United States Patent [191 [11] Patent Number: Kukes [45] Date ‘of Patent: 7 [54] CATALYST FOR DEMETALLIZATION OF HYDROCARBON CONTAINING FEED 3,733,327 5/1973 Vrieland et al. 3,946,079 3/1976 Mizutani et a1. 502/208 502/208 STREAMS 4,059,679 11/1977 502/208 4,400,568 [76] Inventor: [21] and Doescher, P_O_ Box 2443, 4,430,207 2068252 Mar’ 27’ 1984 Division of Ser. No. 538,068, Sep. 30, 1983, Pat. No. 8/1981 United Kingdom .............. .. 502/202 Assistant Examiner-Anthony McFarlane [ 5 7] ABSTRACT Metals contained -in a hydrocarbon containing feed ' 3 stream are removed by contacting the hydrocarbon """""""""" """"""" ° """" ‘T """"""""""""" " 502/349’_ 423/306’ containing feed stream under suitable demetallization conditions with hydrogen and a catalyst composition [58] Field of Search ............. .. 502/208, 344,345, 349; 423/306 _ [56] 502/208 2/ 1984 Kukes ................................ .. 502/208 Primary Examiner-Delbert ‘E. Gantz 4,457,835. ' ' 502/208 FOREIGN PATENT DOCUMENTS Reae l t d U . S . Appicaion l_ f Data [62] Clear?eld .......... .. 4,409,418 10/1983 Johnson et a1. APPL No" 593,742 [22] Flled: Mar. 263 1985 8/1983 Hofmann et al. Simon G. Kukes, c/o French, Hughes Bamesvlne’ Okla' 74°05 4,507,402 c°mpfising zircfmlum Phmphate and °°PPeF Pmsphate The Me and act1v1ty of the catalyst compositlon may be increased by introducing a decomposable metal com References Clted pound selected from the group consisting of the metals U.s. PATENT DOCUMENTS QfIEYI'OFPhV-IP, Gaougrvll-B, Grollllp lYII-B and Group 0 t e erio ic ab e intot e ydrocarbon con gitgzreétai'l """"""""""" " 3:271:447 9/1966 Naylor _____ 5o2/2o8 3,431,311 3/1969 Cooper et al. 3,555,105 1/1971 taining feed stream prior to contacting the hydrocarbon containing feed stream with the catalyst composition. 502/208 Nolan et a1. ...................... .. 502/208 5 Claims, N0 Drawings 1 4,507,402 2 are generally regarded as being too heavy to be dis CATALYST FOR DEMETALLIZATION OF HYDROCARBON CONTAINING FEED STREAMS This application is a division of application Ser. No. 538,068, ?led Sept. 30, 1983, now U.S. Pat. No. LII 4,457,835. pyrophosphates, metaphosphates and polyphosphates. This invention relates to a process for removing met als from a hydrocarbon containing feed stream and a catalyst therefor. tilled. These materials will generally contain the highest concentrations of metals such as vanadium and nickel. The demetallization catalyst employed in the process of the present invention is a composition comprising zirconium phosphate and copper phosphate. As used herein, the term phosphate includes orthophosphates, 10 It is well known that crude oil as well as products The catalyst composition can be prepared by any suitable method. coprecipitation is preferred because the catalyst composition is more effective when pre from extraction and/or liquifaction of coal and lignite, products from tar sands, products from shale oil and pared by coprecipitation. The catalyst is generally pre similar products may contain metals such as vanadium, pared by coprecipitating any suitable zirconium salt and any suitable copper salt with any suitable phosphate. nickel and iron. When these hydrocarbon containing 15 The coprecipitation may be carried out in any suitable feeds are fractionated, the metals tend to concentrate in solvent such as water or alcohol with water being the the heavier fractions such as the topped crude and resid uum. The presence of the metals make further process preferred solvent. The metal salts and the phosphate must be soluble in the solvent used to be suitable. If a phosphate such as diamonium phosphate is uti ing of these heavier fractions difficult since the metals generally act as poisons for catalysts employed in pro lized, the pH of the solution will generally be such that precipitation will occur. However, if other phosphates cesses such as catalytic cracking, hydrogenation or hydrodesulfurization. are used, it may be necessary to add a base such as It is thus an object of this invention to provide a process for removing metals from a hydrocarbon con taining feed stream so as to improve the processability ammonia to achieve a pH which will result in the de sired precipitation. The precipitant formed is washed, dried and calcined in the presence of a free oxygen containing gas such as cially improve the processability of heavier fractions air to form the catalyst. such as topped crude and residuum. It is also an object The drying of the precipitant may be accomplished at of this invention to provide a catalyst composition any suitable temperature. Generally a temperature of which is useful for demetallization. 