Reverse-graded catalyst systems for hydrodemetalation and hydrodesulfurization
AssigneeChevron Research Company
InventorsDonald F. Byrne, David R. Johnson, John V. Heyse
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Abstract
We provide reverse-graded catalyst systems which are capable of removing metals and sulfur from a hydrocarbon feedstock. They comprise two or more catalyst layers in which at least two successive catalyst layers characterized as having decreasing desulfurization activity, and increasing average macropore diameter in the direction of hydrocarbon flow. We also disclose a process for using them.
Claims27
A process for hydrodemetalating and hydrodesulfurizing a hydrocarbon feedstock using a reverse-graded catalyst system, capable of removing metals and sulfur from a hydrocarbon feedstock, which comprises:
- passing said feedstock, in the presence of hydrogen, through said system at hydrodemetalating and hydrdodesulfurizing conditions, wherein said system comprises at least two successive catalyst layers characterized as follows:
- (a) said first layer comprises a fixed bed of catalyst particles having less than 45 vol. % of their pore volume in the form of macropores above 1000.ANG. in diameter, having an average mesopore diameter ranging from about 50.ANG. to about 300.ANG., having a surface area ranging from about 100 m.sup.2 /g to about 300 m.sup.2 /g, having at least 0.5 wt. % of a Group VIII metal, and having at least 3.0 wt. % of a Group VIB metal, and
- (b) said second layer comprises a fixed bed of catalyst particles having at least 25 vol. % of their pore volume in the form of macropores above 5000.ANG. in diameter, having at least 25 vol. % of their pore volume about 1000.ANG. in diameter, having a surface area ranging from about 100 m.sup.2 /g to about 300 m.sup.2 /g, having less than 10 wt. % of a Group VIII metal, and having less than 15 wt. % of a Group VIB metal.
A process for hydrodemetalating and hydrodesulfurizing a hydrocarbon feedstock using a reverse-graded catalyst system, capable of removing metals and sulfur from a hydrocarbon feedstock, which comprises:
- passing said feedstock, in the presence of hydrogen, through said system at hydrodemetalating and hydrodesulfurizing conditions, wherein said system comprises at least two successive catalyst layers characterized as follows,
- (a) said first layer comprises a fixed bed of catalyst particles having an average mesopore diameter ranging from about 200 .ANG. to about 260 .ANG., having an average surface area ranging from about 100 m.sup.2 /g to about 140 m.sup.2 /g, having from about 0.5 to about 2.5 wt. % of a Group VIII metal, and having from about 4.5 to about 8.5 wt. % of a Group VIB metal, and
- (b) said second layer comprises a fixed bed of catalyst particles having at least 25 vol. % of their pore volume in the form of macropores above 5000 .ANG. in diameter, having at least 25 vol. % of their pore volume above 1000 .ANG. in diameter, having a surface area ranging from about 100 m.sup.2 /g to about 300 m.sup.2 /g, having less than 10 wt. % of a Group VIII metal, and having less than 15 wt. % of a Group VIB metal.
A process for hydrodemetalating and hydrodesulfurizing a hydrocarbon feedstock using a reverse-graded catalyst system, capable of removing metals and sulfur from a hydrocarbon feedstock, which comprises:
- passing said feedstock, in the presence of hydrogen, through said system at hydrodemetalating and hydrodesulfurizing conditions, wherein said system comprises at least two successive catalyst layers characterized as follows,
- (a) a first catalyst layer comprising a fixed bed of catalyst particles having about 45 vol. % of their pore volume in the form of macropores above 1000 .ANG. in diameter, having an average mesopore diameter ranging from about 50 .ANG. to about 300 .ANG., having a surface area ranging from about 100 m.sup.2 /g to about 300 m.sup. 2 /g, having at least 0.5 wt. % of a Group VIII metal, and having at least 3.0 wt. % and 10.0 wt. % of a Group VIB metal.
- (b) a second catalyst layer comprising a fixed bed of catalyst particles having at least 25 vol. % of their pore volume in the form of macropores above 5000 .ANG. in diameter, having at least 25 vol. % of their pore volume above 1000 .ANG. in diameter, having a surface area ranging from about 100 m.sup.2 /g to about 300 m.sup.2 /g, having less than 10 wt. % of a Group VIII metal, and having less than 15 wt. % of a Group VIB metal, and
- (c) a third catalyst layer comprising a fixed bed of catalyst particles having high hydrodesulfurization activity;
- comprising passing said feedstock, in the presence of hydrogen, through said layers of catalyst particles at hydrodemetalating and hydrodesulfurizing conditions.
A process for hydrometalating and hydrodesulfurizing a hydrocarbon feedstock using a reverse-graded catalyst system, capable of removing metals and sulfur from a hydrocarbon feedstock, comprising:
- passing said feedstock, in the presence of hydrogen, through said system at hydrodemetalating and hydrodesulfurizing conditions, wherein said system comprises at least two successive catalyst layers characterized as follows,
- (a) a first catalyst layer comprising a fixed bed of catalyst particles having an average mesopore diameter ranging from about 200 .ANG. to about 260 .ANG., having an average surface area ranging from about 100 m.sup.2 /g, to about 140 m.sup.2 /g, having from about 0.5 to about 2.5 wt. % of a Group VIII metal, and having from about 4.5 to about 8.5 wt. % of a Group VIB metal,
- (b) a second catalyst layer comprising a fixed bed of catalyst particles having at least 25 vol. % of their pore volume in the form of macropores greater than 5000 .ANG. in diameter, having at least 25 vol. % of their pore volume above 1000 .ANG. in diameter, having a surface area ranging from about 100 m.sup.2 /g to about 300 m.sup.2 /g, having less than 10 wt. % of a Group VIII metal, and having less than 15 wt. % of a Group VIB metal, and
- (c) a third catalyst layer comprising a fixed bed of catalyst particles having high hydrodesulfurization activity;
- comprising passing said feedstock, in the presence of hydrogen, through said layers of catalyst particles at hydrodemetalating and hydrodesulfurizing conditions.
Dependencies are inferred from the claim text.