Hydrodesulfurization process
In one aspect, a hydrodesulfurization process is provided that selectively desulfurizes a hydrocarbon stream with minimal olefin saturation and minimal recombination of sulfur into mercaptans. In another aspect, the process includes a multi-stage reaction zone including at least first and second serial hydrodesulfurization reaction zones that sequentially remove sulfur from a hydrocarbon stream. In yet another aspect, the process is particularly suited to selectively desulfurize an olefinic naphtha hydrocarbon stream, such as FCC naphtha, steam cracked naphtha, coker naphtha, or other gasoline boiling hydrocarbon streams.
1. A hydrodesulfurization process comprising:
providing an olefinic naphtha stream having an olefin content and a sulfur content;
reacting the olefinic naphtha stream in a first hydrodesulfurization zone at a first reaction temperature effective to convert a portion of the sulfur content to hydrogen sulfide;
reacting the first hydrodesulfurization zone effluent in a second hydrodesulfurization zone at a second, higher reaction temperature and with a catalyst effective to desulfurize forming a second hydrodesulfurization zone effluent; and
the second hydrodesulfurization zone catalyst including an inner core and a thin outer layer about 5 to about 30 microns thick surrounding the inner core, the thin outer layer including a hydrodesulfurization catalyst.
2. The process of claim 1 , wherein less than about 30 percent of the olefin content is saturated in the first hydrodesulfurization zone and less than about 20 percent of the olefin content is saturated in the second hydrodesulfurization zone.
3. The process of claim 1 , wherein a selectivity ratio of the hydrodesulfurization catalyst in the second hydrodesulfurization zone is greater than about 500 wherein
Selectivity Ratio=(100)(Sulfur Conversion/Olefin Conversion);
Sulfur Conversion=(S f −S p )/S f ;
Olefin Conversion=(O f −O p )/O f ;
S f =sulfur content in the first hydrodesulfurization zone effluent;
S p =sulfur content in the second hydrodesulfurization zone effluent;
O f =olefin content in the first hydrodesulfurization zone effluent; and
O p =olefin content in the second hydrodesulfurization zone effluent.
4. The process of claim 1 , wherein the first hydrodesulfurization reaction zone effluent is fed to the second hydrodesulfurization reaction zone without the removal of significant amounts of hydrogen sulfide formed in the first hydrodesulfurization reaction zone.
5. The process of claim 1 , wherein the first hydrodesulfurization zone effluent has an octane number loss from about 0.5 to about 1.5.
6. The process of claim 5 , wherein the second hydrodesulfurization zone effluent has about 10 ppm or less sulfur and an octane number loss from about 0.3 to about 1.
7. The process of claim 1 , wherein the first temperature of the first hydrodesulfurization zone is about 260° C. (500° F.) to about 315° C. (600° F.).
8. The process of claim 1 , wherein the second temperature of the second hydrodesulfurization zone is about 315° C. (600° F.) to about 398° C. (750° F.).
9. The process of claim 1 , wherein the hydrodesulfurization catalyst includes about 0.5 to about 5 weight percent cobalt oxide and about 0.5 to about 20 weight percent molybdenum oxide.
10. A hydrodesulfurization process comprising:
providing an olefinic naphtha stream having an olefin content and a sulfur content;
reacting the olefinic naphtha stream in a first hydrodesulfurization reaction zone at a first temperature effective to favor desulfurization over olefin saturation and forming a first hydrodesulfurization reaction zone effluent having a portion of the sulfur content converted to hydrogen sulfide;
reacting the first hydrodesulfurization reaction zone effluent in a second hydrodesulfurization reaction zone at a second, higher temperature and with a catalyst effective to favor desulfurization over olefin saturation to form a second hydrodesulfurization reaction zone effluent; and
the catalyst including an inner core and a thin outer layer about 5 to about 100 microns thick surrounding the inner core, the thin outer layer including a hydrodesulfurization catalyst having an Olefin Conversion less than about 0.10 and a selectivity ratio greater than about 500 wherein
Selectivity Ratio=(100)(Sulfur Conversion/Olefin Conversion);
Sulfur Conversion=(S f −S p )/S f ;
Olefin Conversion=(Of−O p )/O f ;
S f =sulfur content in the feed to the second hydrodesulfurization zone;
S p =sulfur content in the second hydrodesulfurization zone effluent;
O f =olefin content in the feed to the second hydrodesulfurization zone; and
O p =olefin content in the second hydrodesulfurization zone effluent.
11. The process of claim 10 , wherein converting the olefinic naphtha stream in the first hydrodesulfurization reaction zone saturates less than about 30 percent of the olefin content in the olefinic naphtha stream.
12. The process of claim 11 , wherein the first hydrodesulfurization reaction zone effluent has about 50 to about 80 percent sulfur converted to hydrogen sulfide.
13. The process of claim 10 , wherein converting the first hydrodesulfurization reaction zone effluent in a second hydrodesulfurization forms less than about 10 ppm mercaptans.
14. The process of claim 13 , wherein the second hydrodesulfurization zone effluent has about 10 ppm or less of sulfur.
15. The process of claim 10 , wherein the first hydrodesulfurization reaction zone effluent is fed directly to the second hydrodesulfurization reaction zone without removal of any hydrogen sulfide.
16. The process of claim 10 , wherein the first temperature of the first hydrodesulfurization zone is about 260° C. (500° F.) to about 315° C. (600° F.) and the second temperature of the second hydrodesulfurization zone is about 315° C. (600° F.) to about 398° C. (750° F.).
17. A hydrodesulfurization process comprising:
providing an olefinic naphtha stream having an olefin content and a sulfur content;
reacting the olefinic naphtha stream in a hydrodesulfurization zone at temperatures greater than 315° C. (600° F.) with a catalyst effective to favor desulfurization over olefin saturation to form an effluent having a reduced sulfur content relative to the olefinic naphtha stream;
the catalyst including an inner core and a thin outer layer about 5 to about 30 microns thick surrounding the inner core effective to favor desulfurization over olefin saturation.
18. The hydrodesulfurization process of claim 17 , wherein the catalyst has a selectivity ratio of the catalyst greater than about 500 wherein
Selectivity Ratio=(100) (Sulfur Conversion/Olefin Conversion);
Sulfur Conversion=(S f −S p )/S f ;
Olefin Conversion=(O f −O p )/O f ;
S f =sulfur content in the olefinic naphtha stream;
S p =sulfur content in the effluent;
O f =olefin content in the olefinic naphtha stream; and
O p =olefin content in the effluent.
19. The process of claim 17 , wherein at least about 85 percent of the sulfur content is converted to hydrogen sulfide and less than about 15 percent of the olefin content is saturated.