US20050109679A1 - Process for making lube oil basestocks - Google Patents
Process for making lube oil basestocks Download PDFInfo
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- US20050109679A1 US20050109679A1 US10/949,483 US94948304A US2005109679A1 US 20050109679 A1 US20050109679 A1 US 20050109679A1 US 94948304 A US94948304 A US 94948304A US 2005109679 A1 US2005109679 A1 US 2005109679A1
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- 239000010687 lubricating oil Substances 0.000 title claims abstract description 53
- 238000000034 method Methods 0.000 title claims abstract description 50
- 239000003054 catalyst Substances 0.000 claims abstract description 159
- 238000009835 boiling Methods 0.000 claims abstract description 17
- 229910052751 metal Inorganic materials 0.000 claims description 56
- 239000002184 metal Substances 0.000 claims description 56
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 36
- 239000003921 oil Substances 0.000 claims description 28
- 239000011148 porous material Substances 0.000 claims description 21
- 229910052757 nitrogen Inorganic materials 0.000 claims description 18
- 229910000510 noble metal Inorganic materials 0.000 claims description 15
- 239000000203 mixture Substances 0.000 claims description 14
- 238000006243 chemical reaction Methods 0.000 claims description 13
- 239000002245 particle Substances 0.000 claims description 13
- 239000001257 hydrogen Substances 0.000 claims description 12
- 229910052739 hydrogen Inorganic materials 0.000 claims description 12
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 11
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 claims description 10
- 239000011593 sulfur Substances 0.000 claims description 10
- 229910052717 sulfur Inorganic materials 0.000 claims description 10
- 239000007789 gas Substances 0.000 claims description 9
- 150000002739 metals Chemical class 0.000 claims description 9
- 239000002904 solvent Substances 0.000 claims description 9
- 229910052721 tungsten Inorganic materials 0.000 claims description 9
- 239000001993 wax Substances 0.000 claims description 9
- 229910052750 molybdenum Inorganic materials 0.000 claims description 8
- -1 VIB metals Chemical class 0.000 claims description 7
- 150000001875 compounds Chemical class 0.000 claims description 7
- 239000007788 liquid Substances 0.000 claims description 7
- 238000004821 distillation Methods 0.000 claims description 6
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 5
- 239000000463 material Substances 0.000 claims description 5
- 230000005540 biological transmission Effects 0.000 claims description 4
- 239000012530 fluid Substances 0.000 claims description 4
- 229910044991 metal oxide Inorganic materials 0.000 claims description 4
- 150000004706 metal oxides Chemical class 0.000 claims description 4
- 238000007670 refining Methods 0.000 claims description 4
- 210000002683 foot Anatomy 0.000 claims description 3
- 229910052500 inorganic mineral Inorganic materials 0.000 claims description 3
- 239000011707 mineral Substances 0.000 claims description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims 4
- 229910020630 Co Ni Inorganic materials 0.000 claims 2
- 239000000377 silicon dioxide Substances 0.000 claims 2
- 230000000694 effects Effects 0.000 description 11
- PXHVJJICTQNCMI-UHFFFAOYSA-N nickel Substances [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 9
- 239000000047 product Substances 0.000 description 8
- 241000475481 Nebula Species 0.000 description 6
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 6
- 239000010937 tungsten Substances 0.000 description 6
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 5
- 239000011733 molybdenum Substances 0.000 description 5
- 229910052759 nickel Inorganic materials 0.000 description 4
- 230000008901 benefit Effects 0.000 description 3
- 238000004517 catalytic hydrocracking Methods 0.000 description 3
- 229910017052 cobalt Inorganic materials 0.000 description 3
- 239000010941 cobalt Substances 0.000 description 3
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 3
- 238000001816 cooling Methods 0.000 description 3
- 150000001336 alkenes Chemical class 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 2
- 239000002244 precipitate Substances 0.000 description 2
- 238000001179 sorption measurement Methods 0.000 description 2
- 229910003294 NiMo Inorganic materials 0.000 description 1
- UCKMPCXJQFINFW-UHFFFAOYSA-N Sulphide Chemical compound [S-2] UCKMPCXJQFINFW-UHFFFAOYSA-N 0.000 description 1
- 230000004913 activation Effects 0.000 description 1
- 239000002199 base oil Substances 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 239000000498 cooling water Substances 0.000 description 1
- 239000011258 core-shell material Substances 0.000 description 1
- 238000006477 desulfuration reaction Methods 0.000 description 1
- 230000023556 desulfurization Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 125000005842 heteroatom Chemical group 0.000 description 1
- 150000002431 hydrogen Chemical class 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000002480 mineral oil Substances 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 238000002459 porosimetry Methods 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 239000002002 slurry Substances 0.000 description 1
- 238000000638 solvent extraction Methods 0.000 description 1
- 150000003464 sulfur compounds Chemical class 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
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- B01J35/19—
