Ashland Oil, Inc.

Edward B Cornelius

Stephen M Kovach

William P Hettinger, Jr

James Donald Carruthers

H Wayne Beck

James L Palmer

Oliver J Zandona

Ronald A Kmecak

A process is disclosed for the conversion of a hydrocarbon oil feed having a significant content of vanadium to lighter oil products by contacting the feed under conversion conditions in a conversion zone with a catalyst containing a metal additive to immobilize vanadium compounds. Conversion conditions are such that coke and vanadium are deposited on the catalyst in the conversion zone. Coked catalyst is regenerated in the presence of an oxygen containing gas at a temperature sufficient to remove the coke and regenerated catalyst is recycled to the conversion zone for contact with fresh feed. The metal additive is present on the catalyst in an amount sufficient to immobilize the vanadium compounds in the presence of oxygen containing gas at the catalyst regeneration temperature. A catalyst composition comprises a crystalline alumino-silicate zeolite dispersed in an amorphous inert solid matrix containing the metal additive, which may be introduced into the catalyst during the conversion process or during catalyst manufacture. Metal additives include water soluble inorganic metal salts and hydrocarbon soluble inorganic metal salts and hydrocarbon soluble organometallic compounds of select metals.

Immobilization of vanadia deposited on catalytic materials during

A catalyst nominally containing zeolite, clay and silica-alumina gel. The zeolite is preferably partially exchanged with high La/Ce ratio solution in a wetting step. The catayst and processes for its manufacture and use are disclosed. The catalyst is excellent for processing heavy oils, generally produces higher LCO/slurry oil ratio and has high metals tolerance.

High performance catalysts for carbometallic oil conversion and their

A catalyst nominally containing zeolite, clay and silica-alumina gel is disclosed. The zeolite is preferably partially exchanged with high La/Ce ratio solution in a wetting step. The catalyst and processes for its manufacture and use are disclosed. The catalyst is excellent for processing heavy oils, generally produces higher LCO/slurry oil ratio and has high metals tolerance.

Carbometallic oil conversion with zeolite y containing catalyst

A process is disclosed for the treatment of a hydrocarbon oil feed having a significant content of vanadium to provide a higher grade of oil products by contacting the feed under treatment conditions in a treatment zone with sorbent material containing a metal additive to immobilize vanadium compounds. Treatment conditions are such that coke and vanadium are deposited on the sorbent in the treatment zone. Coked sorbent is regenerated in the presence of an oxygen containing gas at a temperature sufficient to remove the coke, and regenerated sorbent is recycled to the treatment zone for contact with fresh feed. The metal additive is present on the sorbent in an amount sufficient to immobilize the vanadium compounds in the presence of oxygen containing gas at the sorbent regeneration temperature. A sorbent composition disclosed comprises a kaolin clay containing the metal additive, which may be introduced into the clay during the treatment process or during sorbent manufacture. Metal additives include water soluble inorganic metal salts and hydrocarbon soluble organo-metallic compounds of select metals.

Immobilization of vanadia deposited on sorbent materials during

A process is disclosed for the treatment of a hydrocarbon oil feed having a significant content of metals to lighter oil products by contacting the feed under conversion conditions in a conversion zone with a catalyst containing a sacrificial trap material sufficient to immobilize Ni-V-Na compounds. Conversion conditions are such that carbonaceous material and metals are deposited on the catalyst in the conversion zone. The catalyst is regenerated in the presence of an oxygen containing gas at a temperature sufficient to remove the carbonaceous deposits, and regenerated catalyst is recycled to the conversion zone for a contact with fresh feed. The sacrificial trap material is present on the catalyst in an amount sufficient to substantially immobilize the metal compounds in the presence of oxygen containing gas at the catalyst regeneration temperature. A catalyst composition for the above conversion comprises a catalytically active alumino-silicate zeolite dispersed in an amorphous inert solid matrix material containing the sacrificial trap material with or without one or more selected metal additives. The sacrificial trap material preferable includes inexpensive naturally occurring or synthetic zeolites which can be ion exchanged with water soluble metal additives.

Trapping of metals deposited on catalytic materials during carbometallic

A catalyst nominally containing zeolite, preferably HY zeolite and/or ultrastable HY zeolite, clay, alumina and an acidic silica-alumina co-gel matrix. The zeolite is preferably partially exchanged with high La/Ce ratio solution in a wetting step, and rare earths are precipitated onto the matrix. The catalyst has high metals tolerance and is capable of cracking heavy reduced crude oils, producing higher LCO/slurry oil ratio.

An improved process for economically converting carbo-metallic oils to lighter products. Enhanced catalyst activity is enjoyed through use of a select process to vaporize and atomize the high boiling portion of a carbo-metallic oil feed. The carbo-metallic oil feed is dispersed into droplets having a diameter of at least smaller than 350 microns and preferably 100 microns or less. These small droplets ensure more even coverage of the catalyst surface and decrease diffusion problems. The water utilized for dispersion of the carbo-metallic oil feed is present as a homogenized mixture in fine oil droplets with an average diameter below 1,000 microns. The water is dispersed in the carbo-metallic oil feed through use of a select mixing apparatus and can be dispersed as finer droplet sizes through use of an emulsifying or dispersing agent. The ratio of water to carbo-metallic oil feed ranges from about 0.04 to 0.25 by weight and the concentration of emulsifying agent ranges from 0.01 to 10 wt. % based on the weight of water.

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Ashland, KY, United States of America

Edward B Cornelius