WO2006029137A2 - Hydroprocessing catalyst with zeolite and high mesoporosity - Google Patents
Hydroprocessing catalyst with zeolite and high mesoporosity Download PDFInfo
- Publication number
- WO2006029137A2 WO2006029137A2 PCT/US2005/031668 US2005031668W WO2006029137A2 WO 2006029137 A2 WO2006029137 A2 WO 2006029137A2 US 2005031668 W US2005031668 W US 2005031668W WO 2006029137 A2 WO2006029137 A2 WO 2006029137A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- zeolite
- catalyst
- zsm
- group
- mcm
- Prior art date
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- 239000010457 zeolite Substances 0.000 title claims abstract description 90
- 229910021536 Zeolite Inorganic materials 0.000 title claims abstract description 88
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 title claims abstract description 88
- 239000003054 catalyst Substances 0.000 title claims abstract description 67
- 229910052809 inorganic oxide Inorganic materials 0.000 claims abstract description 34
- 238000005984 hydrogenation reaction Methods 0.000 claims abstract description 19
- 238000006243 chemical reaction Methods 0.000 claims abstract description 17
- 229930195733 hydrocarbon Natural products 0.000 claims abstract description 14
- 150000002430 hydrocarbons Chemical class 0.000 claims abstract description 13
- 239000004215 Carbon black (E152) Substances 0.000 claims abstract description 12
- 229910052751 metal Inorganic materials 0.000 claims description 33
- 239000002184 metal Substances 0.000 claims description 33
- 238000000034 method Methods 0.000 claims description 30
- 239000000203 mixture Substances 0.000 claims description 30
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 25
- 230000008569 process Effects 0.000 claims description 24
- 239000002131 composite material Substances 0.000 claims description 13
- 239000000377 silicon dioxide Substances 0.000 claims description 12
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 11
- 238000004517 catalytic hydrocracking Methods 0.000 claims description 11
- 239000003208 petroleum Substances 0.000 claims description 11
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- 229910052750 molybdenum Inorganic materials 0.000 claims description 8
- 238000009835 boiling Methods 0.000 claims description 7
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- 229910052697 platinum Inorganic materials 0.000 claims description 6
- 229910052782 aluminium Inorganic materials 0.000 claims description 5
- 239000011230 binding agent Substances 0.000 claims description 5
- 230000000694 effects Effects 0.000 claims description 5
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- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 4
- 229910052804 chromium Inorganic materials 0.000 claims description 4
- 230000000737 periodic effect Effects 0.000 claims description 4
- 229910052725 zinc Inorganic materials 0.000 claims description 4
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims description 3
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 claims description 3
- 230000001588 bifunctional effect Effects 0.000 claims description 3
- 229910052796 boron Inorganic materials 0.000 claims description 3
- 229910052680 mordenite Inorganic materials 0.000 claims description 3
- 229910052698 phosphorus Inorganic materials 0.000 claims description 3
- 239000011574 phosphorus Substances 0.000 claims description 3
- 229910052719 titanium Inorganic materials 0.000 claims description 3
- 239000010936 titanium Substances 0.000 claims description 3
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- IRMOUQGSNFXEJH-UHFFFAOYSA-N 4,6,11-trioxa-1-aza-5-aluminabicyclo[3.3.3]undecane Chemical compound [Al+3].[O-]CCN(CC[O-])CC[O-] IRMOUQGSNFXEJH-UHFFFAOYSA-N 0.000 claims description 2
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- 125000001183 hydrocarbyl group Chemical group 0.000 claims 1
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- 238000003756 stirring Methods 0.000 description 22
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- 238000001179 sorption measurement Methods 0.000 description 9
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 8
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- 238000002360 preparation method Methods 0.000 description 7
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- 238000009826 distribution Methods 0.000 description 6
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- 229940073455 tetraethylammonium hydroxide Drugs 0.000 description 5
- LRGJRHZIDJQFCL-UHFFFAOYSA-M tetraethylazanium;hydroxide Chemical compound [OH-].CC[N+](CC)(CC)CC LRGJRHZIDJQFCL-UHFFFAOYSA-M 0.000 description 5
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- 230000002378 acidificating effect Effects 0.000 description 4
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 4
- -1 aluminum-triethanolamine Chemical compound 0.000 description 4
- 239000003795 chemical substances by application Substances 0.000 description 4
- 229910017052 cobalt Inorganic materials 0.000 description 4
- 239000010941 cobalt Substances 0.000 description 4
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 4
- 229910052802 copper Inorganic materials 0.000 description 4
- 239000010949 copper Substances 0.000 description 4
- 239000006185 dispersion Substances 0.000 description 4