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
- B01J23/76—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36
- B01J23/84—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with metals, oxides or hydroxides provided for in groups B01J23/02 - B01J23/36 with arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
- B01J23/85—Chromium, molybdenum or tungsten
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- 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
- C10G45/00—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds
- C10G45/02—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing
- C10G45/04—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used
- C10G45/06—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used containing nickel or cobalt metal, or compounds thereof
- C10G45/08—Refining of hydrocarbon oils using hydrogen or hydrogen-generating compounds to eliminate hetero atoms without changing the skeleton of the hydrocarbon involved and without cracking into lower boiling hydrocarbons; Hydrofinishing characterised by the catalyst used containing nickel or cobalt metal, or compounds thereof in combination with chromium, molybdenum, or tungsten metals, or compounds thereof
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- 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
- C10G65/00—Treatment of hydrocarbon oils by two or more hydrotreatment processes only
- C10G65/02—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only
- C10G65/04—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only including only refining steps
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- 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
- C10G65/00—Treatment of hydrocarbon oils by two or more hydrotreatment processes only
- C10G65/02—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only
- C10G65/04—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only including only refining steps
- C10G65/08—Treatment of hydrocarbon oils by two or more hydrotreatment processes only plural serial stages only including only refining steps at least one step being a hydrogenation of the aromatic hydrocarbons
-
- B01J35/647—
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- 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
- C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
- C10G2300/10—Feedstock materials
- C10G2300/1022—Fischer-Tropsch products
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- 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
Abstract
A process for producing lube oil basestocks involving contacting a wax containing feedstock with a stacked bed catalyst system thereby producing a lube oil boiling range basestock.
Description
- This application claims benefit of U.S. Provisional Patent Application Ser. No. 60/518,739 filed Nov. 10, 2003 and Ser. No. 60/608,447 filed Sep. 9, 2004.
- This invention relates to a process for preparing lubricating oil basestocks from lube oil boiling range feedstreams. More particularly, the present invention is directed at a process wherein a wax containing feedstock is hydrotreated over a stacked bed catalyst system thereby producing a lube oil boiling range basestock.
- It has long been recognized that one of the most valuable products generated through the refining of crude mineral oils is lubricating oils. It is common practice to recover lubricating oil basestocks by solvent extracting, with a selective solvent, undesirable components such as sulfur compounds, oxygenated compounds, and aromatics from straight distillates. However, with the decline in the availability of paraffinic base crudes, and a corresponding increase in the proportion of naphthenic and asphaltic base crudes, it is becoming increasingly difficult to meet the demand for lubricating oil basestocks, or base oils. For example, American Petroleum Institute (API) requirements for Group II basestocks include a saturates content of at least 90%, a sulfur content of 0.03 wt. % or less and a viscosity index (VI) between 80 and 120. Thus, there is a trend in the lube oil market to use Group II basestocks instead of Group I basestocks in order to meet the demand for higher quality basestocks that provide for increased fuel economy, reduced emissions, etc.
- Conventional techniques for preparing basestocks such as hydrocracking or solvent extraction require severe operating conditions such as high pressure and temperature or high solvent:oil ratios and high extraction temperatures to reach these higher basestock qualities. Either alternative involves expensive operating conditions and low yields.
- Hydrocracking has been combined with hydrotreating as a preliminary step. However, this combination also results in decreased yields of lubricating oils due to the conversion to distillates that typically accompany the hydrocracking process.
- Thus, as the demand for quality lube oil basestock continues to increase, the search for new and different processes, catalysts, and catalyst systems that exhibit improved activity, increased yields, selectivity and/or longevity is a continuous, ongoing exercise. Therefore, there is a need in the lube oil market to provide processes that can produce lube oil basestocks that meet the demand for increased fuel economy, reduced emissions, etc.
- The FIGURE is a plot of the relative volume activity of various catalysts and catalyst systems versus the days the respective catalysts and catalyst systems were on stream.
