Systems, methods, and catalysts for producing a crude product

Inactive Publication Date: 2006-10-19
SHELL OIL CO
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0018] In some embodiments, the invention provides a method of producing a crude product, comprising: contacting a crude feed with one or more catalysts to produce a total product that includes the crude product, wherein the crude product is a liquid mixture at 25° C. and 0.101 MPa; the crude feed has a micro-carbon residue (“MCR”) content of at least 0.0001 grams per gram of crude feed; and at least one of the catalysts is a Column 6 metal catalyst that comprises: one or more metals from Column 6 of the Periodic Table and/or one or

Problems solved by technology

Disadvantaged crudes with a relatively high TAN may contribute to corrosion of metal components during transporting and / or processing of the disadvantaged crudes.
The use of corrosion-resistant metal often involves significant expense, and thus, the use of corrosion-resistant metal in existing equipment may not be desirable.
The use of corrosion inhibitors may negatively affect equipment used to process the crudes and / or the quality of products produced from the crudes.
Disadvantaged crudes often contain relatively high levels of residue.
Disadvantaged crudes having high levels of residue tend to be difficult and expensive to transport and / or process using conventional facilities.
Organically bound heteroatoms may, in some situations, have an adverse effect on catalysts used to process disadvantaged crudes.
During processing of such crudes, metal contaminants and / or compounds of metal contaminants, may deposit on a surface of the catalyst or in the void volume of the catalyst.
Such deposits may cause a decline in the activity of the catalyst.
Disadvantaged crudes may have components that contribute coke and / or to thermal degradation of the disadvantaged crude.
It may be costly to regenerate the catalytic activity of a catalyst contaminated with coke and / or thermally degraded crude.
Additionally, high temperatures used during regeneration of a catalyst may also diminish the activity of the catalyst and / or cause the catalyst to deteriorate.
Problems are often encountered in conventional catalytic processing of crudes when metals in metal salts of organic acids are present.
Moreover, the metals in metal salts of organic acids may cause rapid deactivation of catalysts.
Treatment facilities that process disadvantaged crudes with an oxygen content of at least 0.002 grams of oxygen per gram of disadvantaged crude may encounter problems during processing.
Organic oxygen compounds, when heated during processing, may form higher oxidation compounds (for example, ketones and / or acids formed by oxidation of alcohols, and / or acids formed by oxidation of ethers) that are difficult to remove from the treated crude and / or may corrode / contaminate equipment during processing and cause plugging in transportation lines.
When processing hydrogen deficient hydrocarbons, consistent quantities of hydrogen generally need to be added, particularly if unsaturated fragments resulting from cracking processes are produced.
Hydrogen is costly to produce and / or costly to transport to treatment facilities.
Disadvantaged crudes also tend to exhibit instability during processing in conventional facilities.
Crude instability tends to result in phase separation of components during processing and / or formation of undesirable by-products (for example, hydrogen sulfide, water, and carbon dioxide).
Removal of these components, however, may cause instability in the crude, thus causing separation of the crude during transportation.
Adding diluent, however, generally increases costs of treating disadvantaged crudes due to the costs of diluent and / or increased costs to handle the disadvantaged crudes.
Addition of diluent to a disadvantaged crude may, in some situations, decrease stability of such crude.
The processes, systems, and catalysts described in these patents, however, have limited applicability because of many of the technical problems set forth above.
In sum, disadvantaged crudes generally have undesirable properties (for example, relatively high TAN, a tendency to become unstable during treatment, and / or a tendency to consume relatively large amounts of hydrogen during treatment).
Disadvantaged crudes may also include relatively high amounts of undesirable components (for example, components that contribute to thermal degradation, residue, organically bound heteroatoms, metal contaminants, metals in metal salts of organic acids, and / or organic oxygen compounds).
Such properties and components tend to cause problems in conventional transportation and / or treatment facilities, including increased corrosion, decreased catalyst life, process plugging, and / or increased usage of hydrogen during treatment.