- 239000007789 gas Substances 0.000 description 4
- 238000010348 incorporation Methods 0.000 description 4
- 238000005342 ion exchange Methods 0.000 description 4
- 239000013335 mesoporous material Substances 0.000 description 4
- 238000012545 processing Methods 0.000 description 4
- 238000012546 transfer Methods 0.000 description 4
- 239000010937 tungsten Substances 0.000 description 4
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 3
- RWSOTUBLDIXVET-UHFFFAOYSA-N Dihydrogen sulfide Chemical compound S RWSOTUBLDIXVET-UHFFFAOYSA-N 0.000 description 3
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 description 3
- DNIAPMSPPWPWGF-UHFFFAOYSA-N Propylene glycol Chemical compound CC(O)CO DNIAPMSPPWPWGF-UHFFFAOYSA-N 0.000 description 3
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 3
- 150000007513 acids Chemical class 0.000 description 3
- 239000011651 chromium Substances 0.000 description 3
- 229910052681 coesite Inorganic materials 0.000 description 3
- 229910052906 cristobalite Inorganic materials 0.000 description 3
- MTHSVFCYNBDYFN-UHFFFAOYSA-N diethylene glycol Chemical compound OCCOCCO MTHSVFCYNBDYFN-UHFFFAOYSA-N 0.000 description 3
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 3
- 229910052737 gold Inorganic materials 0.000 description 3
- 239000010931 gold Substances 0.000 description 3
- 150000002431 hydrogen Chemical class 0.000 description 3
- 229910000037 hydrogen sulfide Inorganic materials 0.000 description 3
- 238000005470 impregnation Methods 0.000 description 3
- 229910052746 lanthanum Inorganic materials 0.000 description 3
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 3
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- 239000000126 substance Substances 0.000 description 3
- 229910052723 transition metal Inorganic materials 0.000 description 3
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- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 3
- 239000011701 zinc Substances 0.000 description 3
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 description 2
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- GYHNNYVSQQEPJS-UHFFFAOYSA-N Gallium Chemical compound [Ga] GYHNNYVSQQEPJS-UHFFFAOYSA-N 0.000 description 2
- 229910019142 PO4 Inorganic materials 0.000 description 2
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 2
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 2
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 230000032683 aging Effects 0.000 description 2
- QGAVSDVURUSLQK-UHFFFAOYSA-N ammonium heptamolybdate Chemical compound N.N.N.N.N.N.O.O.O.O.O.O.O.O.O.O.O.O.O.O.O.O.O.O.O.O.O.O.O.O.[Mo].[Mo].[Mo].[Mo].[Mo].[Mo].[Mo] QGAVSDVURUSLQK-UHFFFAOYSA-N 0.000 description 2
- APUPEJJSWDHEBO-UHFFFAOYSA-P ammonium molybdate Chemical compound [NH4+].[NH4+].[O-][Mo]([O-])(=O)=O APUPEJJSWDHEBO-UHFFFAOYSA-P 0.000 description 2
- 239000011609 ammonium molybdate Substances 0.000 description 2
- 229940010552 ammonium molybdate Drugs 0.000 description 2
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- 125000004429 atom Chemical group 0.000 description 2
- 238000001354 calcination Methods 0.000 description 2
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- 150000004820 halides Chemical class 0.000 description 2
- 239000010687 lubricating oil Substances 0.000 description 2
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 2
- 229910044991 metal oxide Inorganic materials 0.000 description 2
- 150000004706 metal oxides Chemical class 0.000 description 2
- CKFGINPQOCXMAZ-UHFFFAOYSA-N methanediol Chemical compound OCO CKFGINPQOCXMAZ-UHFFFAOYSA-N 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 150000002823 nitrates Chemical class 0.000 description 2
- NWAHZABTSDUXMJ-UHFFFAOYSA-N platinum(2+);dinitrate Chemical compound [Pt+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O NWAHZABTSDUXMJ-UHFFFAOYSA-N 0.000 description 2
- 230000036619 pore blockages Effects 0.000 description 2
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- LZDKZFUFMNSQCJ-UHFFFAOYSA-N 1,2-diethoxyethane Chemical compound CCOCCOCC LZDKZFUFMNSQCJ-UHFFFAOYSA-N 0.000 description 1
- NSYDOBYFTHLPFM-UHFFFAOYSA-N 2-(2,2-dimethyl-1,3,6,2-dioxazasilocan-6-yl)ethanol Chemical compound C[Si]1(C)OCCN(CCO)CCO1 NSYDOBYFTHLPFM-UHFFFAOYSA-N 0.000 description 1
- PAWQVTBBRAZDMG-UHFFFAOYSA-N 2-(3-bromo-2-fluorophenyl)acetic acid Chemical compound OC(=O)CC1=CC=CC(Br)=C1F PAWQVTBBRAZDMG-UHFFFAOYSA-N 0.000 description 1
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- 229910021638 Iridium(III) chloride Inorganic materials 0.000 description 1
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- IYDGMDWEHDFVQI-UHFFFAOYSA-N phosphoric acid;trioxotungsten Chemical compound O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.O=[W](=O)=O.OP(O)(O)=O IYDGMDWEHDFVQI-UHFFFAOYSA-N 0.000 description 1
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- 229910002027 silica gel Inorganic materials 0.000 description 1
- 239000000741 silica gel Substances 0.000 description 1
- CGFYHILWFSGVJS-UHFFFAOYSA-N silicic acid;trioxotungsten Chemical compound O[Si](O)(O)O.O=[W]1(=O)O[W](=O)(=O)O[W](=O)(=O)O1.O=[W]1(=O)O[W](=O)(=O)O[W](=O)(=O)O1.O=[W]1(=O)O[W](=O)(=O)O[W](=O)(=O)O1.O=[W]1(=O)O[W](=O)(=O)O[W](=O)(=O)O1 CGFYHILWFSGVJS-UHFFFAOYSA-N 0.000 description 1