- The present invention is directed at a process to prepare lubricating oil basestocks from lube oil boiling range feedstocks. The process comprises:
-
- a) contacting a lube oil boiling range feedstock with a stacked bed hydrotreating catalyst system in a reaction stage operated under effective conditions thereby producing a hydrotreated effluent comprising at least a gaseous product and a hydrotreated lubricating oil boiling range feedstock; and
- b) stripping the hydrotreated effluent to remove at least a portion of the gaseous product from the hydrotreated effluent thereby producing at least a lubricating oil basestock.
- In one embodiment of the instant invention, the stacked bed hydrotreating catalyst system comprises a first and second catalyst, the first catalyst comprising a conventional hydrotreating catalyst having an average pore diameter of greater than about 10 nm and said second catalyst comprises a bulk metal hydrotreating catalyst.
- It should be noted that the terms “feedstock” and “feedstream” as used herein are synonymous.
- The present process involves hydrotreating a lubricating oil feedstock with a stacked bed hydrotreating catalyst system in a reaction stage operated under effective hydrotreating conditions to produce a hydrotreated effluent comprising at least a gaseous product and a hydrotreated lubricating oil feedstock. The hydrotreated effluent is stripped to remove at least a portion of the gaseous product from the hydrotreated effluent thereby producing at least a lubricating oil basestock. Lube oil basestocks having a saturates content of at least 90%, a sulfur content of 0.03 wt. % or less, and a viscosity index (VI) between 80 and 120 can readily be produced through the use of the instant invention.
- Lubricating Oil Feedstocks
- Feedstocks suitable for use in the present invention are wax-containing feeds that boil in the lubricating oil range, typically having a 10% distillation point greater than 650° F. (343° C.) and an endpoint greater than 800° F. (426° C.), measured by ASTM D 86 or ASTM 2887. These feedstocks can be derived from mineral sources, synthetic sources, or a mixture of the two. Non-limiting examples of suitable lubricating oil feedstocks include those derived from sources such as oils derived from solvent refining processes such as raffinates, partially solvent dewaxed oils, deasphalted oils, distillates, vacuum gas oils, coker gas oils, slack waxes, foots oils and the like, dewaxed oils, automatic transmission fluid feedstocks, and Fischer-Tropsch waxes. Automatic transmission fluid (“ATF”) feedstocks are lube oil feedstocks having an initial boiling point between about 200° C. and 275° C., and a 10% distillation point greater than about 300° C. ATF feedstocks are typically 75-110N feedstocks.
- These feedstocks may also have high contents of nitrogen- and sulfur-contaminants. Feeds containing up to 0.2 wt. % of nitrogen, based on feed and up to 3.0 wt. % of sulfur can be processed in the present process. Feeds having a high wax content typically have high viscosity indexes of up to 200 or more. Sulfur and nitrogen contents may be measured by standard ASTM methods D5453 and D4629, respectively.
- Hydrotreating
- It should be noted that the term “hydrotreating” as used herein refers to processes wherein a hydrogen-containing treat gas is used in the presence of a suitable catalyst that is primarily active for the removal of heteroatoms, such as sulfur, and nitrogen, and saturation of aromatics. In the practice of the present invention, the lubricating oil feedstock is hydrotreated with a stacked bed hydrotreating catalyst system in a reaction stage operated under effective hydrotreating conditions to produce a hydrotreated effluent comprising at least a gaseous product and a hydrotreated lubricating oil feedstock.
- The catalyst system used herein comprises at least a first and second hydrotreating catalyst. By “stacked bed” it is meant that the first catalyst appears in a separate catalyst bed, reactor, or reaction zone, and the second hydrotreating catalyst appears in a separate catalyst bed, reactor, or reaction zone downstream, in relation to the flow of the lubricating oil feedstock, from the first catalyst.
- The first hydrotreating catalyst is a supported catalyst. Suitable hydrotreating catalysts for use as the first catalyst of the present catalyst system include any conventional hydrotreating catalyst. Conventional hydrotreating catalyst as used herein is meant to refer to those which are comprised of at least one Group VIII metal, preferably Fe, Co and Ni, more preferably Co and/or Ni, and most preferably Ni; and at least one Group VI metal, preferably Mo and W, more preferably Mo, on a high surface area support material, preferably alumina. The Group VIII metal is typically present in an amount ranging from about 2 to 20 wt. %, preferably from about 4 to 12%. The Group VI metal will typically be present in an amount ranging from about 5 to 50 wt. %, preferably from about 10 to 40 wt. %, and more preferably from about 20 to 30 wt. %. All metals weight percents are on support. By “on support” we mean that the percents are based on the weight of the support. For example, if the support were to weigh 100 g. then 20 wt. % Group VIII metal would mean that 20 g. of Group VIII metal was on the support.
