Layered catalyst reactor systems and processes for hydrotreatment of hydrocarbon feedstocks

Patent metadata

Field	Value
Publication number	US-11577235-B1
Application number	US-202117401757-A
Country	US
Kind code	B1
Filing date	Aug 13, 2021
Priority date	Aug 13, 2021
Publication date	Feb 14, 2023
Grant date	Feb 14, 2023

Abstract

A layered catalyst reactor system and process for hydrotreatment of hydrocarbon feedstocks. The layered catalyst system reactors comprise vertical bed layers including a demetallization catalyst layer, multiple layers of supported hydrotreating catalyst layer, and multiple alternating layers of supported hydrocracking catalysts and self-supported hydrotreating catalysts. The arrangement of the catalyst layers mitigates the risk of temperature run-aways, with improvements in hydrotreatment performance.

First claim

What is claimed is:

1. A layered catalyst reactor system comprising a vertical bed or stack of catalyst layers arranged from top to bottom in the following order:
(i) a layer comprising one or more demetallization catalysts;
(ii) a layer of one or more supported hydrotreating catalysts;
(iii) a layer of one or more supported hydrocracking catalysts;
(iv) a layer of one or more self-supported hydrotreating catalysts;
(v) a layer of one or more supported hydrocracking catalysts;
(vi) a layer of one or more self-supported hydrotreating catalysts;
(vii) a layer of one or more supported hydrotreating catalysts;
wherein the total volume of the two layers comprising one or more self-supported hydrotreating catalysts is about 10 to about 50% of the total volume of catalysts in the vertical bed; and
wherein the total volume of the two layers comprising one or more supported hydrocracking catalysts is about 10 to about 30% of the total volume of catalysts in the vertical bed.

2. The layered catalyst reactor system of claim 1 , wherein the one or more self-supported hydrotreating catalysts comprises about 5 to about 9 wt % molybdenum, about 21 to 31 wt % nickel, and about 33 to about 42 wt % tungsten.

3. The layered catalyst reactor system of claim 1 , wherein the one or more demetallization catalysts are selected from the group consisting of: synthetic aluminum oxide or natural aluminum silicate enriched with the oxides of molybdenum, cobalt and nickel.

4. The layered catalyst reactor system of claim 1 , wherein the one or more supported hydrotreating catalysts are selected from the group consisting of: catalysts comprising at least one Group VIII metal and at least one Group VIB metal on a support material selected from the group consisting of alumina, zeolites, amorphous silica-alumina, and titania-alumina.

5. The layered catalyst reactor system of claim 1 , wherein the one or more supported hydrotreating catalysts are selected from the group consisting of: catalysts comprising Pd or Pt.

6. The layered catalyst reactor system of claim 1 , wherein the one or more hydrocracking catalysts are selected from the group consisting of: catalysts comprising nickel, nickel-cobalt-molybdenum, cobalt-molybdenum and nickel-tungsten and/or nickel-molybdenum.

7. The layered catalyst reactor system of claim 1 , wherein the one or more hydrocracking catalysts comprise porous support materials comprising a refractory oxide material.

8. The layered catalyst reactor system of claim 1 , wherein the one or more hydrocracking catalysts comprise nickel, cobalt, molybdenum and/or tungsten.

9. A layered catalyst reactor system comprising a vertical bed or stack of catalyst layers arranged from top to bottom in the following order:
(i) a layer comprising one or more demetallization catalysts;
(ii) a layer of one or more supported hydrotreating catalysts;
(iii) a layer of one or more supported hydrocracking catalysts;
(iv) a layer of one or more self-supported hydrotreating catalysts;
(v) a layer of one or more supported hydrocracking catalysts;
(vi) a layer of one or more self-supported hydrotreating catalysts;
(vii) a layer of one or more supported hydrocracking catalysts;
(viii) a layer of one or more self-supported hydrotreating catalysts;
(ix) a layer of one or more supported hydrotreating catalysts;
wherein the total volume of the three layers comprising one or more self-supported hydrotreating catalysts is about 9 to about 45% of the total volume of catalysts in the vertical bed; and
wherein the total volume of the three layers comprising one or more supported hydrocracking catalysts is about 15 to about 30% of the total volume of catalysts in the vertical bed.