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- 229910052814 silicon oxide Inorganic materials 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- HXJUTPCZVOIRIF-UHFFFAOYSA-N sulfolane Chemical compound O=S1(=O)CCCC1 HXJUTPCZVOIRIF-UHFFFAOYSA-N 0.000 description 1
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
- FAGUFWYHJQFNRV-UHFFFAOYSA-N tetraethylenepentamine Chemical compound NCCNCCNCCNCCN FAGUFWYHJQFNRV-UHFFFAOYSA-N 0.000 description 1
- DANYXEHCMQHDNX-UHFFFAOYSA-K trichloroiridium Chemical compound Cl[Ir](Cl)Cl DANYXEHCMQHDNX-UHFFFAOYSA-K 0.000 description 1
- 238000001238 wet grinding Methods 0.000 description 1
- 229910001845 yogo sapphire Inorganic materials 0.000 description 1
Classifications
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- B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
- B01J21/06—Silicon, titanium, zirconium or hafnium; Oxides or hydroxides thereof
- B01J21/08—Silica
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- B01J29/00—Catalysts comprising molecular sieves
- B01J29/005—Mixtures of molecular sieves comprising at least one molecular sieve which is not an aluminosilicate zeolite, e.g. from groups B01J29/03 - B01J29/049 or B01J29/82 - B01J29/89
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- C10G45/00—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
- C10G45/58—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to change the structural skeleton of some of the hydrocarbon content without cracking the other hydrocarbons present, e.g. lowering pour point; Selective hydrocracking of normal paraffins
- C10G45/60—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to change the structural skeleton of some of the hydrocarbon content without cracking the other hydrocarbons present, e.g. lowering pour point; Selective hydrocracking of normal paraffins characterised by the catalyst used
- C10G45/64—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to change the structural skeleton of some of the hydrocarbon content without cracking the other hydrocarbons present, e.g. lowering pour point; Selective hydrocracking of normal paraffins characterised by the catalyst used containing crystalline alumino-silicates, e.g. molecular sieves
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- C10G47/00—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions
- C10G47/02—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions characterised by the catalyst used
- C10G47/10—Cracking of hydrocarbon oils, in the presence of hydrogen or hydrogen- generating compounds, to obtain lower boiling fractions characterised by the catalyst used with catalysts deposited on a carrier
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- C10G47/14—Inorganic carriers the catalyst containing platinum group metals or compounds thereof
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- C10G49/00—Treatment of hydrocarbon oils, in the presence of hydrogen or hydrogen-generating compounds, not provided for in a single one of groups C10G45/02, C10G45/32, C10G45/44, C10G45/58 or C10G47/00
- C10G49/02—Treatment of hydrocarbon oils, in the presence of hydrogen or hydrogen-generating compounds, not provided for in a single one of groups C10G45/02, C10G45/32, C10G45/44, C10G45/58 or C10G47/00 characterised by the catalyst used
- C10G49/08—Treatment of hydrocarbon oils, in the presence of hydrogen or hydrogen-generating compounds, not provided for in a single one of groups C10G45/02, C10G45/32, C10G45/44, C10G45/58 or C10G47/00 characterised by the catalyst used containing crystalline alumino-silicates, e.g. molecular sieves
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- B01J29/08—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
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- B01J29/16—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y containing arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
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- B01J37/0009—Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
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- C—CHEMISTRY; METALLURGY
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- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
- C10G2400/06—Gasoil
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- C—CHEMISTRY; METALLURGY
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- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
- C10G2400/10—Lubricating oil
Definitions
- the present invention relates to a bifunctional catalyst having both hydrogenation and acidic functions.
- zeolite catalysts are well known in the art and possess well-arranged pore systems with uniform pore sizes. However, these materials tend to possess either only micropores or only mesopores. Micropores are defined as ppres having a diameter less than about 2 nm. Mesopores are defined as pores having a diameter ranging from about 2 nm to about 50 nm. [004] Because such hydrocarbon processing reactions are mass-transfer limited, a catalyst with an ideal pore size will facilitate transport of the reactants to active catalyst sites and transport the products out of the catalyst. [005] There is yet need for an improved material having functionalized sites within a porous framework for processes directed to the catalytic conversion and/or adsorption of hydrocarbons and other organic compounds.