- However, not all conventional hydrotreating catalysts fitting the above-described criteria are suitable for use in the present invention. The inventors hereof have unexpectedly found that the average pore diameter of the first catalyst must have a specific size to be suitable for use herein. Thus, in the practice of the present invention, a conventional catalyst, as described above, but having an average pore diameter greater than 10 nm, as measured by water adsorption porosimetry, must be used as the first catalyst of the present stacked bed catalyst system. It is preferred that the average pore diameter of the first catalyst, i.e. the conventional hydrotreating catalyst, of the present stacked bed catalyst system be greater than 11 nm, more preferably greater than 12 nm.
- The second hydrotreating catalyst is a bulk metal catalyst. By bulk metal, it is meant that the catalysts are unsupported wherein the bulk catalyst particles comprise 30-100 wt. % of at least one Group VIII non-noble metal and at least one Group VIB metal, based on the total weight of the bulk catalyst particles, calculated as metal oxides and wherein the bulk catalyst particles have a surface area of at least 10 m2/g. It is furthermore preferred that the bulk metal hydrotreating catalysts used herein comprise about 50 to about 100 wt. %, and even more preferably about 70 to about 100 wt. %, of at least one Group VIII non-noble metal and at least one Group VIB metal, based on the total weight of the particles, calculated as metal oxides. The amount of Group VIB and Group VIII non-noble metals can easily be determined VIB TEM-EDX.
- Bulk catalyst compositions comprising one Group VIII non-noble metal and two Group VIB metals are preferred. It has been found that in this case, the bulk catalyst particles are sintering-resistant. Thus the active surface area of the bulk catalyst particles is maintained during use. The molar ratio of Group VIB to Group VIII non-noble metals ranges generally from 10:1-1:10 and preferably from 3:1-1:3. In the case of a core-shell structured particle, these ratios of course apply to the metals contained in the shell. If more than one Group VIB metal is contained in the bulk catalyst particles, the ratio of the different Group VIB metals is generally not critical. The same holds when more than one Group VIII non-noble metal is applied. In the case where molybdenum and tungsten are present as Group VIB metals, the molybenum:tungsten ratio preferably lies in the range of 9:1-1:9. Preferably the Group VIII non-noble metal comprises nickel and/or cobalt. It is further preferred that the Group VIB metal comprises a combination of molybdenum and tungsten. Preferably, combinations of nickel/molybdenum/tungsten and cobalt/molybdenum/tungsten and nickel/cobalt/molybdenum/tungsten are used. These types of precipitates appear to be sinter-resistant. Thus, the active surface area of the precipitate is remained during use. The metals are preferably present as oxidic compounds of the corresponding metals, or if the catalyst composition has been sulfided, sulfidic compounds of the corresponding metals.
- It is also preferred that the bulk metal hydrotreating catalysts used herein have a surface area of at least 50 m2/g and more preferably of at least 100 m2/g. It is also desired that the pore size distribution of the bulk metal hydrotreating catalysts be approximately the same as the one of conventional hydrotreating catalysts. More in particular, these bulk metal hydrotreating catalysts have preferably a pore volume of 0.05-5 ml/g, more preferably of 0.1-4 ml/g, still more preferably of 0.1-3 ml/g and most preferably 0.1-2 ml/g determined by nitrogen adsorption. Preferably, pores smaller than 1 nm are not present. Furthermore these bulk metal hydrotreating catalysts preferably have a median diameter of at least 50 nm, more preferably at least 100 nm, and preferably not more than 5000 μm and more preferably not more than 3000 μn. Even more preferably, the median particle diameter lies in the range of 0.1-50 μm and most preferably in the range of 0.5-50 μm.
- The reaction stage containing the stacked bed hydrotreating catalyst system used in the present invention can be comprised of one or more fixed bed reactors or reaction zones each of which can comprise one or more catalyst beds of the same or different catalyst. Although other types of catalyst beds can be used, fixed beds are preferred. Such other types of catalyst beds include fluidized beds, ebullating beds, slurry beds, and moving beds. Interstage cooling or heating between reactors, reaction zones, or between catalyst beds in the same reactor, can be employed since some olefin saturation can take place, and olefin saturation and the desulfurization reaction are generally exothermic. A portion of the heat generated during hydrotreating can be recovered. Where this heat recovery option is not available, conventional cooling may be performed through cooling utilities such as cooling water or air, or through use of a hydrogen quench stream. In this manner, optimum reaction temperatures can be more easily maintained.
