US2006231457A1PendingUtilityA1

Systems, methods, and catalysts for producing a crude product

44
Individually held — no corporate assignee on recordPriority: Apr 11, 2005Filed: Apr 7, 2006Published: Oct 19, 2006
Est. expiryApr 11, 2025(expired)· nominal 20-yr term from priority
Inventors:Opinder Kishan Bhan
C10G 45/10B01J 21/04B01J 21/12B01J 23/28B01J 23/882B01J 23/883B01J 37/0009B01J 37/20C10G 45/04C10G 45/08C10G 65/04B01J 35/60B01J 35/635B01J 35/66B01J 35/647B01J 35/615
44
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Claims

Abstract

Methods and systems for contacting of a crude feed with one or more catalysts to produce a total product that includes a crude product are described. The crude product is a liquid mixture at 25° C. and 0.101 MPa. The crude product has a nitrogen content of at most 90% of the nitrogen content of the crude feed. One or more other properties of the crude product may be changed by at least 10% relative to the respective properties of the crude feed.

Claims

exact text as granted — not AI-modified
1 . A method of producing a crude product, comprising: 
 contacting a crude feed with one or more catalysts to produce a total product that includes the crude product, wherein the crude product is a liquid mixture at 25° C. and 0.101 MPa; the crude feed has a nitrogen content of at least 0.0001 grams per gram of crude feed; and at least one of the catalysts is a Column 6 metal catalyst that comprises: one or more metals from Column 6 of the Periodic Table and/or one or more compounds of one or more metals from Column 6 of the Periodic Table; a pore size distribution with a median pore diameter of greater than 110 Å; and a pore volume in which pores having a pore diameter of at least 350 Å provide at most 10% of the pore volume, wherein pore diameter and pore volume are as determined by ASTM Method D4282; and    controlling contacting conditions such that the crude product has a nitrogen content of at most 90% of the nitrogen content of the crude feed, wherein nitrogen content is as determined by ASTM Method D5762.    
     
     
         2 . The method as claimed in  claim 1 , wherein pores having a pore diameter of at least 350 Å provide at most 5% of the pore volume.  
     
     
         3 . The method as claimed in claims  1 , wherein the nitrogen content of the crude product is at most 50% of the nitrogen content of the crude feed.  
     
     
         4 . The method as claimed in  claim 1 , wherein the nitrogen content of the crude product is in a range from 0.1% to 75% of the nitrogen content of the crude feed.  
     
     
         5 . The method as claimed in  claim 1 , wherein the crude feed has from 0.0001 grams to 0.1 grams, 0.001 grams to 0.05 grams of nitrogen per gram of crude feed.  
     
     
         6 . The method as claimed in  claim 1 , wherein the crude product has from 0.00001 grams to 0.05 grams of nitrogen per gram of crude product.  
     
     
         7 . The method as claimed in  claim 1 , wherein the Column 6 metal catalyst has, per gram of catalyst, from 0.0001 grams to 0.3 grams of one or more of the Column 6 metals and/or one or more of the Column 6 metal compounds, calculated as total weight of Column 6 metal.  
     
     
         8 . The method as claimed in  claim 1 , wherein the Column 6 metal catalyst comprises in addition one or more metals from Columns 7-10 of the Periodic Table and/or one or more compounds of one or more metals from Columns 7-10 of the Periodic Table.  
     
     
         9 . The method as claimed in  claim 8 , wherein the Column 6 metal catalyst has, per gram of catalyst, from 0.001 grams to 0.1 grams of one or more of the Columns 7-10 metals and/or one or more of the Columns 7-10 metal compounds, calculated as total weight of Columns 7-10 metals.  
     
     
         10 . The method as claimed in  claim 1 , wherein the Column 6 metal catalyst comprises in addition one or more metals from Column 10 of the Periodic Table and/or one or more compounds of one or more metals from Column 10 of the Periodic Table.  
     
     
         11 . The method as claimed in  claim 1 , wherein the Column 6 metal catalyst comprises molybdenum and/or tungsten.  
     
     
         12 . The method as claimed in  claim 11 , wherein the Column 6 metal catalyst comprises nickel.  
     
     
         13 . The method as claimed in  claim 11 , wherein the Column 6 metal catalyst comprises nickel and iron.  
     
     
         14 . The method as claimed in  claim 13 , wherein a molar ratio of total molybdenum to total nickel and iron is at least 1.5.  
     
     
         15 . The method as claimed in  claim 1 , wherein the Column 6 metal catalyst comprises in addition one or more elements from Column 15 of the Periodic Table and/or one or more compounds of one or more elements from Column 15 of the Periodic Table.  
     
     
         16 . The method as claimed in  claim 15 , wherein the catalyst has, per gram of catalyst, from 0.000001 grams to 0.1 grams of one or more of the Column 15 elements and/or one or more of the Column 15 element compounds, calculated as total weight of Column 15 element.  
     
