Porous material for removing impurities in feedstocks

Patent metadata

Field	Value
Publication number	US-12122965-B2
Application number	US-202118000578-A
Country	US
Kind code	B2
Filing date	Jul 6, 2021
Priority date	Jul 7, 2020
Publication date	Oct 22, 2024
Grant date	Oct 22, 2024

Abstract

A porous material including alumina, the alumina including alpha-alumina, the porous material including one or more metals selected from Co, Mo, Ni, W and combinations thereof, and the porous material having a BET-surface area of 1-110 m 2 /g, a total pore volume of 0.50-0.80 ml/g, as measured by mercury intrusion porosimetry, and a pore size distribution (PSD) with at least 30 vol % of the total pore volume being in pores with a radius ≥400 Å, suitably pores with a radius ≥500 Å. A process for removing impurities such as phosphorous (P) from a feedstock, by contacting the feedstock with a guard bed including the above porous material. A guard bed for a hydrotreatment system including the porous material, a hydrotreatment system including a guard bed which includes the porous material and a downstream hydrotreatment section including at least one hydrotreatment catalyst.

First claim

The invention claimed is:

1. A porous material comprising alumina,
said alumina comprising alpha-alumina,
said porous material comprising one or more metals selected from Co, Mo, Ni, W, and combinations thereof,
said porous material having a BET-surface area of 1-110 m 2 /g, wherein
the porous material has a total pore volume of 0.50-0.80 ml/g, as measured by mercury intrusion porosimetry, and
the porous material has a pore size distribution (PSD) with at least 30 vol % of the total pore volume being in pores with a radius ≥400 Å.

2. The porous material according to claim 1 , with up to 60 vol % of the total pore volume being in pores with a radius below 400 Å.

3. The porous material according to claim 1 , wherein the content of alpha-alumina is 50-100 wt %.

4. The porous material according to claim 1 , the alumina further comprising theta-alumina.

5. The porous material according to claim 1 , wherein the content of the one or more metals is 0.25-20 wt %.

6. The porous material according to claim 1 , further comprising a compound selected from Al-borates, calcium aluminates, silicon aluminates, and combinations thereof.

7. The porous material according to claim 1 , wherein the one or more metals comprise Mo and its content is 0.5-15 wt %.

8. The porous material according to claim 7 , further comprising 0.1-5 wt % of at least one of Ni, Co, and W.

9. The porous material according to claim 7 , further comprising 0.05-0.5 wt % of Ni.

10. The porous material according to claim 1 , wherein the BET-surface area is 1-70 m 2 /g.

11. The porous material according to claim 1 , wherein the porous material is an extruded or tabletized pellet having a shape selected from trilobal, tetralobal, pentalobal, cylindrical, spherical, hollow, and combinations thereof.

12. The porous material according to claim 1 , wherein the porous material has a total pore volume of 0.55-0.80 ml/g, as measured by mercury intrusion porosimetry.

13. The porous material according to claim 1 , wherein the porous material has a total pore volume of 0.6-0.80 ml/g, as measured by mercury intrusion porosimetry.

14. The porous material according to claim 1 , wherein the porous material has a pore size distribution (PSD) with at least 30 vol % of the total pore volume being in pores with a radius of 400 Å to 5000 Å.

15. The porous material according to claim 1 , wherein the porous material has a pore size distribution (PSD) with at least 40 vol % of the total pore volume being in pores with a radius of 400 Å to 5000 Å.

16. The porous material according to claim 1 , wherein the porous material has a pore size distribution (PSD) with at least 50 vol % of the total pore volume being in pores with a radius of 400 Å to 5000 Å.

17. The porous material according to claim 1 , wherein the porous material has a pore size distribution (PSD) with at least 30 vol % of the total pore volume being in pores with a radius of 500 Å to 5000 Å.

18. The porous material according to claim 1 , wherein the porous material has a pore size distribution (PSD) with at least 40 vol % of the total pore volume being in pores with a radius of 500 Å to 5000 Å.

19. The porous material according to claim 1 , wherein the porous material has a pore size distribution (PSD) with at least 50 vol % of the total pore volume being in pores with a radius of 500 Å to 5000 Å.

20. The porous material according to claim 1 , wherein the porous material has a pore size distribution (PSD) with 40 to 60 vol % of the total pore volume being in pores with a radius between 40 to 400 Å.

21. A process for removing one or more impurities from a feedstock, said process comprising the step of contacting said feedstock with a guard bed comprising a porous material according to claim 1 , thereby providing a purified feedstock.

22. The process of claim 21 , wherein the one or more impurities are selected from a vanadium-containing impurity, silicon-containing impurity, a halide-containing impurity, an iron-containing impurity, a phosphorous-containing impurity, and combinations thereof.

23. The process according to claim 21 , which process is carried out at a temperature of 100-400° C.

24. The process according to claim 21 , wherein the feedstock is:
i) a renewable source obtained from a raw material of renewable origin; or
ii) a feedstock originating from a fossil fuel; or
iii) a feedstock originating from combining a renewable source according to i) and a feedstock originating from a fossil fuel according to ii).

25. The process according to claim 24 , wherein the portion of the feedstock originating from a renewable source is 5-60 wt %.

26. The process according to claim 22 , wherein the one or more impurities is a phosphorous (P)-containing impurity and said feedstock contains 0.5-1000 ppm P.

27. The process according to claim 21 , wherein the purified feedstock is subsequently processed in a hydrotreatment stage in the presence of a hydrotreatment catalyst.

28. The process according to claim 21 , wherein the feedstock is a renewable source obtained from a raw material of renewable origin.

29. The process according to claim 21 , wherein the feedstock is a feedstock originating from combining a renewable source obtained from a raw material of renewable origin and a feedstock originating from a fossil fuel.

30. A guard bed for a hydrotreatment system, said guard bed comprising a porous material according to claim 1 .

31. A hydrotreatment system for hydrotreating a feedstock, said hydrotreatment system comprising:
a guard bed comprising a porous material according to claim 1 ; and
a hydrotreatment section comprising at least one hydrotreatment catalyst, arranged downstream of said guard bed.

32. A method comprising a step of using a porous material according to claim 1 as a phosphorus guard in a hydrotreatment process.

Assignees

• Topsoe As
• Haldor Topsoe As

Inventors

• Weise Christian Frederik
• Lutecki Michal
• Johansson Frank Bartnik

Classifications

• B01J35/615

  100-500 m2/g · CPC title

• B01J20/28061

  being in the range 100-500 m2/g · CPC title

• B01J2235/30

  Scanning electron microscopy; Transmission electron microscopy · CPC title

• B01J2235/15

  X-ray diffraction · CPC title

• C10G2300/202

  Heteroatoms content, i.e. S, N, O, P · CPC title