- The catalyst system of the present invention comprises about 5-95 vol. % of the first catalyst with the second catalyst comprising the remainder, preferably about 40-60 vol. %, more preferably about 5 to about 50 vol. %. Thus, if the catalyst system comprises 50 vol. % of the first catalyst, the second catalyst will comprise 50 vol. % also.
- Effective hydrotreating conditions include temperatures of from 150 to 400° C., a hydrogen partial pressure of from 1480 to 20786 kPa (200 to 3000 psig), a space velocity of from 0.1 to 10 liquid hourly space velocity (LHSV), and a hydrogen to feed ratio of from 89 to 1780 m3/m3 (500 to 10000 scf/B).
- As stated above, the contacting of the lube oil boiling range feedstock with the stacked bed hydrotreating catalyst system produces a hydrotreated effluent comprising at least a gaseous product and a hydrotreated lubricating oil feedstock. The hydrotreated effluent is stripped to remove at least a portion of the gaseous product from the hydrotreated effluent thereby producing at least a lubricating oil basestock The means used herein to strip the hydrotreated effluent is not critical to the present invention. Thus, any stripping method, process, or means known can be used. Non-limiting examples of suitable stripping methods, means, and processes include flash drums, fractionators, knock-out drums, steam stripping, etc.
- The above description is directed to preferred embodiments of the present invention. Those skilled in the art will recognize that other embodiments that are equally effective could be devised for carrying out the spirit of this invention.
- The following examples will illustrate the improved effectiveness of the present invention, but is not meant to limit the present invention in any fashion.
- A medium vacuum gas oil having the properties outlined in Table 1 was processed in an isothermal pilot plant over three catalysts systems at 1200 psig hydrogen partial pressure. The catalyst systems and operating conditions are given in Table 2. Catalyst B is a conventional hydrotreating catalyst having about 4.5 wt. % Group VI metal, about 23 wt. % Group VIII metal on an alumina support and has an average pore size of 14.0 nm. The bulk metal hydrotreating catalyst was a commercial bulk metal hydrotreating catalyst marketed under the name Nebula by Akzo-Nobel.
- In the Examples, all the catalyst systems were lined out at about 50 days on stream. A first order kinetic model with an activation energy of 31,000 cal/gmol was used to compare volume activities between the catalysts.
TABLE 1 Medium Vacuum Gas Oil Density at 70° C. (g/cc) 0.88 Nitrogen (wppm) 700 Sulfur (wt. %) 2.6 GCD 5 WT % Boiling Point (° C.) 334 GCD 50 WT % Boiling Point (° C.)441 GCD 95 WT % Boiling Point (° C.) 531 -
TABLE 2 50 vol. % Catalyst B 100 vol. % 100 vol. % followed by Catalyst System Catalyst B Nebula 1 50 vol. % Nebula 1 Average Catalyst 370 380 370 Temperature (° C.) Liquid Hourly 2 1 1 Space Velocity (hr−1) Stripped reactor 227 17 34 Effluent Nitrogen Content (wppm) Nitrogen Removal 1 1.18 1.34 Relative Volume Activity - The Nitrogen Removal Relative Volume Activity (“RVA”) for each catalyst system was calculated by simple first order kinetic modeling. As shown in Table 2, the 50/50 vol. % stacked bed catalyst system, with the large average pore size Catalyst B upstream of the bulk metal catalyst, showed higher nitrogen removal activity than either of the single catalyst systems demonstrated on their own.
- The hydrotreating ability of different stacked beds of Catalyst B and Nebula were analyzed by hydrotreating different feedstreams over the stacked beds in the in two parallel reactor trains of the same isothermal pilot plant unit used in Example 1 above. The feedstreams used were Medium Cycle Oils (“MCO”) from an FCC unit and blends of the MCO with a virgin feedstock were tested in two parallel reactor trains. The feed properties are described in Table 3, below.
- In this Example, one reactor train consisted entirely of a conventional NiMo on Alumina hydrotreating catalyst, Catalyst C, with an average pore diameter of 7.5 nm. The other reactor train contained a stacked bed system with 75-vol. % of Catalyst C followed by 25-vol. % of Catalyst A, a bulk multimetallic sulfide catalyst having an average pore diameter of 5.5 nm.
- The separate reactors in both trains were immersed in a fluidized sandbath for efficient heat transfer. Thus, the temperature of the first 75-vol. % of Catalyst C was at the same temperature whether it was in train 1 or 2. Likewise, the last 25-vol. % of Catalyst C in train 1 was at the same temperature as the last 25-vol. % of Catalyst A in train 2. Therefore, In Example 2, each of the two reactor trains was divided into two separate reactor vessels where the temperature of the first 75-volume % containing 75 vol. % of the catalyst loading of that reactor could be independently controlled from the last 25-volume % of catalyst.