30 about 20° C. to about 200° C., preferably about 100° C. In accordance with the present invention, a hydro to about 150° C., is utilized for a time in the range of carbon containing feed stream, which also contains about 1 hr. to about 30 hrs. metals, is contacted with a catalyst composition com The calcining step is utilized to remove traces of prising zirconium phosphate and copper phosphate in nitrates, traces of carbon, and water and to make the the presence of hydrogen under suitable demetallization 35 structure of the catalyst composition harder. Any suit conditions. It is believed that the metals contained in able calcining temperature can be utilized. Generally, heterocyclic compounds such as porphyrines are re the calcining temperature will be in the range of about moved from the heterocyclic compounds by the combi 300° C. to about 800° C. with a temperature in the range nation of heat, hydrogen and the catalyst composition of about 500° C. to about 650° C. being preferred for a of the present invention and are trapped in pores in the 40 time in the range of about 1 to about 24 hours, prefera catalyst composition. Removal of the metals from the bly about 2 to about 6 hours. hydrocarbon containing feed stream in this manner The catalyst composition can have any suitable sur of such hydrocarbon containing feed stream and espe provides for improved processability of the hydrocar face area and pore volume. In general, the surface area bon containing feed stream in processes such as cata Other objects and advantages of the invention will be apparent from the foregoing brief description of the will be in the range of about 2 to about 400 m2/g, prefer ably about 10 to about 200 m2/g, while the pore volume will be in the range of about 0.2 to about 4.0 cc/g, pref erably about 0.4 to about 2.0 cc/g. Any suitable phosphates may be utilized to prepare invention and the appended claims as well as the de the catalyst composition. Suitable phosphates include lytic cracking, hydrogenation and hydrodesulfuriza tion. 45 tailed description of the invention which follows. 50 (NH4)H2P04, (NH4)zHP04, (NH4)sP04, (NH4)4P207, Any metal which can be trapped in the pores of the corresponding phosphates and pyrophosphates of lith catalyst composition of the present invention can be ium, sodium, potassium, rubidium, and cesium, and removed from a hydrocarbon containing feed stream in H3PO4. Phosphonic acids such as phenyl phosphonic accordance with the present invention. The present acids and the metal salts of phosphonic acids may also invention is particularly applicable to the removal of 55 be used to derive phosphates for the catalyst composi vanadium and nickel. tion if desired. Metals may be removed from any suitable hydrocar Any suitable zirconium and copper to phosphorus bon containing feed streams. Suitable hydrocarbon con ratio in the catalyst composition may be used. The ratio taining feed streams include petroleum products, coal will generally be about stoichiometric. Any suitable pyrolyzates, products from extraction and/or liquifac- 60 ratio of zirconium to copper may be used. The molar tion of coal and lignite, products from tar sands, prod ratio of zirconium to copper will generally be in the ucts from shale oil and similar products. Suitable hydro range of about 10:1 to about 1:10 and more preferably in carbon feed streams include gas oil having a boiling the range of about 3:1 to about 1:2. range from about 205° C. to