- a catalyst for hydrocarbon conversion comprising at least three components (1) at least one element with a hydrogenation function, (2) at least one type of microporous zeolite, and (3) a porous, noncrystalline inorganic oxide having randomly interconnected mesopores and having an X-ray reflection in 2 ⁇ between 0.5 degrees to 2.5 degrees.
- FIG. 1 depicts X-ray diffraction (XRD) patterns of pure zeolite beta and zeolite beta/TUD-1 as prepared in Examples 1, 2 and 3;
- FIG. 2 depicts the mesoporosity of pure zeolite beta and zeolite beta/TUD-
- FIG. 3 depicts XRD patterns for mesoporous material, MCM-22 zeolite, and the composite prepared in Example 4;
- FIG. 4 illustrates the mesopore size distribution of the composite zeolite/TUD-1 prepared in Example 4.
- FIG. 5 depicts XRD patterns of pure zeolite Y and of Sample 5 prepared in Example 5.
- the inventive catalyst has a novel composition essentially comprising three active components: (1) at least one metal selected from group VIII, IB, IIB, VIEB and VD3 in the periodic table of the elements; (2) at least one type of microporous zeolite providing some acidic function; and (3) a noncrystalline inorganic oxide having randomly interconnected mesopores ranging from 1.5 to 25 run in diameter.
- the catalyst can also optionally include boron and/or phosphorus as another component.
- the catalyst may further comprise a binder.
- the metal is mainly selected from transition metals, noble metals and their combinations. These metals include titanium, vanadium, zirconium, manganese, zinc, copper, gold, lanthanum, chromium, molybdenum, nickel, cobalt, iron, tungsten, palladium, rhodium, ruthenium and platinum. Some of the metals can be located on the pore surface of the mesoporous, inorganic oxide; some of them can be incorporated within the zeolite framework as substitutions of lattice atoms and/or located inside the zeolite micropores. Also, some of the metal can be located on the catalyst binder.
- the metal content in the catalyst ranges from 0.3 wt. % to 30 wt. % based on the weight of the catalyst.
- its contents preferably ranges from 0.2 to 5wt%
- transition metals its contents preferably ranges from 3 to 30 wt.%.
- the zeolite described herein includes a microporous zeolite embedded in a non-crystalline, porous inorganic oxide.
- the microporous zeolite can be any type of microporous zeolite. Some examples are zeolite Beta, zeolite Y (including "ultra stable Y” ⁇ USY), mordenite, Zeolite L, ZSM-5, ZSM-11, ZSM-12, ZSM-20, Theta-1, ZSM-23, ZSM-34, ZSM-35, ZSM-48, SSZ-32, PSH-3, MCM-22, MCM-49, MCM-56, ITQ-I, ITQ-2, ITQ-4, ITQ-21, SAPO-5, SAPO-Il, SAPO-37, Breck-6 (also known as EMT), ALPO 4 -5, etc.
- the zeolite can be incorporated into the inorganic oxide or can be in-situ synthesized in the noncrystalline porous oxide.
- the catalyst's zeolite content can range from less than about 1% by weight to more than about 99% by weight or any range therebetween. However, it is preferably from about 3% by weight to 90% by weight, and more preferably from about 4% by weight to about 80% by weight.
- the catalyst with zeolite included preferably contains no more than about 10 volume percent of micropores.
- the noncrystalline, porous inorganic oxide is preferably a three- dimensional, mesoporous inorganic oxide material containing at least 97 volume percent mesopores (i.e., no more than 3 volume percent micropores) based on micropores and mesopores of the inorganic oxide material (i.e., without any zeolite incorporated therein), and generally at least 98 volume percent mesopores.
- This material is described in U.S. Pat. No. 6,358,486, and it is denoted as TUD-I .
- a method for making a preferred porous inorganic oxide is disclosed in US patent 6,358,486 and U.S. patent application serial No: 10/764,797.
- the main chemical composition of the preferred porous inorganic oxide includes, but is not limited to, silica, alumina, silica-alumina, titanium oxide, zirconium oxide, magnesium oxide and their combination.
- the porous inorganic oxide TUD-I can further comprise vanadium, zinc, copper, gold, gallium, lanthanum, chromium, molybdenum, nickel, cobalt, iron and tungsten.
- TUD-I is a noncrystalline material (i.e., no crystallinity is observed by presently available x-ray diffraction techniques). Its average mesopore size, as determined from N 2 -porosimetry, ranges from about 2 nm to about 25 nm.
- the mesoporous inorganic oxide is generally prepared by heating a mixture of (1) a precursor of the inorganic oxide, and (2) an organic templating agent that mixes well with the oxide precursor or the oxide species generated from the precursor.
- the starting material is generally an amorphous material and may be comprised of one or more inorganic oxides such as silicon oxide or aluminum oxide, with or without additional metal oxides.