- The operating conditions for the two trains were 1350 psig H2, liquid hourly space velocities (“LHSV”) of 1.4 vol./hr/vol., and 5500-6300 SCF/B of hydrogen. The temperature schedule for both trains is described in Table 4 below.
TABLE 3 FEED 50% 67% 100% 100% Normal Normal Normal Heavy FCC MCO FCC MCO FCC MCO FCC MCO API Gravity 18.1 15.0 9.5 7.0 Hydrogen, 10.65 10.04 8.77 8.61 wt. % Sulfur, wt. % 3.23 3.53 4.28 4.40 Nitrogen, ppm 959 1153 1485 1573 Aromatics- — — 12.0 8.8 Mono, wt. % Aromatics-Di, — — 43.9 41.7 wt. % Aromatics- — — 22.4 30.7 Poly, wt. % Distillation, D2887 GCD 10 498 493 485 493 50 627 625 618 642 90 703 705 706 749 95 726 721 724 777 -
TABLE 4 Days on Oil Feedstock 75%/25% Temperatures, ° F. 4-6 50% FCC MCO 585/650 7-15 67% FCC MCO 585/650 16-30 100% FCC MCO 585-610/650-675 31-50 100% Heavy FCC MCO 610-635/675-700 - The relative HDN volume activity of the stacked bed Catalyst C/Catalyst A compared to Catalyst A is shown in the FIGURE below. Note that for the 50%, 67% and 100% FCC MCO feeds the stacked bed system with only 25-volume % of catalyst A shows a stable activity advantage of about 275%.
- As shown in the FIGURE, when the 100% Heavy FCC MCO was used as the feed note the activity advantage for the stacked bed catalyst system containing begins to decrease from about 275% to about 225% and then was subsequently reduced over about 20 days to slightly less than 150%.
- In this Example, a stacked bed catalyst system containing 75 vol. % of Catalyst B and 25 vol. % Nebula, both as described above, was used to hydrotreat a light cycle cat oil feed (“Feed A”) and a heavier medium cycle cat oil feed (“Feed B”) as described in Table 5 below. Example 2 was conducted in the same two reactor train pilot plant unit as described in Example 2 above. The operating conditions for the two trains were 1200 psig H2, liquid hourly space velocities of 2 vol./hr/vol., and 5000 SCF/B of hydrogen.
- The reactor effluents were stripped with nitrogen in an oven at 100° C. to remove substantially all of the gaseous reaction products. The nitrogen content of the liquid reactor effluent was then analyzed by ASTM 4629. The temperature schedules for both trains along with the results of this example are described in Table 5 below.
TABLE 5 FEED Feed A Feed B API Gravity 0.973 0.9 Sulfur, wt. % 2.6 2.50 Nitrogen, ppm 713 742 Distillation, D2887 GCD 5 427 448 50 551 590 95 707 755 EP 764 823 Catalyst B Temperature 570 617 Nebula Temperature 645 692 Stripped Reactor Effluent 2 7 Nitrogen Content Nitrogen Removal Relative 1.75 1.75 Volume Activity - As can be seen in Table 5, when a conventional catalyst having an average pore diameter of 14 nm was used in the first 75 vol. % of the reactor, the Nitrogen Removal Relative Volume Activity (“RVA”) for the catalyst system remained constant when the heavier feed was used. In comparing the results of Example 3 to those obtained in Example 2, one can see that when a catalyst having a pore volume of 7.5 nm preceded the bulk metal catalyst, the RVA of the catalyst system decreased. However, in Example 3, the heavier feed did not negatively impact the RVA of the catalyst system.
Claims (31)
1. A process to prepare lubricating oil basestocks from a lube oil boiling range feedstock comprising:
a) contacting a lube oil boiling range feedstock with a stacked bed hydrotreating catalyst system in a reaction stage operated under effective hydrotreating conditions thereby producing a hydrotreated effluent comprising at least a gaseous product and a hydrotreated lubricating oil boiling range feedstock; and
b) stripping the hydrotreated effluent to remove at least a portion of the gaseous product from the hydrotreated effluent thereby producing at least a lubricating oil basestock.
2. The process according to claim 1 wherein said lubricating oil feedstock has a 10% distillation point greater than 650° F. (343° C.) and an endpoint of greater than 800° F. (426° C.), measured by ASTM D 86 or ASTM 2887, and are derived from mineral sources, synthetic sources, or a mixture of the two.