10. The layered catalyst reactor system of claim 9 , wherein the one or more self-supported hydrotreating catalysts comprises about 5 to about 9 wt % molybdenum, about 21 to 31 wt % nickel, and about 33 to about 42 wt % tungsten.

11. The layered catalyst reactor system of claim 9 , wherein the one or more demetallization catalysts are selected from the group consisting of: synthetic aluminum oxide or natural aluminum silicate enriched with the oxides of molybdenum, cobalt and nickel.

12. The layered catalyst reactor system of claim 9 , wherein the one or more supported hydrotreating catalysts are selected from the group consisting of: catalysts comprising at least one Group VIII metal and at least one Group VIB metal on a support material selected from the group consisting of alumina, zeolites, amorphous silica-alumina, and titania-alumina.

13. The layered catalyst reactor system of claim 9 , wherein the one or more supported hydrotreating catalysts are selected from the group consisting of: catalysts comprising Pd or Pt.

14. The layered catalyst reactor system of claim 9 , wherein the one or more hydrocracking catalysts are selected from the group consisting of: catalysts comprising nickel, nickel-cobalt-molybdenum, cobalt-molybdenum and nickel-tungsten and/or nickel-molybdenum.

15. The layered catalyst reactor system of claim 9 , wherein the one or more hydrocracking catalysts comprise porous support materials comprising a refractory oxide material.

16. The layered catalyst reactor system of claim 9 , wherein the one or more hydrocracking catalysts comprise nickel, cobalt, molybdenum and/or tungsten.

17. A process for hydrotreatment of hydrocarbon feedstocks comprising: (i) contacting a hydrocarbon feedstock which contains contaminants comprised of metals, sulfur, nitrogen and olefins with a layered catalyst reactor system in the presence of hydrogen to produce hydrocarbon product having a lower content of metals sulfur, nitrogen and olefins than the hydrocarbon feedstock; (ii) passing the hydrocarbon feedstock sequentially through the layers of the layered catalyst reactor system vertically from top to bottom; and (iii) recovering the hydrocarbon product from the bottom of the layered catalyst reactor system;
wherein the layered catalyst system comprises a vertical bed or stack of catalyst layers arranged from top to bottom in the following order:
(i) a layer comprising one or more demetallization catalysts;
(ii) a layer of one or more supported hydrotreating catalysts;
(iii) a layer of one or more supported hydrocracking catalysts;
(iv) a layer of one or more self-supported hydrotreating catalysts;
(v) a layer of one or more supported hydrocracking catalysts;
(vi) a layer of one or more self-supported hydrotreating catalysts;
(vii) a layer of one or more supported hydrotreating catalysts;
wherein the total volume of the two layers comprising one or more self-supported hydrotreating catalysts is about 10 to about 50% of the total volume of catalysts in the vertical bed; and
wherein the total volume of the two layers comprising one or more supported hydrocracking catalysts is about 10 to about 30% of the total volume of catalysts in the vertical bed;
or
wherein the layered catalyst reactor system comprises a vertical bed or stack of catalyst layers arranged from top to bottom in the following order:
(i) a layer comprising one or more demetallization catalysts;
(ii) a layer of one or more supported hydrotreating catalysts;
(iii) a layer of one or more supported hydrocracking catalysts;
(iv) a layer of one or more self-supported hydrotreating catalysts;
(v) a layer of one or more supported hydrocracking catalysts;
(vi) a layer of one or more self-supported hydrotreating catalysts;
(vii) a layer of one or more supported hydrocracking catalysts;
(viii) a layer of one or more self-supported hydrotreati

Assignees

• Chevron Usa Inc

Inventors

• Brait Axel
• Ouyang Xiaoying
• Kuperman Alexander
• Maesen Theodorus Ludovicus Michael

Classifications

• C10G45/08

  in combination with chromium, molybdenum, or tungsten metals, or compounds thereof · CPC title

• C10G49/002

  Apparatus for fixed bed hydrotreatment processes · CPC title

• C10G67/02

  plural serial stages only · CPC title

• C10G47/06

  Sulfides · CPC title

• C10G65/10

  including only cracking steps · CPC title