about 538° C., topped crude The demetallization process of this invention can be having a boiling range in excess of about 343° C. and 65 carried out by means of any apparatus whereby there is residuum. However, the present invention is particu achieved a contact of the catalyst composition with the larly directed to heavy feed streams such as heavy topped crudes and residuum and other materials which hydrocarbon containing feed stream and hydrogen under suitable demetallization conditions. The process 3 4,507,402 4 is in no way limited to the use of a particular apparatus. The process of this invention can be carried out using a The time in which the catalyst composition will maintain its activity for removal of metals will depend ?xed catalyst bed, ?uidized catalyst bed or a moving upon the metals concentration in the hydrocarbon con taining feed streams being treated. It is believed that the catalyst composition may be used for a period of time long enough to accumulate 20-200 wt.% of metals, reactor or may be used in combination with essentially mostly Ni and V, based on the weight of the catalyst inert materials such as alumina, silica, titania, magnesia, composition, from oils. silicates, aluminates, alumina silicates, titanates and It is believed that the life of the catalyst composition phosphates. A layer of the inert material and a layer of and the ef?ciency of the demetallization process can be 10 the catalyst composition may be used or the catalyst improved by introducing a decomposable metal com composition may be mixed with the inert material. Use pound into the hydrocarbon containing feed stream. It of the inert material provides for better dispersion of the is believed that the metal in the decomposable metal hydrocarbon containing feed stream. Also, other cata compound could be selected from the group consisting lyst such as known hydrogenation and desulfurization of the metals of Group V-B, Group VI-B, Group VII-B catalysts may be used in the reactor- to achieve simulta and Group VIII of the Periodic Table. Preferred metals neous demetallization, desulfurization and hydrogena are molybdenum, tungsten, manganese, chromium, tion or hydrocracking if desired. nickel and iron. Molybdenum is a particularly preferred Any suitable reaction time between the catalyst com metal which may be introduced as a carbonyl, acetate, position and the hydrocarbon containing feed stream acetylacetonate, octoate (octanoate), naphthenate or may be utilized. In general, the reaction time will range 20 dithiocarbamate. Molybdenum hexacarbonyl is a partic from about 0.1 hours to about 10 hours. Preferably, the ularly preferred additive. catalyst bed. Presently preferred is a ?xed catalyst bed. The catalyst composition may be used alone in the reaction time will range from about 0.4 to about 4 hours. Thus, the ?ow rate of the hydrocarbon containing feed stream should be such that the time required for the passage of the mixture through the reactor (residence time) will preferably be in the range of about 0.4 to about 4 hours. This generally requires a liquid hourly space velocity (LHSV) in the range of about 0.10 to Any suitable concentration of the additive may added to the hydrocarbon containing feed stream. general, a suf?cient quantity of the additive will added to the hydrocarbon containing feed stream be In be to result in a concentration of the metal in the range of about 1 to about 1000 parts per million and more prefer ably in the range of about 5 to about 100 parts per mil about 10 cc of oil per cc of catalyst per hour, preferably lion. from about 0.2 to about 2.5 cc/cc/hr. The following examples are presented in further illus The demetallization process of the present invention tration of the invention. can be carried out at any suitable temperature. The EXAMPLE I temperature will generally be in the range of about 150° to about 550° C. and will preferably be in the range of 35 In this example the preparation and pertinent proper about 350° to about 450° C. Higher temperatures do ties of various phosphates