- the silicon atoms may be replaced in part by other metal atoms.
- metals include, but are not limited to, aluminum, titanium, vanadium, zirconium, gallium, boron, manganese, zinc, copper, gold, lanthanum, chromium, molybdenum, nickel, cobalt, iron, tungsten, palladium and platinum. These metals can be incorporated into the inorganic oxide inside mesopore wall and/or on the mesopore surface. The additional metals may optionally be incorporated into the material prior to initiating the process for producing a structure that contains mesopores. Also after preparation of the material, cations in the system may optionally be replaced with other ions such as those of an alkali metal (e.g., sodium, potassium, lithium, etc.)
- an alkali metal e.g., sodium, potassium, lithium, etc.
- the organic templating agent a mesopore-forming organic compound
- the organic templating agent has a boiling point of at least about 15O 0 C.
- zeolite In order to incorporate zeolite into the porous inorganic oxide, the preferred process is described in US 6,762,143 and US patent publication 2004/0138051.
- the preformed zeolite and/or pretreated zeolite are suspended in a mixture with water.
- the suspension is mixed with an inorganic oxide or a precursor of an inorganic oxide, and at least one mesopore-forming organic compound to form a mixture.
- the mixture preferably forms gel by ageing and/or stirring at certain temperature from room temperature to 100°C and/or by drying at a temperature from 60-120°C.
- the gel is heated up to a temperature from 140 to 200°C and for a period of time sufficient to form a mesoporous inorganic oxide structure.
- the organic pore-forming agent is removed by extraction or extraction together with calcination to obtain a composition having zeolite incorporated into a noncrystalline, porous inorganic oxide.
- U.S. patent application serial No 10/764,797 discloses a method to prepare the noncrystalline, porous inorganic oxide by using complexes.
- Complexes such as, e.g., silitrane, alumatrane, titanatrane, and particularly, silicon- triethanolamine, aluminum-triethanolamine and their mixture can be used as the precursor of the noncrystalline, porous inorganic oxide.
- silitrane, alumatrane, titanatrane, and particularly, silicon- triethanolamine, aluminum-triethanolamine and their mixture can be used as the precursor of the noncrystalline, porous inorganic oxide.
- a composition having zeolite incorporated into a noncrystalline, porous inorganic oxide (TUD-I) can be obtained.
- the said metal having a hydrogenation function can be introduced into the catalyst in different stages of catalyst preparation.
- the metal can be loaded by conventional impregnation and ion exchange. It is also possible that the metal is introduced into zeolite before zeolite incorporated into the porous inorganic oxide (TUD-I) by impregnation or ion exchange.
- the zeolite/TUD-1 is preferable to be shaped using certain binders, such as alumina. After catalyst shaping, the metal can be introduced to the catalyst.
- the composite zeolite/TUD-1 impregnates with at least one solution containing at least one element from group VIB, VIEB, IB, IEB and VIII.
- Sources of group VIB elements that can be used are well known to the skilled person.
- molybdenum and tungsten sources are oxides and hydroxides, molybdic acids and tungstic acids and their salts, in particular ammonium salts such as ammonium molybdate, ammonium heptamolybdate, ammonium tungstate, phosphomolybdic acid, phosphotungstic acid and their salts, silicomolybdic acid, silicotungstic acid and their salts.
- oxides and ammonium salts are used, such as ammonium molybdate, ammonium heptamolybdate and ammonium metatungstate.
- the sources of the group VIII, VIIB, IB and BOB elements that can be used are well known to the skilled person.
- sources of nonnoble metals are nitrates, sulfates, phosphates, halides, for example chlorides, bromides and fluorides, and carboxylates, for example acetates and carbonates.
- sources of noble metals are halides, for example chlorides, nitrates, acids such as chloroplatmic acid, and oxychlorides such as ammoniacal ruthenium oxychloride.
- the catalysts obtained in the present invention are formed into grains of different shapes and dimensions.
- the catalyst can be used in hydrocracking, hydrotreating, and hydroisomerization, in which all catalysts are bifunctional, combining an acid function and a hydrogenating function. It is important to balance these two functions in a certain process.
- the metal selected from transition metal and noble metal offers hydrogenation function.
- the incorporated zeolite offers acid function.
- the noncrystalline porous oxide, TUD-I can offer acid function and/or hydrogenation function, depending the chemical composition of the oxide.
- the porous oxide is a mixed oxide, silica-alumina, and then it supplies acid function.
- the porous oxide is silica containing nickel and molybdenum; it offers hydrogenation function.
- the porous oxide may not offer any acid and hydrogenation function, for example, if the porous oxide is pure silica. So this novel catalyst has a great deal of flexibility to adjust acid function and hydrogenation function.
- Another important feature of this catalyst offers high mesoporosity by using the noncrystalline porous oxide, significantly enhancing mass-transfer and consequently improves the catalytic performance.
- intraparticle mass-transfer limitations reduce catalyst utilization and lower overall catalytic performance.