     
         17 . The method as claimed in  claim 1 , wherein the Column 6 metal catalyst comprises in addition phosphorus.  
     
     
         18 . The method as claimed in  claim 1 , wherein the Column 6 metal catalyst has, per gram of catalyst, from 0.001 grams to 0.15 grams of molybdenum and/or one or more compounds of molybdenum, calculated as total weight of molybdenum; and from 0.001 grams to 0.05 grams of nickel and/or one or more compounds of nickel, calculated as total weight of nickel.  
     
     
         19 . The method as claimed in  claim 18 , wherein the Column 6 metal catalyst has in addition, per gram of catalyst, from 0.001 grams to 0.05 grams of phosphorus and/or one or more compounds of phosphorus, calculated as total weight of phosphorus.  
     
     
         20 . The method as claimed in  claim 19 , wherein the Column 6 metal catalyst has in addition, per gram of catalyst, from 0.001 grams to 0.05 grams of iron and/or one or more compounds of iron, calculated as total weight of iron.  
     
     
         21 . The method as claimed in  claim 1 , wherein the Column 6 metal catalyst has at most 0.001 grams per gram of catalyst of one or more metals from Column 5 of the Periodic Table and/or one or more compounds of one or more metals from Column 5 of the Periodic Table, calculated as total weight of Column 5 metal.  
     
     
         22 . The method as claimed in  claim 1 , wherein the Column 6 metal catalyst has a median pore diameter of at least 120 Å or at most 300 Å, wherein pore size distribution is as determined by ASTM Method D4282.  
     
     
         23 . The method as claimed in  claim 1 , wherein the Column 6 metal catalyst has a pore size distribution such that at least 60% of the total number of pores in the pore size distribution are within 45 Å of the median pore diameter of the pore size distribution.  
     
     
         24 . The method as claimed in  claim 1 , wherein the Column 6 metal catalyst comprises in addition a support, and the support has, per gram of support, at least 0.8 grams of gamma alumina.  
     
     
         25 . The method as claimed in  claim 24 , wherein the support has, per gram of support, at most 0.1 grams of silica.  
     
     
         26 . The method as claimed in  claim 1 , wherein the Column 6 metal catalyst is obtainable by combining a mixture with one or more of the Column 6 metals and/or one or more of the Column 6 metal compounds, and the mixture comprises: one or more metals from Columns 7-10 of the Periodic Table and/or one or more compounds of one or more metals from Columns 7-10 of the Periodic Table; and a support.  
     
     
         27 . The method as claimed in  claim 26 , wherein at least one of the Columns 7-10 metals comprises nickel, cobalt, iron, or mixtures thereof.  
     
     
         28 . The method as claimed in  claim 1 , wherein crude feed also has a C 5  asphaltenes content, and the crude product has a C 5  asphaltenes content of at most 90% of the C 5  asphaltenes content of the crude feed, wherein C 5  asphaltenes content is as determined by ASTM Method D2007.  
     
     
         29 . The method as claimed in  claim 1 , wherein the crude product has a viscosity at 37.8° C. (100° F.) of at most 90% of the viscosity at 37.8° C. of the crude feed, wherein viscosity is as determined by ASTM Method D445.  
     
     
         30 . The method as claimed in  claim 1 , wherein the crude feed also has a sulfur content, and the crude product has a sulfur content of at most 90% of the sulfur content of the crude feed, wherein sulfur content is as determined by ASTM Method D4294.  
     
     
         31 . The method as claimed in  claim 1 , wherein the crude feed also has a residue content, and the crude product has a residue content of at most 90% of the residue content of the crude feed, wherein residue content is as determined by ASTM Method D5307.  
     
     
         32 . The method as claimed in  claim 1 , wherein the contacting is performed in the presence of a hydrogen source.  
     
     
         33 . The method as claimed in  claim 1 , wherein the contacting conditions comprise: a temperature within the range of 50° C. to 500° C.; a total pressure within a range of 0.1 MPa to 20 MPa; a liquid hourly space velocity of at least 0.05 h −1 ; and a ratio of a gaseous hydrogen source to the crude feed in a range from 0.1 Nm 3 /m 3  to 100,000 Nm 3 /m 3 .  
     
     
         34 . The method as claimed in  claim 33 , wherein the total pressure is at most 18 MPa.  
     
     
         35 . The method as claimed in  claim 33 , wherein the temperature is at most 430° C.  
     
     
         36 . The method as claimed in  claim 1 , wherein a crude feed/total product mixture has a P-value of at least 1.5 during contacting.  
     
     
         37 . The method as claimed in  claim 1 , wherein the method further comprises combining the crude product with a crude that is the same as or different from the crude feed to form a blend.  
     
     
         38 . The method of  claim 1  or  claim 37  further comprising the step of processing the crude product or blend to produce transportation fuel, heating fuel, lubricants, or chemicals.

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