employed as heavy oil deme improve the removal of metals but temperatures should tallization catalysts are described. not be utilized which will have adverse effects on the Zr3(PO4)4 was prepared by ?rst dissolving 301 grams hydrocarbon containing feed stream, such as coking, and also economic considerations must be taken into account. Lower temperatures can generally be used for lighter feeds. of zirconyl nitrate, ZrO(NO3)2, in 1 liter of hot water and then adding to this solution, with stirring, a solution of 151 grams of (NH4)2HPO4 in 400 cc of hot water. The resulting solution was ?ltered to obtain the zirco Any suitable pressure may be utilized in the demetall nium phosphate precipitate. The precipitate was ization process. The reaction pressure will generally be washed with 2 liters of water, dried at about 120° C. in the range of about atmospheric to about 5,000 psig. 45 overnight, and calcined in air at 550° C. for 5 hours. The Preferably, the pressure will be in the range of about calcined Zr3(PO4)4 had a surface area of 64.9 mZ/gram, 100 to about 2500 psig. Higher pressures tend to reduce a pore volume of 0.76 cc/gram, a bound Zr content of coke formation but operation at high pressure may have 43.5 weight-%, a bound P content of 15.9 weight-%, a adverse economic consequences. bound 0 content of 42.3 weight-%, and was essentially Any suitable quantity of hydrogen can be added to amorphous as indicated by X-ray diffraction measure the demetallization process. The quantity of hydrogen ment. This zirconium phosphate catalyst was employed used to contact the hydrocarbon containing feed stock in Runs 1, 2, 4 and 5. will generally be in the range of about 100 to about Mixed zirconium phosphate-nickel phosphate was 10,000 standard cubic feet per barrel of the hydrocar prepared by dissolving 116.5 grams (0.5 mole) of bon containing feed stream and will more preferably be ZrOCl2.4H2O and 145 grams (0.5 mole) of Ni(NO3)2.6 in the range of about 1000 to about 6000 standard cubic H2O in 1.5 liters of hot water. A solution of 150 grams feet per barrel of the hydrocarbon containing feed of (NH4)2HPO4 in 0.7 liter of warm water was added to the ?rst solution (containing zirconyl chloride and stream. In general, the catalyst composition is utilized for nickel nitrate) with stirring for 30 minutes. The result demetallization until a satisfactory level of metals re ingmixture was ?ltered to obtain the precipitate. The moval fails to be achieved which is believed to result zirconium phosphate-nickel phosphate (Zr-Ni-PO4) from the coating of the catalyst composition with the ?lter cake was washed with 1 liter of warm water. The ?lter cake was then slurried in 2 liters of hot water, metals being removed. It is possible to remove the met stirred for 1 hour, ?ltered and washed with 1 liter of hot als from the catalyst composition by certain leaching procedures but these procedures are expensive and it is 65 water. The washed nickel phosphate-zirconium phos phate was dried for about 16 hours in a vacuum oven at generally contemplated that once the removal of metals 120° C. and calcined in air at about 560° C. for 4 hours. falls below a desired level, the used catalyst will simply The resulting catalyst’s surface area was 56 m2/grams, be replaced by a fresh catalyst. 4,507,402 5 6 its pore volume (determined by mercury porosimetry) was 0.90 cc/gram, and the yolume of pores having a was moved within the axial thermocouple well. The liquid product was collected in a receiver, ?ltered diameter smaller than 300 A (calculated from BET through a glass frit and analyzed. Exiting hydrogen gas nitrogen adsorption) was 0.16 cc/gram. This catalyst was vented. Vanadium and nickel content in oil was was employed in runs 15 and 16. determined by plasma emission analysis. The catalyst of this invention, coprecipitated The feed was a mixture of 26 weight-% toluene and Zr3(PO4)4-Cu3(PO4)2, was prepared as follows: 47 grams of cupric nitrate and 27 grams of ZrO(NO3)2 74 weight-% Venezuelan Monagas pipeline oil having an API gravity of about 