- Introduction of mesoporosity will boost the overall catalytic performance.
- many refining processes are using heavy petroleum feeds, which need large pores to facilitate the big molecules into and out the catalytic particles.
- Petroleum feeds can include, for example, undeasphalted petroleum residua, deasphalted petroleum residua, tar sands bitumen, shale oil and coal liquid.
- the noncrystalline, porous oxide TUD-I having mesopores size from 1.5 to 30 run can fulfill the need to enhance the mass-transfer.
- the noncrystalline, porous oxide has not only tunable mesopores, but also has randomly interconnected mesopores.
- its randomly interconnected mesopores structure distinguishes from other mesoporous materials, such as MCM-41.
- the randomly interconnected mesopores reduce the chance of pore blockage compared to the materials with one- or two-dimensional pore system.
- the novel catalyst will have a longevity advantage regarding pore blockage deactivation.
- the catalyst preferably have noncrystalline silica-aluminas as porous material, have zeolites selected from zeoliteY, ZSM-5, zeolite Beta, MCM-56 and/or MCM-22, and have metals selected from group VIII and/or VIB in the periodic table. It is even preferable that, given a significant, heteroatomic poison content in the feed, some metals of group VIB and VIII are in the sulfided or oxysulfided form.
- One conventional sulfiding method which is well known to the skilled person consists of heating in the presence of hydrogen sulfide (pure or, for example, in a stream of a hydrogen/hydrogen sulfide mixture or a nitrogen/hydrogen sulfide mixture) to a temperature in the range 15O 0 C to 800 0 C, preferably in the range 25O 0 C to 600 0 C, generally in a traversed bed reaction zone.
- the hydrocracking process conditions e.g. temperature, pressure, hydrogen circulation rate, and space velocity
- the temperature is generally over 200 0 C, and usually in the range 25O 0 C to 48O 0 C.
- the pressure is over 0.1 MPa and usually over 1 MPa.
- the quantity of hydrogen is a minimum of 50 liters of hydrogen per liter of feed and usually in the range 80 to 5000 liters of hydrogen per liter of feed.
- the hourly space velocity is generally in the range 0.1 to 20 volumes of feed per volume of catalyst per hour.
- Hydrocracking products can include, for example, middle distillates with a boiling range of from about 15O 0 C to about 400 0 C, diesel fuel and lube base oil.
- hydroisomerization catalyst e.g. for upgrading a Fischer-ray
- Tropsch product (disclosed in US 6,570,047), comprises one or more Group VIII catalytic metal components supported on an acidic metal oxide support to give the catalyst both a hydrogenation function and an acid function for hydroisomerizing the hydrocarbons.
- Hydroisomerization conditions typically include a temperature of from about 150 0 C to about 500 0 C, a pressure from about 1 bar to about 240 bars, and a LHSV from about 0.1 to about 20.
- the catalytic metal component may comprise a Group VIII noble metal, such as Pt or Pd, and preferably Pt.
- the catalytic metal component comprise one or more less expensive, non-noble Group VIII metals, such as Co, Ni and Fe, which will typically also include a Group VIB metal (e.g., Mo or W) oxide promoter.
- the catalyst may also have a Group IB metal, such as copper, as a hydrogenolysis suppressant. Phosphorus may also be included to enhance the solubility of the metals and to aid in overall stability.
- the cracking and hydrogenating activity of the catalyst is determined by its specific composition, as is known.
- the present invention provides a preferred catalyst composition having catalytically active metal, e.g. cobalt and molybdenum, the oxide support or carrier including silica, alumina, silica-alumina, silica-alumina-phosphates, titania, zirconia, vanadia, and other Group II, FV 5 V or VI oxides, as well as acidic zeolite, such as zeolite Y (including USY), zeolite Beta and ZSM-5.
- the oxide support or carrier including silica, alumina, silica-alumina, silica-alumina-phosphates, titania, zirconia, vanadia, and other Group II, FV 5 V or VI oxides
- acidic zeolite such as zeolite Y (including USY), zeolite Beta and ZSM-5.
- This example demonstrates the incorporation of zeolite Beta into silica TUD-I .
- 4.6 parts calcined zeolite Beta with a SiO 2 ZAl 2 O 3 molar ratio of 75 and an average particle size of 0.2 ⁇ m were suspended in 51 parts water and stirred for 30 minutes. Then 23 parts triethanolamine were added to the suspension while stirring. After continuous stirring for another 30 minutes, 63.5 parts tetraethyl orthosilicate ("TEOS”) were added. After stirring again for another 30 minutes, 12.6 parts tetraethylammonium hydroxide aqueous solution (35%) were added drop-wise to the mixture. After stirring for about 2 hours, the mixture formed a thick, nonflowing gel.
- TEOS tetraethyl orthosilicate
- This gel was aged at room temperature under static conditions for 24 hours. Next, the gel was dried in air at 100°C for 24 hours. The dried gel was transferred into autoclaves and hydro thermally treated at 180°C for 4 hours. Finally, it was calcined at 600°C for 10 hours in air with a heating rate of l°C/min.