3. The process according to claim 2 wherein said lubricating oil feedstock is selected from those derived from sources such as oils derived from solvent refining processes such as raffinates, partially solvent dewaxed oils, deasphalted oils, distillates, vacuum gas oils, coker gas oils, slack waxes, foots oils and the like, dewaxed oils, automatic transmission fluid feedstocks, and Fischer-Tropsch waxes.
4. The process according to claim 2 wherein said lubricating oil feedstock contains up to 0.2 wt. % of nitrogen, based on the lubricating oil feedstock, and up to 3.0 wt. % of sulfur, based on the lubricating oil feedstock.
5. The process according to claim 1 wherein said catalyst system comprises at least a first and second hydrotreating catalyst.
6. The process according to claim 5 wherein said first hydrotreating catalyst is selected from supported hydrotreating catalysts comprising about 2 to 20 wt. % of at least one Group VIII metal, and about 5 to 50 wt. % of at least one Group VI metal on a high surface area support material having an average pore diameter of greater than 10 nm.
7. The process according to claim 6 wherein said Group VIII metal is selected from Co Ni, and mixtures thereof, said Group VI metal is selected from Mo, W, and mixtures thereof, and said high surface area support material is selected from silica, alumina, and mixtures thereof.
8. The process according to claim 5 wherein said second catalyst is a bulk metal hydrotreating catalyst comprising about 30 to about 100 wt. % of at least one Group VIII non-noble metal and at least one Group VIB metal, based on the total weight of the bulk catalyst particles, calculated as metal oxides and wherein the bulk catalyst particles have a surface area of at least 10 m2/g.
9. The process according to claim 8 wherein said bulk metal hydrotreating catalyst comprises one Group VIII non-noble metal and two Group VIB metals wherein the molar ratio of Group VIB to Group VIII non-noble metals ranges from 10:1-1:10.
10. The process according to claim 8 wherein the at least one Group VIII non-noble metal and at least one Group VIB metals are present as oxidic compounds of the corresponding metals, or if the catalyst composition has been sulfided, sulfidic compounds of the corresponding metals
11. The process according to claim 10 wherein the bulk metal hydrotreating catalysts have a surface area of at least 50 m2/g, a pore size volume of about 0.05 to about 5 ml/g, and a median diameter of at least 50 nm.
12. The process according to claim 1 wherein said effective hydrotreating conditions include temperatures of from 150 to 400° C., a hydrogen partial pressure of from 1480 to 20786 kPa (200 to 3000 psig), a space velocity of from 0.1 to 10 liquid hourly space velocity (LHSV), and a hydrogen to feed ratio of from 89 to 1780 m3/m3 (500 to 10000 scf/B).
13. The process according to claim 5 wherein the catalyst system of the present invention comprises about 5-95 vol. % of the first hydrotreating catalyst with the second hydrotreating catalyst comprising the remainder.
14. The process according to claim 6 wherein said first hydrotreating catalyst has an average pore diameter of greater than 11 nm.
15. The process according to claim 6 wherein said first hydrotreating catalyst has an average pore diameter of greater than 12 nm.
16. The process according to claim 5 wherein the catalyst system of the present invention comprises about 40-60 vol. % of the first catalyst with the second hydrotreating catalyst comprising the remainder.
17. The process according to claim 5 wherein the catalyst system of the present invention comprises about 5-50 vol. % of the first catalyst with the second hydrotreating catalyst comprising the remainder.
18. A process to prepare lubricating oil basestocks from a lube oil boiling range feedstock comprising:
a) contacting a lube oil boiling range feedstock with a stacked bed hydrotreating catalyst system comprising at least a first and second hydrotreating catalyst in a reaction stage operated under effective hydrotreating conditions thereby producing a hydrotreated effluent comprising at least a gaseous product and a hydrotreated lubricating oil boiling range feedstock; and
b) stripping the hydrotreated effluent to remove at least a portion of the gaseous product from the hydrotreated effluent thereby producing at least a lubricating oil basestock;
wherein said first hydrotreating catalyst is selected from supported hydrotreating catalysts comprising about 2 to 20 wt. % of at least one Group VIII metal, and about 5 to 50 wt. % of at least one Group VI metal on a high surface area support material having an average pore diameter of greater than 10 nm and said second hydrotreating catalyst is selected from bulk metal hydrotreating catalyst comprising about 30 to about 100 wt. % of at least one Group VIII non-noble metal and at least one Group VIB metal, based on the total weight of the bulk catalyst particles, calculated as metal oxides and wherein the bulk catalyst particles have a surface area of at least 10 m2/g.
