# US 5,344,553 A · Upgrading of a hydrocarbon feedstock utilizing a graded, mesoporous catalyst system > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 5,344,553 A - Document ID: US5344553A - Status: Granted - Kind: A - Application number: 08/020,946 - Filed: 1993-02-22 - Granted: 1994-09-06 - Earliest claimed: 1993-02-22 - Assignees: Mobil Oil Corporation - Inventors: Stuart S. Shih - Web page: https://patentgrep.com/patent/US5344553A ## CPC - C10G 65/04: including only refining steps - C10G: CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION (cracking to hydrogen or synthesis gas C01B; cracking or pyrolysis of hydrocarbon gases to individual hydrocarbons or mixtures thereof of definite or specified constitution C07C; cracking to cokes C10B); RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES ## Abstract There is provided a process for upgrading hydrocarbon feedstocks, such as resids or shale oil. The process uses a catalyst comprising at least one Group VIA or Group VIII metal, such as nickel and molybdenum, and an ultra-large pore oxide material. The ultra-large pore oxide material is used in decreasing pore size from top to bottom of the reactor. ## Claims ### Claim 1 A process for upgrading a hydrocarbon feedstock, said process comprising contacting said hydrocarbon feedstock with a catalyst under hydrogen pressure of at least about 2860 kPa in a first reaction zone, said catalyst comprising at least one Group VIA or Group VIII metal and an inorganic, porous crystalline phase material having, after calcination, an X-ray diffraction pattern with at least one peak at a d-spacing greater than about 18 Angstrom Units with a relative intensity of 100 and a benzene adsorption capacity of greater than 15 grams benzene per 100 grams of said material at 50 torr and 25.degree. C., wherein said material has a pore size in the range of about 40 to about 120 Angstroms; and contacting the effluent from said first reaction zone with a catalyst in a second reaction zone said catalyst comprising at least one Group VIA or Group VIII metal and an inorganic, porous crystalline phase material having, after calcination, an X-ray diffraction pattern with at least one peak at a d-spacing greater than about 18 Angstrom Units with a relative intensity of 100 and a benzene adsorption capacity of greater than 15 grams benzene per 100 grams of said material at 50 torr and 25.degree. C., and wherein said material has a pore size in the range of less than about 60 Angstroms. ### Claim 2 A process for upgrading a hydrocarbon feedstock, said process comprising contacting said hydrocarbon feedstock with a catalyst under hydrogen pressure of at least about 2860 kPa in a first reaction zone, said catalyst comprising at least one Group VIA or Group VIII metal and an inorganic, porous crystalline phase material having, after calcination, an X-ray diffraction pattern with at least one peak at a d-spacing greater than about 18 Angstrom Units with a relative intensity of 100 and a benzene adsorption capacity of greater than 15 grams benzene per 100 grams of said material at 50 torr and 25.degree. C., wherein said material has a pore size in the range of about 60 to about 120 Angstroms; contacting the effluent from said first reaction zone with a catalyst in a second reaction zone said catalyst comprising at least one Group VIA or Group VIII metal and an inorganic, porous crystalline phase material having, after calcination, an X-ray diffraction pattern with at least one peak at a d-spacing greater than about 18 Angstrom Units with a relative intensity of 100 and a benzene adsorption capacity of greater than 15 grams benzene per 100 grams of said material at 50 torr and 25.degree. C., and wherein said material has a pore size in the range of about 40 to less than about 60 Angstroms; and contacting the effluent from said second reaction zone with a catalyst in a third reaction zone said catalyst comprising at least one Group VIA of Group VIII metal and an inorganic, porous crystalline phase material having, after calcination, an X-ray diffraction pattern with at least one peak at a d-spacing greater than about 18 Angstrom Units with a relative intensity of 100 and a benzene adsorption capacity of greater than 15 grams benzene per 100 grams of said material at 50 torr and 25.degree. C., and wherein said material has a pore size of in the range of about 20 to less than about 40 Angstroms. ### Claim 3 (depends on 2) The process according to claim 2 wherein said at least one Group VIA or Group VIII metal is selected from the group consisting of molybdenum, cobalt, nickel or any combination thereof. ### Claim 4 (depends on 2) The process according to claim 2 wherein said first reaction zone, said second reaction zone and said third reaction zone are in the same reactor. ### Claim 5 (depends on 2) The process according to claim 2 wherein said first reaction zone, said second reaction zone and said third reaction zone are in separate reactors in series. ### Claim 6 (depends on 2) The process according to claim 2 wherein said hydrocarbon feedstock is contacted with a catalyst in more than three reaction zones. ### Claim 7 (depends on 2) The process according to claim 2, wherein said process is operated at a temperature between about 260.degree. C. and 455.degree. C. and a liquid hourly space velocity between about 0.1 and 10 hr.sup.-1. ### Claim 8 (depends on 2) The process according to claim 2, wherein said feedstock is substantially composed of hydrocarbons boiling above 340.degree. C. ### Claim 9 (depends on 8) The process according to claim 8, wherein said feedstock is an atmospheric resid. ### Claim 10 (depends on 2) The process according to claim 2 wherein said feedstock is shale oil. ### Claim 11 A process for upgrading a hydrocarbon feedstock, said process comprising contacting said hydrocarbon feedstock with a catalyst under hydrogen pressure of at least about 2860 kPa in a first reaction zone, said catalyst comprising at least one Group VIA or Group VIII metal and a zeolite having the structure of MCM-41, wherein said zeolite having the structure of MCM-41 has a pore size in the range of about 60 to about 120 Angstroms; contacting the effluent from said first reaction zone with a catalyst in a second reaction zone said catalyst comprising at least one Group VIA or Group VIII metal and a zeolite having the structure of MCM-41, wherein said zeolite having the structure of MCM-41 has a pore size in the range of about 40 to less than about 60 Angstroms; and contacting the effluent from said second reaction zone with a catalyst in a third reaction zone said catalyst comprising at least one Group VIA or Group VIII metal and a zeolite having the structure of MCM-41, wherein said zeolite having the structure of MCM-41 has a pore size of in the range of about 20 to less than about 40 Angstroms. ### Claim 12 (depends on 11) The process according to claim 11 wherein said at least one Group VIA or Group VIII metal is selected from the group consisting of molybdenum, cobalt, nickel or any combination thereof. ### Claim 13 (depends on 11) The process according to claim 11 wherein said first reaction zone, said second relation zone and said third reaction zone are in the same reactor. ### Claim 14 (depends on 11) The process according to claim 11 wherein said first reaction zone, said second reaction zone and said third reaction zone are in separate reactors in series. ### Claim 15 (depends on 11) The process according to claim 11 wherein said hydrocarbon feedstock is contacted with a catalyst in more than three reaction zones. ### Claim 16 (depends on 11) The process according to claim 11 wherein said process is operated at a temperature between about 260.degree. C. and 455.degree. C. and a liquid hourly space velocity between about 0.1 and 10 hr.sup.-1. ### Claim 17 (depends on 11) The process according to claim 11 wherein said feedstock is substantially composed of hydrocarbons boiling above 340.degree. C. ### Claim 18 (depends on 17) The process according to claim 17, wherein said feedstock is an atmospheric resid. ### Claim 19 (depends on 11) The process according to claim 11 wherein said feedstock is shale oil.