Production of lower molecular weight hydrocarbons

Abstract

The present invention relates generally to processes for upgrading (cracking and hydrogenation) of high molecular weight hydrocarbons using a catalytic composition at moderate temperatures, methods for stabilizing the upgraded product, and methods for reducing carbon oxides using a catalytic composition.

1 . A method of cracking a high molecular weight hydrocarbon to form a lower molecular weight hydrocarbon product, comprising:
 (I) admixing (a) a high molecular weight hydrocarbon having an API value of less than about 12 and (b) an aqueous catalytic composition prepared by admixing and reacting, in an aqueous solution, a transition metal salt and particles of silicon dioxide, aluminum oxide, ferric oxide, calcium oxide, and titania or boron oxide;   (II) reacting the admixture from step (I) at a temperature from about 50° C. to about 200° C., thereby hydrogenating and cracking the high molecular weight hydrocarbon to form a lower molecular weight hydrocarbon product; said lower molecular weight product having an API value greater than the API value of the high molecular weight hydrocarbon composition.   
     
     
         2 . The method of  claim 1 , wherein the aqueous catalytic composition is prepared by admixing and reacting, in an aqueous solution
 i. about 15 to 40 weight percent cement,   ii. about 55 to 80 weight percent volcanic ash,   iii. about 2 to 8 weight percent titanium dioxide or boron oxide, and   iv. about 3 to 10 weight percent transition metal salt,   the weight percents being based on the total weight of components (i)-(iv).   
     
     
         3 . The method of  claim 2 , wherein the volcanic ash component is one or more components selected from scoria, basalt, pyroclastic rock, tuff, tuffstone, volcanic glass, pumice, mafic rock, ultramafic rock, and silicate-based zeolites. 
     
     
         4 . The method of  claim 1 , wherein step (I) comprises admixing (a) a high molecular weight hydrocarbon having an API value of less than about 12, (b) carbon dioxide, and (c) an aqueous catalytic composition prepared by admixing and reacting, in an aqueous solution, a transition metal salt and particles of silicon dioxide, aluminum oxide, ferric oxide, calcium oxide, and titania or boron oxide. 
     
     
         5 . The method of  claim 1 , further comprising (III) stabilizing the lower molecular weight hydrocarbon product by admixing it with a diluent comprising a saturated hydrocarbon having from 5 to 25 carbon atoms. 
     
     
         6 . The method of  claim 4 , further comprising (III) stabilizing the lower molecular weight hydrocarbon product by admixing it with a diluent comprising a saturated hydrocarbon having from 5 to 25 carbon atoms. 
     
     
         7 . The method of  claim 1 , further comprising:
 (III) recovering the lower molecular weight hydrocarbon from the product of step (II); and   (IV) admixing said lower molecular weight hydrocarbon from step (III) with a second aqueous catalytic composition thereby forming a hydrocarbon product having a molecular weight still lower than said lower molecular weight hydrocarbon product,   wherein the second aqueous catalytic compositions is prepared by admixing and reacting, in an aqueous solution, a transition metal salt and particles of silicon dioxide, aluminum oxide, ferric oxide, calcium oxide, and titania or boron oxide.   
     
     
         8 . The method of  claim 1 , wherein the high molecular weight hydrocarbon is formed by diluting bitumens, asphaltenes, heavy oils, or tars. 
     
     
         9 . The method of  claim 7 , wherein the high molecular weight hydrocarbon is formed by diluting the bitumens, asphaltenes, heavy oils, or tars with a C 5  to C 25  alkane or cycloalkane. 
     
     
         10 . The method of  claim 1 , wherein the high molecular weight hydrocarbon is admixed with the aqueous catalytic composition at a weight ratio of from 2:1 to 4:1. 
     
     
         11 . The method of  claim 1 , wherein the transition metal salt is ferrous chloride. 
     
     
         12 . The method of  claim 10 , wherein the aqueous catalytic composition is formed from the following components:
 i. about 25 to 50 weight percent silicon dioxide,   ii. about 6 to 20 weight percent aluminum oxide,   iii. about 5 to 15 weight percent ferric oxide,   iv. about 15 to 30 weight percent calcium oxide,   v. about 2 to 10 weight percent titania or boron oxide, and   vi. about 2 to 10 weight percent ferrous chloride,   the weight percents being based on the total weight of components (i)-(vi).   
     
     
         13 . The method of  claim 1 , wherein the aqueous catalytic composition is formed from the following components:
 i. about 15 to 40 weight percent cement,   ii. about 55 to 80 weight percent volcanic ash,   iii. about 2 to 8 weight percent titanium dioxide or boron oxide, and   iv. about 3 to 10 weight percent transition metal salt,   the weight percents being based on the total weight of components (i)-(iv).   
     
     
         14 . A method of forming and stabilizing a lower molecular weight hydrocarbon prepared from the cracking and hydrogenating of a high molecular weight hydrocarbon, comprising:
 admixing (a) a high molecular weight hydrocarbon having an API value of less than about 12, (b) carbon dioxide, and (c) an aqueous catalytic composition, said aqueous catalytic composition having been prepared by admixing and reacting, in an aqueous solution, a transition metal salt and particles of silicon dioxide, aluminum oxide, ferric oxide; calcium oxide, and titania or boron oxide, thereby forming a stabilized lower molecular weight hydrocarbon product.   
     
     
         15 . The method of  claim 13 , wherein the amount of carbon dioxide relative to the 1 bbl. of the high molecular weight hydrocarbon is from 5 to 50 scft. 
     
     
         16 . The method of  claim 13 , further comprising admixing with the lower molecular lower molecular weight hydrocarbon a diluent comprising a saturated hydrocarbon having from 5 to 25 carbon atoms. 
     
     
         17 . A method of reducing the concentration of carbon oxides in a gaseous or liquid medium comprising: passing said medium into an aqueous catalytic composition or an admixture of the aqueous catalytic composition and optionally a liquid hydrocarbon, at a temperature of at least 50° C. and pressure sufficient to react the carbon oxides; said aqueous catalytic composition being prepared by admixing and reacting, in an aqueous solution, a transition metal salt and particles of silicon dioxide, aluminum oxide, ferric oxide, calcium oxide, and titania or boron oxide. 
     
     
         18 . A method of forming a lower molecular weight hydrocarbon from a high molecular weight hydrocarbon, comprising:
 (a) admixing a high molecular weight hydrocarbon having an API value of less than about 12 and a first aqueous catalytic composition thereby forming a lower molecular weight hydrocarbon product;   (b) recovering the lower molecular weight hydrocarbon from the product of step (a); and   (c) admixing said lower molecular weight hydrocarbon from step (b) with a second aqueous catalytic composition thereby forming a hydrocarbon product having a molecular weight still lower than said lower molecular weight hydrocarbon product,   
       wherein each of the first and second aqueous catalytic compositions is prepared by admixing and reacting, in an aqueous solution, a transition metal salt and particles of silicon dioxide, aluminum oxide, ferric oxide, calcium oxide, and titania or boron oxide, and the first and second aqueous catalytic compositions are the same or different.