- the XRD pattern of the resultant product, designated as Sample 1 is shown in FIG. 1, which clearly shows two characteristic peaks of zeolite beta. There is about 20wt % zeolite beta in the final composite. Nitrogen adsorption revealed its surface area of about 730 m 2 /g, pore volume of about 1.08 cm 3 /g. The mesopore size distribution of Sample 1 is shown in FIG. 2.
- EXAMPLE 2 [040] The zeolite Beta used here is the same as that in Example 1. First, 12.2 parts zeolite Beta were suspended in 51 parts water and stirred for 30 minutes. Then 23 parts triethanolamine were added to the suspension with stirring. After continuous stirring for another 30 minutes, 63.5 parts TEOS were added. After stirring again for another 30 minutes, 12.7 parts tetraethylammonium hydroxide aqueous solution (35%) were added drop-wise to the mixture. The same procedure was followed as described in Example 1. After calcination, its XRD pattern (corresponding to Sample 2) is shown in FIG. 1, which clearly shows two characteristic peaks of zeolite Beta.
- This example illustrates incorporation of MCM-22.
- 2.4 parts as- synthesized zeolite MCM-22 with a SiO 2 AAl 2 O 3 molar ratio of 6.4 and an average particle size of 2,5 ⁇ m were suspended in 10.5 parts water and stirred for 30 minutes. Then 9.2 parts triethanolamine were added to the above suspension under stirring. After continuous stirring for another 30 minutes, 12.7 parts TEOS were added. After stirring again for another 30 minutes, 2.52 parts tetraethylammonium hydroxide aqueous solution (35%) were added drop-wise to the mixture. After stirring for about 2 hours, the mixture formed a thick, nonflowing gel. This gel was aged at room temperature under static conditions for 24 hours.
- the XRD pattern of the resultant product designated as Sample 4 and shown as the uppermost plot in FIG. 3, clearly shows characteristic peaks of zeolite MCM-22 (middle plot) and mesoporous material (lowest plot). There is about 40wt % zeolite MCM-22 in Sample 4, and elemental analysis confirmed this number based on aluminum content, assuming no aluminum from siliceous mesoporous material.
- Nitrogen adsorption revealed its surface area of about 686 m 2 /g, pore volume of about 0.82 cm 3 /g. Its mesopore size distribution centered around 10 nm in FIG. 4. Argon adsorption showed micropores centered at 0.5 nm.
- the XRD pattern of Sample 5 is shown as the upper plot in FIG. 5, which clearly shows two characteristic peaks of zeolite Y and mesostructure material.
- the lower plot depicts an XRD pattern of zeolite Y.
- Nitrogen adsorption revealed its surface area of about 694 m 2 /g, pore volume of about 1.1 cmVg.
- This example demonstrates catalyst extrusion using alumina as binder.
- the proton form (i.e. H + ) of the Sample 5 was obtained by ion exchange, mixing one part of Composite 5 with ten parts of 1 N ammonium nitrate solution at 6O 0 C for 6 hours while stirring.
- the solid material was filtered, washed and dried at 11O 0 C to get a white powder. After a second ion exchange, the solid material was calcined at 55O 0 C for 6 hours in air.
- This example demonstrates the preparation of silica precursor, silica- triethanolamine complexes.
- 250 parts of silica gel, 697 parts of triethanolamine (TEA) and 286 parts of ethylene glycol (EG) were loaded into a flask equipped with a condenser. After the contents of the flask were mixed well with a mechanical stirrer, the mixture was heated up to 200-210 0 C while stirring. This setup removed most of water generated during reaction together with a small portion of EG from the top of the condenser. Meanwhile, most of the EG and TEA remained in the reaction mixture. After about six hours, heating was stopped; and the reaction mixture was collected after cooling down to 55°C. This reaction mixture was slightly brown, denoted as silica- triethanolamine complexes.
- This example demonstrates the zeolite/TUD-1 preparation using silica- triethanolamine complexes as a silica source.
- the final zeolite/TUD-1 composite contains 45 wt% of zeolite. Nitrogen gas adsorption showed that it has a BET surface area of about 560 m 2 /g, total pore volume of 1.2 cnrVg and average mesopore size of about 5.7 nm.
- Example 6 This is an example showing metals incorporation into the catalyst.
- the extrudate obtained in Example 6 is further functionalized by impregnation with Ni and W.
- Five (5) parts of nickel nitrate aqueous solution (14 wt % Ni) is mixed with 8.4 parts of ammonium metatungstate solution (39.8 wt % W) under stirring.
- the mixture is then diluted with 9 parts of water under stirring.
- 12.5 Parts of extrudate obtained in Example 6 are impregnated with the above Ni/W solution, dried at 118 0 C for 2 hours and calcined at 500 0 C for 2 hours.