19. The process according to claim 18 wherein said lubricating oil feedstock has a 10% distillation point greater than 650° F. (343° C.) and an endpoint of greater than 800° F. (426° C.), measured by ASTM D 86 or ASTM 2887, and are derived from mineral sources, synthetic sources, or a mixture of the two.
20. The process according to claim 19 wherein said lubricating oil feedstock is selected from those derived from sources such as oils derived from solvent refining processes such as raffinates, partially solvent dewaxed oils, deasphalted oils, distillates, vacuum gas oils, coker gas oils, slack waxes, foots oils and the like, dewaxed oils, automatic transmission fluid feedstocks, and Fischer-Tropsch waxes.
21. The process according to claim 19 wherein said lubricating oil feedstock contains up to 0.2 wt. % of nitrogen, based on the lubricating oil feedstock, and up to 3.0 wt. % of sulfur, based on the lubricating oil feedstock.
22. The process according to claim 18 wherein said Group VIII metal of said first hydrotreating catalyst is selected from Co Ni, and mixtures thereof, said Group VI metal of said first hydrotreating catalyst is selected from Mo, W, and mixtures thereof, and high surface area support material is selected from silica, alumina, and mixtures thereof.
23. The process according to claim 18 wherein said bulk metal hydrotreating catalyst comprises one Group VIII non-noble metal and two Group VIB metals wherein the molar ratio of Group VIB to Group VIII non-noble metals ranges from 10:1-1:10.
24. The process according to claim 23 wherein the at least one Group VIII non-noble metal and at least one Group VIB metals are present as oxidic compounds of the corresponding metals, or if the catalyst composition has been sulfided, sulfidic compounds of the corresponding metals.
25. The process according to claim 18 wherein the bulk metal hydrotreating catalysts have a surface area of at least 50 m2/g, a pore size volume of about 0.05 to about 5 ml/g, and a median diameter of at least 50 nm.
26. The process according to claim 18 wherein said effective hydrotreating conditions include temperatures of from 150 to 400° C., a hydrogen partial pressure of from 1480 to 20786 kPa (200 to 3000 psig), a space velocity of from 0.1 to 10 liquid hourly space velocity (LHSV), and a hydrogen to feed ratio of from 89 to 1780 m3/m3 (500 to 10000 scf/B).
27. The process according to claim 18 wherein the catalyst system of the present invention comprises about 5-95 vol. % of the first hydrotreating catalyst with the second hydrotreating catalyst comprising the remainder.
28. The process according to claim 18 wherein said first hydrotreating catalyst has an average pore diameter of greater than 11 nm.
29. The process according to claim 18 wherein said first hydrotreating catalyst has an average pore diameter of greater than 12 nm.
30. The process according to claim 27 wherein the catalyst system of the present invention comprises about 40-60 vol. % of the first hydrotreating catalyst with the second hydrotreating catalyst comprising the remainder.
31. The process according to claim 18 wherein the catalyst system of the present invention comprises about 5-50 vol. % of the first hydrotreating catalyst with the second hydrotreating catalyst comprising the remainder.
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EP (1) | EP1685213B1 (en) |
JP (1) | JP2007510797A (en) |
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EP2414098A1 (en) * | 2009-03-31 | 2012-02-08 | ExxonMobil Research and Engineering Company | A hydrotreating catalyst system suitable for use in hydrotreating hydrocarbonaceous feedstreams |
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP2414098A1 (en) * | 2009-03-31 | 2012-02-08 | ExxonMobil Research and Engineering Company | A hydrotreating catalyst system suitable for use in hydrotreating hydrocarbonaceous feedstreams |
EP2414098A4 (en) * | 2009-03-31 | 2013-01-23 | Exxonmobil Res & Eng Co | A hydrotreating catalyst system suitable for use in hydrotreating hydrocarbonaceous feedstreams |
Also Published As
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AU2004288902A1 (en) | 2005-05-26 |
NO20062680L (en) | 2006-06-09 |
JP2007510797A (en) | 2007-04-26 |
CA2544208A1 (en) | 2005-05-26 |
WO2005047432A1 (en) | 2005-05-26 |
NO341108B1 (en) | 2017-08-28 |
EP1685213A1 (en) | 2006-08-02 |
EP1685213B1 (en) | 2015-03-04 |
CA2544208C (en) | 2013-05-07 |
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