(12) United States Patent (10) Patent No.: US 8,969.242 B2 Klein Et Al
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USOO8969242B2 (12) United States Patent (10) Patent No.: US 8,969.242 B2 Klein et al. (45) Date of Patent: Mar. 3, 2015 (54) CATALYST SUPPORTAND CATALYSTS (58) Field of Classification Search PREPARED THEREFROM CPC ........ B01J 35/04; B01J 21/04; B01J 37/0009; F01N3/291; F01N 2330/02 (75) Inventors: Darryl P. Klein, Ellicott City, MD (US); See application file for complete search history. Nan Chen, Berkeley, CA (US); Matthew P. Woods, Baltimore, MD (56) References Cited (US); Bruno Nesci, Oak Lawn, IL (US) U.S. PATENT DOCUMENTS (73) Assignee: Advanced Refining Technologies LLC, 4,066,574 A 1/1978 Tamm Columbia, MD (US) 4,113,661 A 9, 1978 Tamm (*) Notice: Subject to any disclaimer, the term of this (Continued) patent is extended or adjusted under 35 U.S.C. 154(b) by 0 days. FOREIGN PATENT DOCUMENTS EP 1932431 B1 8, 2006 (21) Appl. No.: 13/822,340 WO 2005O28106 A1 3, 2005 (22) PCT Fled: Aug. 3, 2012 OTHER PUBLICATIONS (86) PCT NO.: PCT/US2O12/0494.15 “High Production Volume (HPV) Chemical Challenge Program, Test Plan, Heavy Fuel Oils Category”. Submitted to the US EPA. The S371 (c)(1), Petroleum HPV Testing Group (Jun. 17, 2004), Appendix A, pp. (2), (4) Date: May 3, 2013 38-42. (87) PCT Pub. No.: WO2O13/032628 (Continued) PCT Pub. Date: Mar. 7, 2013 Primary Examiner — Colleen Dunn (65) Prior Publication Data (74) Attorney, Agent, or Firm — Lerner, David, Littenberg, Krumholz & Mentlik, LLP US 2014/O174983 A1 Jun. 26, 2014 (57) ABSTRACT Related U.S. Application Data A Supported catalyst useful in processes for chemically refin (60) Provisional application No. 61/530,108, filed on Sep. ing hydrocarbon feedstocks, the catalyst comprising a metal 1, 2011. from Group 6, a metal from Group 8, and optionally phos phorous, wherein the carrier or Support, comprises porous (51) Int. C. alumina comprising: (a) equal to or greater than about 78% to BOI 2L/04 (2006.01) about 95% of TPV in pores having a diameter of less than BOI. 23/02 (2006.01) about 200 Angstroms (A); (b) greater than about 2% to less (Continued) than about 19% of the TPV in pores having a diameter of (52) U.S. C. about 200 to less than about 1000 A; (c) equal to or greater CPC B01J 27/24 (2013.01); B01J 23/00 (2013.01); than 3% to less than 12% of the TPV in pores having a B01J 37/28 (2013.01); B01J 21/04 (2013.01); diameter equal to or greater than about 1000 A. (Continued) 15 Claims, 1 Drawing Sheet Example of Pore Size Distribution US 8,969.242 B2 Page 2 (51) Int. C. 7,390,766 B1 6/2008 Klein BOI 27/24 (2006.01) 7,560.407 B2 7, 2009 Klein 7,642.212 B2 1/2010 Klein BOI. 23/00 (2006.01) 2002fOOOO397 A1 1/2002 Sherwood, Jr. et al. BOI. 37/28 (2006.01) 2004/0050754 A1 3/2004 Abe et al. ................ 208,216 PP BOI. 23/85 (2006.01) 2009, 0255850 A1 10, 2009 Bhan et al. BOI. 23/883 (2006.01) 2010, 0006475 A1 1/2010 Ginestra BOI 35/10 (2006.01) OTHER PUBLICATIONS CIOG 45/10 (2006.01) CIOG 47/4 (2006.01) ASTM D 3037-93 Standard Test Method for Distillation of Petro CIOG 65/12 (2006.01) leum Products at Reduced Pressure, “Withdrawn Standard: ASTM BOIJ 37/03 (2006.01) D3037-93 Standard Test Methods for Carbon Black-Surface Area BOIJ 37/02 (2006.01) by Nitrogen Avsorption (Withdrawn 1999). <http://astm.org/Stan (52) U.S. C. dards/D3037.htm>, downloaded Sep. 13, 3013. CPC ................ B01J 23/85 (2013.01); B01J 23/883 ASTM D11 60-06 Standard Test Method for Distillation of Petroleum (2013.01); B01.J35/1042 (2013.01); B01.J Products at Reduced Pressure, “Historical Standard: STM D1 160-06 35/1047 (2013.01); B01J 35/1061 (2013.01); Standard Test Method for Distallation of Petroleum at Reduced Pres B01.J35/108 (2013.01): CI0G 45/10 (2013.01); Sure', downloaded Sep. 20, 2013. ASTM D4284-07. “A Standard Test Method for Determining Pore CI0G 47/14 (2013.01): CI0G 65/12 (2013.01); Volume Distribution of Catalysts by Mercury Intrusion B01J 37/031 (2013.01); B01J 37/020.1 Porosimetry”, pp. 1-6, published Oct. 1992. (2013.01) ASTM D4530 Standard Test Method for Distillation of Petroleum USPC ............................................. 502/439; 208/89 Products at Reduced Pressure, “Historical Standard: STM D4530-00 Standard Test Method for Determination of Carbon Residue (Micro (56) References Cited Method), downloaded Sep. 20, 2013. ASTM D4870 Standard Test Method for Determination of Total U.S. PATENT DOCUMENTS Sediment in Residual Fuels, “Standard Test Method for D4870’, downloaded Sep. 20, 2013. 