- the resulting modified extrudates contains 4.0 wt % of Ni and 18.7 wt % W.
- zeolite/TUD-1 0.3wt% platinum/zeolite-TUD-1 by incipient wetness.
- the zeolite/TUD-1 obtained in Example 2 is impregnated with an aqueous solution comprising 0.42 parts of tetraammine platinum nitrate, 12.5 parts of aqueous solution of tetraammine palladium nitrate (5% Pd) and 43 parts of water. Impregnated zeolite/TUD-1 is aged at room temperature for 5 hours before dried at 90°C for 2 hours. The dried material is finally calcined in air at 350 0 C for 4 hours with a heating rate of l°C/min.
- Noble metal dispersion is measured using CO chemisorption; the powder is then reduced in a hydrogen stream at 100 0 C for 1 hr followed by heating to 35O 0 C at 5°C/min and is maintained at this temperature for 2 hr. A dispersion of 51% is measured for the metal assuming a Pt:CO stoichiometry of 1.
- EXAMPLE Il This example demonstrates catalyst preparation of 0.90wt% iridium/zeolite/TUD-1 by incipient wetness. 0.134 Parts of iridium (III) chloride are dissolved in 5.3 parts of deionized water. This solution is added to 8 parts of zeolite/TUD-1 obtained in Example 4 with mixing. The powder was dried at 25 0 C. [054] For dispersion measurement using CO chemisorption, the powder is then reduced in a hydrogen stream at 100 0 C for 1 hr followed by heating to 35O 0 C at 5°C/min and is maintained at this temperature for 2 hr. CO chemisorption showed a 78% dispersion for the metal assuming an Ir: CO stoichiometry of 1.
- Example 9 This example illustrates the use of the catalyst obtained in Example 9 as a hydrocracking catalyst, which is evaluated for middle distillates selectivity in hydrocracking.
- the evaluation is carried out in a flow reactor with presulfided form (in a conventional way) using a hydrotreated heavy vacuum gas oil as a feedstock. It is operated at LHSV of 1.5 kg /liter hour, total pressure of 140 bar (partial pressure OfH 2 S of 5.5 bar, and a partial pressure of ammonia of 0.075 bar) and a gas/feed ratio of 1500 NL/kg.
- the properties of feedstock are shown in Table 1.
- the composite zeolite/TUD-1 obtained in Example 6 is impregnated with tetraammine platinum nitrate as described in Example 9, and the final catalyst has about 0.6 wt% Pt.
- a typical, deoiled wax feed has the composition shown in Table 2 below. This deoiled wax is obtained from the solvent (MEK) dewaxing of a 300 SUS (65 cst) neutral oil obtained from an Arab Light crude.
- the total liquid product from the hydrocracking step is further upgraded and hydroisomerized by processing over a low acidity Pt/zeolite Beta/TUD-1 catalyst obtained to effectively hydroisomerize and convert most of the unconverted wax to very high quality, very high VI lube oil containing essentially all isoparaffms, primarily singly branched.
- the waxy total liquid product is processed over the catalyst at 400 psia H 2 partial pressure, 2500 SCFfB hydrogen, and 0.5 LHSV over a range of conversion levels.
- the total liquid product is then distilled to a nominal 700° F+ cut- point.
- the waxy bottoms are then solvent dewaxed to produce lube oils having improved lube yield.
- Table 3 contains results of these experiments using zeolite containing hydrocracking catalyst.
Abstract
Description
Claims
Priority Applications (5)
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EP05797636A EP1791640A2 (en) | 2004-09-07 | 2005-09-07 | Hydroprocessing catalyst with zeolite and high mesoporosity |
CA002579228A CA2579228A1 (en) | 2004-09-07 | 2005-09-07 | Hydroprocessing catalyst with zeolite and high mesoporosity |
BRPI0514985-1A BRPI0514985A (en) | 2004-09-07 | 2005-09-07 | zeolite and high mesoporosity hydroprocess catalyst |
JP2007530469A JP2008512231A (en) | 2004-09-07 | 2005-09-07 | Zeolite and hydrogenation catalyst with high mesoporosity |
IL181780A IL181780A0 (en) | 2004-09-07 | 2007-03-07 | Hydroprocessing catalyst with zeolite and high mesoporosity |
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Also Published As
Publication number | Publication date |
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IN2007MU00366A (en) | 2007-07-20 |
CA2579228A1 (en) | 2006-03-16 |
RU2007112928A (en) | 2008-10-20 |
KR20070073758A (en) | 2007-07-10 |
WO2006029137A3 (en) | 2006-04-20 |
EP1791640A2 (en) | 2007-06-06 |
CN101035618A (en) | 2007-09-12 |
JP2008512231A (en) | 2008-04-24 |
BRPI0514985A (en) | 2008-07-01 |
IL181780A0 (en) | 2007-07-04 |
RU2362623C2 (en) | 2009-07-27 |
SG155886A1 (en) | 2009-10-29 |
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