Systems, methods, and catalysts for producing a crude product
Methods and systems for contacting of a crude feed with one or more catalysts produces a total product that includes a crude product are described. At least one of the catalysts is an uncalcined catalyst. 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.
1. A method of producing a crude product, comprising:
contacting a crude feed with two 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 nitrogen content of at least 0.0001 grams per gram of crude feed; wherein at least on the catalysts is a Column(s) 5-10 metal catalyst comprising at least vanadium and one other metal selected from Column(s) 5-10 of the Period Table and/or one or more compounds of vanadium and one or more metals from Column(s) 5-10 of the Periodic Table and a support comprised of at least 0.5 grams of theta alumina per gram of support; and wherein at least one of the catalysts is a Column 6 metal catalyst that is obtainable by heating an uncalcined Column 6 metal catalyst precursor in the presence of one or more sulfur containing compounds at a temperature below 500° C., wherein the uncalcined Column 6 metal catalyst precursor comprises: one or more metals from Column 6 of the Periodic Table and/or one or more compounds of one or more metals from Column 6 of the Periodic Table and a support; and
controlling contacting conditions such that the crude product has a nitrogen content of at most 90% of the nitrogen content of the crude feed as determined by ASTM Method D5762.
2. The method as claimed in claim 1 , wherein the nitrogen content of the crude product is at most 50% of the nitrogen content of the crude feed.
3. The method as claimed in claim 1 , wherein the nitrogen content of the crude product is in a range from 0.1% to 75% of the nitrogen content of the crude feed.
4. The method as claimed in claim 1 , wherein the crude feed has from 0.0001 grams to 0.1 grams of nitrogen per gram of crude feed.
5. The method as claimed in claim 1 , wherein the crude product has from 0.00001 grams to 0.05 grams of nitrogen per gram of crude product.
6. The method as claimed in claim 1 , wherein the Column 6 metal catalyst has, per gram of catalyst, from 0.0001 grams to 0.3 grams of one or more of the Column 6 metals and/or one or more of the Column 6 metal compounds, calculated as total weight of Column 6 metal.
7. The method as claimed in claim 1 , wherein the Column 6 metal catalyst comprises in addition one or more metals from Columns 7-10 of the Periodic Table and/or one or more compounds of one or more metals from Columns 7-10 of the Periodic Table.
8. The method as claimed in claim 7 , wherein the Column 6 metal catalyst has, per gram of catalyst, from 0.001 grams to 0.1 grams of one or more of the Columns 7-10 metals and/or one or more of the Columns 7-10 metal compounds, calculated as total weight of Columns 7-10 metals.
9. The method as claimed in any of claim 1 , wherein the Column 6 metal catalyst comprises in addition one or more metals from Column 10 of the Periodic Table and/or one or more compounds of one or more metals from Column 10 of the Periodic Table.
10. The method as claimed in claim 1 , wherein the Column 6 metal catalyst comprises molybdenum and/or tungsten.
11. The method as claimed in claim 10 , wherein the Column 6 metal catalyst further comprises nickel.
12. The method as claimed in claim 10 , wherein the Column 6 metal catalyst further comprises nickel and iron.
13. The method as claimed in claim 12 , wherein a molar ratio of total molybdenum to total nickel and iron is at least 1.5.
14. The method as claimed in claim 1 , wherein the Column 6 metal catalyst comprises in addition one or more elements from Column 15 of the Periodic Table and/or one or more compounds of one or more elements from Column 15 of the Periodic Table.
15. The method as claimed in claim 1 , wherein the Column 6 metal catalyst comprises in addition phosphorus.
16. The method as claimed in claim 15 , wherein the Column 6 metal catalyst has in addition, per gram of catalyst, from 0.001 grams to 0.05 grams of phosphorus and/or one or more compounds of phosphorus, calculated as total weight of phosphorus.
17. The method as claimed in claim 1 , wherein the Column 6 metal catalyst has at most 0.001 grams per gram of catalyst of one or more metals from Column 5 of the Periodic Table and/or one or more compounds of one or more metals from Column 5 of the Periodic Table, calculated as total weight of Column 5 metal.
18. The method as claimed in claim 1 , wherein the Column 6 metal catalyst has a median pore diameter of at least 120 Å and at most 300 Å, wherein pore size distribution is as determined by ASTM Method D4282.
19. The method as claimed in claim 1 , wherein the Column 6 metal catalyst has a pore size distribution such that at least 60% of the total number of pores in the pore size distribution are within 45 Å of the median pore diameter of the pore size distribution.
20. The method as claimed in claim 1 , wherein the Column 6 metal catalyst comprises in addition a support, and the support has, per gram of support, at least 0.8 grams of gamma alumina.
21. The method as claimed in claim 20 , wherein the Column 6 metal catalyst support has, per gram of support, at most 0.1 grams of silica.
22. The method as claimed in claim 1 , wherein crude feed also has a C 5 asphaltenes content, and the crude product has a C 5 asphaltenes content of at most 90% of the C 5 asphaltenes content of the crude feed, wherein C 5 asphaltenes content is as determined by ASTM Method D2007.
23. The method as claimed in claim 1 , wherein the crude product has a viscosity at 37.8° C. (100° F.) of at most 90% of the viscosity at 37.8° C. of the crude feed, wherein viscosity is as determined by ASTM Method D445.
24. The method as claimed in claim 1 , wherein the crude feed also has a sulfur content, and the crude product has a sulfur content of at most 90% of the sulfur content of the crude feed, wherein sulfur content is as determined by ASTM Method D4294.
25. The method as claimed in claim 1 , wherein the crude feed also has a residue content, and the crude product has a residue content of at most 90% of the residue content of the crude feed, wherein residue content is as determined by ASTM Method D5307.
26. The method as claimed in claim 1 , wherein the contacting is performed in the presence of a hydrogen source.
27. The method as claimed in claim 26 , wherein the contacting conditions comprise: a temperature within the range of 50° C. to 500° C.; a total pressure within a range of 0.1 MPa to 20 MPa; a liquid hourly space velocity of at least 0.05 h −1 ; and a ratio of a gaseous hydrogen source to the crude feed in a range from 0.1 Nm 3 /m 3 to 100,000 Nm 3 /m 3 .
28. The method as claimed in claim 1 , wherein a crude feed/total product mixtures has a P-value of at least 1.5 during contacting.
29. The method as claimed in claim 1 , wherein the method further comprises combining the crude product with a crude that is the same as or different from the crude feed to form a blend.
30. The method of claim 1 or claim 29 further comprising the step of processing the crude product or blend to produce transportation fuel, heating fuel, lubricants, or chemicals.
31. The method of claim 1 wherein the crude feed is contacted with the Column(s) 5-10 metal catalyst and is subsequently contacted with the Column 6 metal catalyst.