17-18 with the exception of runs 15 and 16 in which undiluted Monagas pipeline oil were dissolved in 1 liter of hot water. Then a solution of 83 grams of (NH4)2HPO4 in 400 mL of water was added - O was used. The hydrogen pressure was maintained at to the ?rst solution with stirring. The formed precipi about 1000 psig in all experiments (with the exception of Runs 15 and 16) which generally lasted from about 2-6 hours. The reactor temperature (average of thermo couple readings at four reactor locations) was about tate was ?ltered from the mixture of the two solutions, washed twice with 1.5 liter of hot water, dried at about 120° C. overnight, and calcined in air at 550° C. for 4 hours. The surface area of this coprecipitated Cu3( 375°—435° C. The liquid hourly space velocity (LHSV) PO4)2-Zr3(PO4)4 (determined by BET with N2) was 73.4 mz/g, and its pore volume (determined by mercury porosimetry) was 1.05 cc/g. Elemental analysis data were: 29.0 weight-% Zr, 11.3 weight-% Cu, 16.7 weight-% P and 42.3 weight-% 0. The atomic ratio of ZrzCu was about 1.8:1. This coprecipitated phosphate of the feed ranged from about 0.5 cc/cc catalyst/hour to about 2 cc/cc catalyst/hour. 20 was employed in runs 3, 6-14. EXAMPLE III Results of heavy oil demetallization runs at 425° C. in accordance with the procedure described in Example II are summarized in Table I. TABLE I Feed LHSV Run 1 2 3 4 5 6 7 8 9 10 (Control) (Control) (Invention) (Control) (Control) (Invention) (Invention) (Invention) (Invention) (Invention) (c/cc/hr) Catalyst 0.99 0.96 1.02 1.60 1.53 1.48 1.48 1.98 2.00 2.01 Zr3(PO4)4 Zr3(PO4)4 Zr—Cu—PO4 Zr3(PO4)4 Zr3(PO4)4 Zr—-Cu—PO4 Zr—Cu——PO4 Zr—Cu—PO4 Zr—Cu—PO4 Zr—Cu—PO4 Product Pore Run Vana- Total Vana- Volume Time dium Nickel (V + Ni) dium Nickel (V + Ni) Total (cc/g) (Hours) (ppm) (mm) (mm) (ppm) (ppm) 0.76 0.76 1.05 0.76 0.76 1.05 1.05 1.05 1.05 1.05 3.0 4.0 3.4 2.5 2.1 3.0 2.0 3.9 5.5 5.7 269 217 296 269 217 296 296 296 296 296 62.6 39.2 73.5 62.6 39.2 92.1 92.1 73.5 73.5 73.5 331.6 256.2 369.5 331.6 256.2 388.1 388.1 369.5 369.5 369.5 81.8 74.1 26.8 148.0 113.0 126.0 98.7 165.0 198.0 201.0 27.0 19.4 21.2 42.7 27.1 43.2 35.7 57.4 63.4 62.9 Removal of Metals (ppm) (%) 109.8 93.5 48.0 190.7 140.1 169.2 134.4 222.4 261.4 263.9 77 64 87 42 45 56 65 40 29 29 Data in Table I show that at com arable LHSV co p precipitated Zr3(PO4)4-Cu3(PO4)2 was more effective EXAMPLE II This example illustrates the experimental setup for 40 than Zr3(PO4)4 in removing Ni and V from heavy oil at investigating the demetallization of heavy oils by em 425° C. (compare run 3 with runs 1 and 2; runs 6, 7 with ploying various phosphate catalysts. Oil, with or with runs 4, 5). out a dissolved decomposable molybdenum compound, was pumped by means of a LAPP Model 211 (General Electric Company) pump to a metallic mixing T-pipe 45 where it was mixed with a controlled amount of hydro EXAMPLE IV Results of the demetallization of heavy oils at 400° C. in accordance with the procedure described in Example gen gas. The oil/hydrogen mixture was pumped down II are summarized in Table II. TABLE II Feed Pore LHSV Run 11 12 13 14 (Invention) (Invention) (Invention) (Invention) (c/cc/hr) Catalyst 0.45 1.05 1.49 1.52 Zr-Cu-P04 Zr—Cu—PO4 Zr—Cu-—P04 Zr—Cu—PO4 Run Vana- Product Total Vana- Total Removal of Volume Time dium Nickel (V + Ni) dium Nickel (V + Ni) (cc/g) (Hours) (ppm) (ppm) (ppm) (ppm) (ppm) (ppm) ‘(V + Ni) (%) 1.05 1.05 1.05 1.05 6.0 3.0 3.0 2.0 296 296 296 296 73.5 73.5 92.1 73.5 369.5 369.5 388.1 369.5 16.9 64.9 213.0 89.8 14.7 36.0 60.0 43.7 31.6 100.9 273.0 133.5 91 73 30 64 ward through a stainless steel trickle bed reactor, 28.5 inches long and 0.75 inches in diameter, ?tted inside Data in Table II show that, at 400° C., the coprecipi with a 0.25 O.D. axial thermocouple well. The reactor 60 tated Zr3(PO4)4-Cu3(PO4)z catalyst was quite effective was ?lled with a top layer (3.5 inches below the oil/H2 in removing Ni and V from heavy oil, especially at a feed inlet) of 50 cc of low surface area (less than 1 low liquid hourly space velocity of