US2007295646A1PendingUtilityA1

Method for producing a crude product with a long-life catalyst

48
Individually held — no corporate assignee on recordPriority: Jun 22, 2006Filed: Jun 20, 2007Published: Dec 27, 2007
Est. expiryJun 22, 2026(expired)· nominal 20-yr term from priority
Inventors:Opinder Kishan BhanScott Lee Wellington
B01J 2235/15B01J 35/37B01J 2235/00B01J 23/24C10G 65/04B01J 23/883C10G 45/08B01J 23/28C10G 45/04B01J 23/22B01J 23/85C10G 47/10C10G 47/12B01J 35/19B01J 35/647B01J 35/66
48
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Claims

Abstract

Continuously contacting a crude feed with one or more catalysts for at least 500 hours at a liquid hourly space velocity of at least 1 h −1 produces a total product that includes a crude product. At least one of the catalysts has a pore size distribution with a median pore diameter of at least 180 Å and includes 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.

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 for at least 500 hours at a liquid hourly space velocity (LHSV) of at least 1 h −1  to produce a total product that includes the crude product, wherein the one or more catalysts are not replaced during treatment of the crude feed, and wherein the crude product is a liquid mixture at 25° C. and 0.101 MPa, and at least one of the catalysts has a pore size distribution with a median pore diameter of at least 180 Å, as determined by ASTM Method D4282, and the catalyst having the pore size distribution comprising one or more metals from Column 6 of the Periodic Table, one or more compounds of one or more metals from Column 6 of the Periodic Table, or mixtures thereof; and wherein the TAN of the crude product remains at most 30% of the TAN of the crude feed during contact of the crude feed with one or more catalysts, wherein TAN is as determined by ASTM Method D664.  
     
     
         2 . The method of  claim 1 , wherein the catalyst having the pore size distribution is supported, and the support has a theta alumina content of at least 0.5 grams, per gram of support.  
     
     
         3 . The method of  claim 1 , wherein the crude feed has, per gram of crude feed, a total content of alkali metal and alkaline-earth metal in metal salts of organic acids of at least 0.00001 grams and the crude product has a total content of alkali metal and alkaline-earth metal in metal salts of organic acids of at most 90% of the content of alkali metal, and alkaline-earth metal, in metal salts of organic acids in the crude feed.  
     
     
         4 . The method of  claim 1 , wherein the crude feed has a content of Columns 5-12 metals in metal salts of organic acids, and the crude product has a content of Columns 5-12 metals in metal salts of organic acids of at most 90% of the content of Columns 5-12 metals in metal salts of organic acids of the crude feed.  
     
     
         5 . The method of  claim 1 , wherein the crude feed comprises silicon, and the crude product has a content of silicon of at most 90% of the content of the silicon of the crude feed.  
     
     
         6 . The method of  claim 1 , wherein the method further comprises fractionating the crude product into one or more distillate fractions, and producing transportation fuel from at least one of the distillate fractions.  
     
     
         7 . 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 having a total acid number (TAN) of at least 0.1, at least one of the catalysts having a pore size distribution with a median pore diameter of at least 180 Å, as determined by ASTM Method D4282, and the catalyst having the pore size distribution comprising one or more metals from Column 6 of the Periodic Table, one or more compounds of one or more metals from Column 6 of the Periodic Table, or mixtures thereof; and    controlling contacting conditions such that the crude product has a TAN of at most 30% of the TAN of the crude feed after 500 hours of continuous use at a liquid hourly space velocity (LHSV) of at least 1 h −1  of the one or more catalysts, wherein TAN is as determined by ASTM Method D664.    
     
     
         8 . The method of  claim 7 , wherein the catalyst having the pore size distribution is supported, and the support has a theta alumina content of at least 0.5 grams, per gram of support.  
     
     
         9 . The method of  claim 7 , wherein the crude feed has, per gram of crude feed, a total content of alkali metal and alkaline-earth metal in metal salts of organic acids of at least 0.00001 grams and the crude product has a total content of alkali metal and alkaline-earth metal in metal salts of organic acids of at most 90% of the content of alkali metal, and alkaline-earth metal, in metal salts of organic acids in the crude feed.  
     
     
         10 . The method of  claim 7 , wherein the crude feed has a content of Columns 5-12 metals in metal salts of organic acids, and the crude product has a content of Columns 5-12 metals in metal salts of organic acids of at most 90% of the content of Columns 5-12 metals in metal salts of organic acids of the crude feed.  
     
     
         11 . The method of  claim 7 , wherein the crude feed comprises silicon, and the crude product has a content of silicon of at most 90% of the content of the silicon of the crude feed.  
     
     
         12 . The method of  claim 7 , wherein the method further comprises fractionating the crude product into one or more distillate fractions, and producing transportation fuel from at least one of the distillate fractions.  
     
