of  claim 26  further comprising a hydrofinishing step following step (c).  
     
     
         31 . The process of  claim 26  wherein the dewaxing catalyst includes ZSM-48.  
     
     
         32 . An integrated process for dewaxing a raffinate feedstock containing up to 20,000 ppmw sulfur and up to 1000 ppmw nitrogen which comprises: (a) contacting the feedstock with a hydrotreating catalyst under hydrotreating conditions to produce a hydrotreated feedstock and gaseous nitrogen- and sulfur-containing contaminants, and (b) passing at least a portion of the hydrotreated feedstock and gaseous components from step (a) without disengagement to a hydrodewaxing zone containing a ZSM-48 dewaxing catalyst and hydrodewaxing the hydrotreated feedstock under hydrodewaxing conditions, said dewaxing catalyst including a metal hydrogenation component which is at least one Group 6 metal, at least one Group 8-10 metal, or mixtures of Group 6 and Group 8-10 metals, to form a hydrodewaxed product.  
     
     
         33 . The process of  claim 32  wherein the hydrotreating conditions temperatures of 315-425° C., pressures of 2170-20786 kPa, Liquid Hourly Space Velocities (LHSV) of 0.1-10 and hydrogen treat rates of 89-1780 m 3 /m 3 .  
     
     
         34 . The process of  claim 32  wherein the metal hydrogenation component is Pt, Pd or mixtures thereof.  
     
     
         35 . The process of  claim 32  wherein the hydrodewaxing conditions include a temperature of 360 to 425° C., hydrogen pressures of from 2859-20786 kPa, liquid hourly space velocities of 0.1 to 10 LHSV and hydrogen treat gas rates of from 53.4-1780 m 3 /m 3 .  
     
     
         36 . The process of  claim 32  further comprising a hydrofinishing step following step (b).  
     
     
         37 . The process of  claim 32  wherein the dewaxing catalyst further comprises a second dewaxing catalyst.