Method used

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  • Systems, methods, and catalysts for producing a crude product
  • Systems, methods, and catalysts for producing a crude product
  • Systems, methods, and catalysts for producing a crude product

Examples

Experimental program
Comparison scheme
Effect test

example 1

Preparation of a Catalyst Support

[0218] An alumina / silica support was prepared by mulling 550 grams of an alumina / silica mixture, 26 grams of calcined alumina fines, 585 grams of water, and 8 grams of 16M nitric acid for 35 minutes. The alumina / silica mixture was prepared by combining at least 0.98 grams of alumina / silica mixture (Criterion Catalysts and Technologies LP) per gram of support with up to 0.02 grams of silica (Criterion Catalysts and Technologies LP) per gram of alumina / silica mixture. The mulled mixture was extruded through 1.94 mm and 3.28 mm diameter die plates, and then heat-treated at a temperature in a range from 93° C. (200° F.) to 121° C. (250° F.) until a loss on ignition in a range of 27 wt % to 30 wt %, based on initial extrudate weight, was obtained. Loss on ignition was performed by heating the extrudates to 540° C. for 15 minutes to 50 minutes, and then determining the relative amount of weight lost by the extrudates. The extrudates were further heat-trea...

example 2

Preparation of a Catalyst having a Median Pore Diameter of 115 Å and a Selected Pore Volume Distribution

[0219] A catalyst was prepared as follows. An alumina / silica support prepared as described in Example 1 was impregnated with a molybdenum / nickel / phosphorus impregnation solution prepared as follows. A first solution was made by combining 62.34 grams of (NH4)2Mo2O7, 17.49 grams of MoO3, 12.22 grams of 30% H2O2, and 50.47 grams of deionized water to form a slurry. MEA (3.0 grams) was added to the slurry at a rate sufficient to control the exotherm of dissolution. The slurry was heated to 64° C. (147° F.) until the solids dissolved, and then cooled to room temperature. The pH of the first solution was 5.34.

[0220] A second solution was made by combining 8.2 grams of Ni(NO3)2-6H2O and 5.47 grams of NiCO3 with 30.46 grams of deionized water, and then adding 29.69 grams of 85 wt % H3PO4. The pH of the second solution was 0.29. The first solution and second solution were combined, and s...

example 3

Contact of a Crude Feed with Two Catalysts

[0224] A tubular reactor with a centrally positioned thermowell was equipped with thermocouples to measure temperatures throughout a catalyst bed. The catalyst bed was formed by filling the space between the thermowell and an inner wall of the reactor with catalysts and silicon carbide (20-grid, Stanford Materials; Aliso Viejo, Calif.). Such silicon carbide is believed to have low, if any, catalytic properties under the process conditions described herein. All catalysts were mixed with silicon carbide in a volume ratio of 2 parts silicon carbide to 1 part catalyst before placing the mixture into the contacting zone portions of the reactor.

[0225] The crude feed flow to the reactor was from the top of the reactor to the bottom of the reactor. Silicon carbide was positioned at the bottom of the reactor to serve as a bottom support. A bottom catalyst / silicon carbide mixture (81 cm3) was positioned on top of the silicon carbide to form a bottom...

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Abstract

Methods and systems for contacting of a crude feed with one or more catalysts to produce a total product that includes a crude product are described. The crude product is a liquid mixture at 25° C. and 0.101 MPa. The crude product has a nitrogen content of at most 90% of the nitrogen content of the crude feed. One or more other properties of the crude product may be changed by at least 10% relative to the respective properties of the crude feed.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims priority to U.S. Provisional Application 60 / 670,136 filed on Apr. 11, 2005, herein incorporated by reference in its entirety.FIELD OF THE INVENTION [0002] The present invention generally relates to systems, methods, and catalysts for treating crude feed. More particularly, certain embodiments described herein relate to systems, methods, and catalysts for conversion of a crude feed to a total product, wherein the total product includes a crude product that is a liquid mixture at 25° C. and 0.101 MPa, and has one or more properties that are changed relative to the respective property of the crude feed. DESCRIPTION OF RELATED ART [0003] Crudes that have one or more unsuitable properties that do not allow the crudes to be economically transported, or processed using conventional facilities, are commonly referred to as “disadvantaged crudes”. [0004] Disadvantaged crudes may include acidic components that contribute to...

Claims

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Application Information

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IPC IPC(8): C10G71/00
CPCB01J21/04C10G65/04B01J23/28B01J23/882B01J23/883B01J35/10B01J35/1019B01J35/1042B01J35/1061B01J35/108B01J37/0009B01J37/20C10G45/04C10G45/08C10G45/10B01J21/12B01J35/60B01J35/635B01J35/66B01J35/647B01J35/615
InventorBHAN, OPINDER KISHAN
OwnerSHELL OIL CO