4,154,812 A 5, 1979 Sanchez et al. 4,341,625. A 7, 1982 Tamm Barrett et al., “The Determination of Pore Volume and Area Distri 4497,909 A 2f1985 Itoh et al. butions in Porous Substances. I. Computations from Nitrogen Iso 4,917,791 A 4/1990 Kang therms,” J. Am. Chem. Soc., 1951, 73 (1), p. 373. 4.941,964 A 7, 1990 Dai et al. Brunauer et al., “ Adsorption of gases in multimolecular layers'. 5,047,142 A 9, 1991 Sherwood, Jr. et al. Journal of American Chemical Society, 60, pp. 309-319 (1938). 5,087,348 A 2f1992 Dai et al. Dai and Campbell. “Mild Hydrocracking of Heavy Oils with Modi 5,089,463 A * 2/1992 Johnson ........................ 502,313 fied Alumina Based Catalysts”, Catalytic Hydroprocessing of Petro 5,094,994 A 3/1992 Sherwood, Jr. et al. leum and Distillates, edited by Oballa and Shih, Marcel Dekker Inc., 5,322,616 A 6, 1994 Dai et al. New York (1994). 5,370,788 A 12/1994 Dai et al. Dai et al., “The effect of additives and impregnation stabilizers on 5,399,259 A 3, 1995 Dai et al. hydrodesulfurization activity”, ACS 208th national meeting, Aug. 5,416,054 A 5, 1995 Dai et al. 1994. 5,435,908 A 7, 1995 Nelson et al. 5,436,216 A 7/1995 Toyao et al. Drake et al., “Macropore-Size Distributions in Some Typical Porous 5,468.371 A 11/1995 Nelson et al. Substances'. Industrial and Engineering Chemistry, Analytical Edi 5,498,586 A 3, 1996 Dai et al. tion 17,787 (1945). 5,514,273 A 5/1996 Sherwood, Jr. et al. McKnight et al., "Joint ebullated bed catalyst development program 5,545,602 A 8, 1996 Nelson et al. results in over 30% reduction in catalyst usage”. EPC bottom of the 5,616,530 A 4, 1997 Sherwood, Jr. et al. barrel conference, Athens, 2006. 5,827,421 A 10/1998 Sherwood, Jr. Periodic Table of the Elements as published in “Hawley's Condensed 5,868,923 A 2f1999 Porter et al. Chemical Dictionary” (2001) (the "CAS” system). 5,928,499 A 7/1999 Sherwood, Jr. et al. Periodic Table of the Elements, published by the International Union 5,968,248 A 10, 1999 Shibasaki et al. of Pure and Applied Chemistry(IUPAC), published on-line at http:// 5,968,348 A * 10/1999 Sherwood, Jr. ......... 208,216 PP oldiupac.org/reports/periodic table?; version dated Feb. 19, 2010. 6,387,248 B2 5/2002 Sherwood, Jr. et al. 6,403,526 B1 6/2002 Lussier et al. Van Kerkvoort, W. J. and Nieuwstad, A. J. J., “Determination of 6,589,908 B1 7/2003 Ginestra et al. Dry-sludge content of fuel oils: Development of the shell hot filtra 6,919,294 B2 7/2005 Saito et al. tion test (SHFT)”, Journal of the Inst. of Petroleum (1951), 37, pp. 6,928.499 B2 8, 2005 Kitakami 596-604. 6,984,310 B2 1/2006 Ginestra et al. 7,169,294 B2 1/2007 Abe et al. * cited by examiner U.S. Patent Mar. 3, 2015 US 8,969.242 B2 Example Of POre Size Distribution US 8,969,242 B2 1. 2 CATALYST SUPPORTAND CATALYSTS reduced catalyst life and metals present in Such streams which PREPARED THEREFROM deposit on hydroprocessing catalysts tend to poison or deac tivate the catalyst. Moreover, asphaltenes tend to reduce the CROSS-REFERENCE TO RELATED susceptibility of the hydrocarbons to desulfurization. If a APPLICATIONS catalyst, such as a desulfurization catalyst or a fluidized cracking catalyst, is exposed to a hydrocarbon fraction that The present application is a national phase entry under 35 contains metals and asphaltenes, the catalyst can become U.S.C. S371 of International Application No. PCT/US2012/ deactivated rapidly and thus be subject to premature replace 04.9415 filed Aug. 3, 2012, published in English, which ment. claims priority from U.S. Provisional Patent Application No. 10 Various hydroconversion processes are effectively carried 61/530,108 filed Sep. 1, 2011, all of which are incorporated out using an ebullated bed (EB) system. In an EB, preheated herein by reference. hydrogen and resid feedstock enter the bottom of a reactor wherein the upward flow of resid with or without an liquid BACKGROUND OF THE INVENTION internal recycle Suspend the catalyst particles in the liquid 15 phase. In improved EB processes, part of the catalyst is con There is a continuing need in the petroleum industry for tinuously or intermittently removed in a series of cyclones improved catalyst Supports and Supported catalysts derived and fresh catalyst is added to maintain activity. Approxi therefrom, which have enhanced activity and improved cata mately about 1 wt.% of the catalyst inventory is replaced each lyst life and exhibiting a desirable balance of morphological day in an ebulated bed system.