     
         13 . 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 having a total acid number (TAN) of at least 1, at least one of the catalysts having a pore size distribution with a median pore diameter of at least 180 Å, as determined by ASTM Method D4282, and the catalyst having the pore size distribution comprising one or more metals from Column 6 of the Periodic Table, one or more compounds of one or more metals from Column 6 of the Periodic Table, or mixtures thereof; and    controlling contacting conditions such that the crude product has a TAN from about 0.001 to about 0.5 after 500 hours of continuous use at a liquid hourly space velocity (LHSV) of at least 1 h −1  of the one or more catalysts, wherein TAN is as determined by ASTM Method D664.    
     
     
         14 . The method of  claim 13 , wherein the catalyst having the pore size distribution is supported, and the support has a theta alumina content of at least 0.5 grams, per gram of support.  
     
     
         15 . The method of  claim 13 , wherein the crude feed has, per gram of crude feed, a total content of alkali metal and alkaline-earth metal in metal salts of organic acids of at least 0.00001 grams and the crude product has a total content of alkali metal and alkaline-earth metal in metal salts of organic acids of at most 90% of the content of alkali metal, and alkaline-earth metal, in metal salts of organic acids in the crude feed.  
     
     
         16 . The method of  claim 13 , wherein the crude feed has a content of Columns 5-12 metals in metal salts of organic acids, and the crude product has a content of Columns 5-12 metals in metal salts of organic acids of at most 90% of the content of Columns 5-12 metals in metal salts of organic acids of the crude feed.  
     
     
         17 . The method of  claim 13 , wherein the crude feed comprises silicon, and the crude product has a content of silicon of at most 90% of the content of the silicon of the crude feed.  
     
     
         18 . The method of  claim 13 , wherein the method further comprises fractionating the crude product into one or more distillate fractions, and producing transportation fuel from at least one of the distillate fractions.  
     
     
         19 . 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 having a total acid number (TAN) of at least 0.1, at least one of the catalysts having a pore size distribution with a median pore diameter of at least 180 Å, as determined by ASTM Method D4282, and the catalyst having the pore size distribution comprising one or more metals from Column 6 of the Periodic Table, one or more compounds of one or more metals from Column 6 of the Periodic Table, or mixtures thereof; and    controlling contacting conditions of:, a total hydrogen partial pressure of at most 3.5 MPa, a temperature above 360° C., and a liquid hourly space velocity (LHSV) of at least 1 h −1 ; wherein the one or more catalysts are capable of producing crude product with a TAN of at most 30% of the TAN of the crude feed after at least 500 hours of continuous use of the one or more catalysts, wherein TAN is as determined by ASTM Method D664.    
     
     
         20 . The method of  claim 19 , wherein the LHSV is at least 10 h −1 .  
     
     
         21 . The method of  claim 19 , wherein the catalyst having the pore size distribution is supported, and the support has a theta alumina content of at least 0.5 grams, per gram of support.  
     
     
         22 . The method of  claim 19 , wherein the crude feed has, per gram of crude feed, a total content of alkali metal and alkaline-earth metal in metal salts of organic acids of at least 0.00001 grams and the crude product has a total content of alkali metal and alkaline-earth metal in metal salts of organic acids of at most 90% of the content of alkali metal, and alkaline-earth metal, in metal salts of organic acids in the crude feed.  
     
     
         23 . The method of  claim 19 , wherein the crude feed has a content of Columns 5-12 metals in metal salts of organic acids, and the crude product has a content of Columns 5-12 metals in metal salts of organic acids of at most 90% of the content of Columns 5-12 metals in metal salts of organic acids of the crude feed.  
     
     
         24 . The method of  claim 19 , wherein the crude feed comprises silicon, and the crude product has a content of silicon of at most 90% of the content of the silicon of the crude feed.  
     
     
         25 . The method of  claim 19 , wherein the method further comprises fractionating the crude product into one or more distillate fractions, and producing transportation fuel from at least one of the distillate fractions.  
     
     
         26 . A method for producing a crude product, comprising contacting a crude feed comprising a whole or topped crude having a TAN of at least 0.1 with one or more catalysts at an LHSV of at least 1 h −1  for a run time of at least 500 hours to produce a total product that includes the crude product, wherein the one or more catalysts are not replaced during contact with the crude feed, and at least one of the catalysts has a pore size distribution with a median pore diameter of at least 180 angstroms, as determined by ASTM Method D4282, the catalyst having the pore size distribution comprising one or more metals from Column 6 of the Periodic Table, one or more compounds of one or more metals from Column 6 of the Periodic Table, or mixtures thereof.  
     
     
         27 . The method for producing a crude product of  claim 26  wherein the crude feed is contacted with the one or more catalyst at a hydrogen partial pressure of at most 3.5 MPa.  
     
     
         28 . The method for producing a crude product of  claim 26  wherein the crude feed is contacted with the one or more catalysts at a temperature of from 50° C. to 450° C.  
     
     
         29 . The method for producing a crude product of  claim 26  wherein the crude feed is contacted with the one or more catalysts at an LHSV of at least 10 h −1 .  
     
     
         30 . The method for producing a crude product of  claim 26  wherein the catalyst having the pore size distribution is supported, and the support has a theta alumina content of at least 0.5 grams per gram of support.  
     
     
         31 . The method of  claim 26  wherein the method further comprises fractionating the crude product into one or more distillate fractions and producing transportation fuel from at least one of the distillate fractions.

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