about 0.5-1.1. m2/gram) a-alumina, a middle layer of 50 cc of a phos EXAMPLE V phate catalyst, and a bottom layer of 50 cc of a-alumina. The reactor tube was heated by a Thermcraft (Winston 65 In this example, the results of extended demetalliza Salem, NC.) Model 211 3-zone furnace. The reactor temperature was usually measured in four locations tion runs of up to 3 months in an automated reactor along the reactor bed by a traveling thermocouple that the coprecipitated catalyst (Zr-Ni-PO4) similar to the similar to the one described in Example II employing 4,507,402 7 8 Data in Table III show that the catalyst of this exam inventive one (Zr-Cu-PO4) are described. Undiluted, heavy Monagas pipeline oil was used as the feed. It ple, Zr3(PO4)4-Ni3(PO4)2, essentially retained its activ contained 88. ppm of Ni, 337 ppm of V, 2.73 weight-% ity after about 2 months on stream. However, when the feed oil contained about 70 ppm of Mo (as dissolved S, 73.7 volume‘-% residual oil (boiling point higher than 650° F.), 24.7 volume-% of distillate (boiling range of 5 Mo(CO)6, the demetallization activity of the zirconium phosphate-nickel phosphate increased about 10% after 400°-650° F .); and it had an API gravity of 12.3°. almost 500 hours (3 weeks) on stream. The removal of In this demetallization run, the reactor temperature V and Ni was consistently higher, especially after about was 407° C. (765' F.), the oil feed LHSV was 0.9-1.1 200 hours on-strearn, than a system without Mo(CO)6 cc/cc catalyst/hr, the total pressure was 2250 psig, and the hydrogen feed rate was 4800 SCF/bbl (standard cubic feet of Hz per barrel of oil). The metal removal achieved with zirconium-nickel phosphate was greater when Mo(CO)6 was added as an additional demetalliza tion agent to the feed oil. Results are summarized in Table III. (compare Runs 15 and 16). Substantially all iron (ap proximately 56 ppm in oil) was also removed with zir conium phosphate-nickel phosphate with and without added Mo(CO)5. Based on these results, it is believed that the addition of molybdenum to the feed oil would 15 also be bene?cial when the inventive zirconium phos phate-copper phosphate catalyst is used. TABLE III M0 in Run 15 16 Feed (ppm) 0 0 0 0 0 0 0 0 0 0 0 0 0 70 70 70 70 70 70 70 70 Hours Catalyst Zr-Ni--PO4 Zr--Ni—PO4 Zr—-Ni-—PO4 Zr—Ni—P04 Zr-—Ni—-PO4 Zr—-Ni--PO4 Zr—Ni—PO4 Zr-—Ni-PO4 Zr—Ni—-PO4 Zr—~Ni—PO4 Zr--Ni—PO4 Zr—Ni—PO4 Zr-—Ni—PO4 Zr--Ni—-PO4 Zr-Ni-PO4 Zr-Ni—-PO4 Zr—Ni—PO4 Zr-Ni—PO4 Zr—Ni-PO4 Zr—Ni—PO4 Zr—-Ni--PO4 That which is claimed is: Metals in on Mpg-L V+Ni Stream V Ni V+Ni (%) 117 233 257 303 390 436 532 789 1008 1228 1416 1717 2189 124 220 244 327 375 423 471 495 93 114 109 104 113 108 109 89 118 108 110 135 135 90 92 68 78 81 74 68 64 49 55 54 51 50 45 49 47 42 46 42 48 49 40 42 36 38 37 36 35 34 142 I69 163 155 168 153 158 136 160 154 152 183 184 130 134 104 116 118 110 103 98 1. A catalyst composition comprising a coprecipi tated mixture of zirconium phosphate and copper phos Removal of 66 60 61 63 60 64 63 68 62 64 64 57 57 69 68 75 73 72 74 76 77 phate. 2. A composition in accordance with claim 1 wherein said catalyst composition has a surface area in the range of about 2 to about 400 m2/gram and has a pore volume in the range of about 0.2 to about 4.0 cc/gram. 3. A composition in accordance with claim 2 wherein 25 said catalyst composition has a surface area in the range of about 2 to about 400 m2/gram and has a pore volume in the range of about 0.4 to about 2.0 cc/gram. 4. A composition in accordance with claim 1 wherein 30 the ratio of zirconium and copper to phosphorus in said catalyst composition is about stoichiometric and wherein the molar ratio of zirconium to copper is in the range of about 10:1 to about 1:10. 5. A composition in accordance with claim 4 wherein 35 the ratio of zirconium and copper to phosphorus in said catalyst composition is about stoichiometric and wherein the molar ratio of zirconium to copper is in the range of about 3:1 to about 1:2. * 45 55 65 * * * =1!
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