METHOD FOR HYDROCRACKING HYDROCARBON LOADS USING CATALYST COMPRISING ZEOLITE AND AMORPHOUS MESOPOROU

专利摘要:
The present invention describes a process for the hydrocracking of at least one hydrocarbon feedstock of which at least 50% by weight of the compounds have an initial boiling point of greater than 300 ° C. and a final boiling point of less than 540 ° C. using at least at least one catalyst comprising at least one Group VIB metal and / or at least one Group VIII metal of the Periodic Table and a support comprising at least one zeolite having at least one series of channels whose opening is defined by a ring at 12 atoms of oxygen (12MR), and at least one binder said support being prepared from a highly dispersible alumina gel, said hydrocracking process operating at a temperature between 200 ° C and 480 ° C, a total pressure of between 1 MPa and 25 MPa with a volume ratio of hydrogen per volume of hydrocarbon feedstock of between 80 and 5000 liters per liter and at a rate per hour volume (VVH) defined by the ratio of the flow rate v liquid hydrocarbon feedstock liquid by the volume of catalyst loaded into the reactor between 0.1 and 50 h-1.
公开号:FR3044677A1
申请号:FR1561975
申请日:2015-12-08
公开日:2017-06-09
发明作者:Malika Boualleg；Antoine Daudin；Emmanuelle Guillon
申请人:IFP Energies Nouvelles IFPEN；
IPC主号:

专利说明:

Le gel d'alumine est ensuite séché par atomisation avec une température d'entrée de 250°C et de sortie de 130°C.
Le gel d'alumine séché est introduit dans un malaxeur de type Brabender en mélange avec une poudre de zéolithe USY présentant les caractéristiques décrites dans le tableau 2.
Tableau 2 : Caractéristique de la zéolithe USY.
De l'eau acidifiée avec de l'acide nitrique à un taux d'acide total de 2 %, exprimé en poids par rapport à la masse de gel séché introduit dans le malaxeur, est ajoutée en 5 minutes, pendant un malaxage à 20 tours/min. Le malaxage acide est poursuivi pendant 10 minutes. Une étape de neutralisation est ensuite réalisée par ajout d'une solution ammoniacale dans le malaxeur, à un taux de neutralisation de 20%, exprimé en poids d'ammoniaque par rapport à la quantité d'acide nitrique introduit dans le malaxeur pour l'étape d'acidification. Le malaxage est poursuivi pendant 3 minutes.
La pâte obtenue est ensuite extrudée à travers une filière de 2 mm trilobées. Le support est obtenu après mise en forme et extrusion en mélangeant 20 % poids de la zéolithe USY-1 avec 80% de gel d'alumine.
Les extrudés obtenus sont séchés à 100°C pendant ure nuit puis calciné pendant 2 h à 600 °C.
Les caractéristiques du support formé sont reportées dans le tableau 3 :
Tableau 3 : caractéristiques du support S1 obtenu selon l'exemple 1.
Exemple 2 : (selon l'invention) : Préparation des supports S2 et S3 (conforme) comprenant une alumine préparée selon l'invention et une zéolithe USY-1
On réalise dans un premier temps la synthèse de deux supports S2 et S3 selon un procédé de préparation conforme à l'invention dans un réacteur de 7L et une suspension finale de 5L en 3 étapes, deux étapes de précipitation suivie d'une étape de mûrissement.
La concentration finale en alumine visée est de 45g/L. La quantité d'eau ajoutée dans le réacteur est de 3267 ml. L’agitation est de 350 rpm tout au long de la synthèse.
Une première étape de co-précipitation dans de l'eau, de sulfate d'aluminium AI2(S04) et d'aluminate de sodium NaAlOO est réalisée à 30°C etpH=9,5 pendant une durée de 8 minutes. Les concentrations des précurseurs d'aluminium utilisées sont les suivantes : AI2(S04)= à 102g/L en Al203 et NaAlOO à 155g/L en Al203.
Une solution de sulfate d'aluminium AI2(S04) est ajoutée en continu pendant 8 minutes à un débit de 69,6 ml/min à une solution d'aluminate de sodium NaAlOO à un débit de 84,5 ml/min selon un ratio massique base/acide = 1,84 de manière à ajuster le pH à une valeur de 9,5. La température du milieu réactionnel est maintenu à 30°C.
Une suspension contenant un précipité d'alumine est obtenue.
La concentration finale en alumine visée étant de 45g/L, le débit des précurseurs sulfate d'aluminium AI2(S04) et aluminate de sodium NaAlOO contenant de l'aluminium introduit dans la première étape de précipitations sont respectivement de 69,6 ml/min et 84,5 ml/min.
Ces débits de précurseurs acide et basique contenant de l'aluminium permettent d'obtenir à l'issue de la première étape de précipitation un taux d'avancement de 72%.
La suspension obtenue est ensuite soumise à une montée en température de 30 à 68°C.
Une deuxième étape de co-précipitation de la suspension obtenue est ensuite réalisée par ajout de sulfate d'aluminium AI2(S04) à une concentration de 102g/L en Al203 et d'aluminate de sodium NaAlOO à une concentration de 155g/L en Al203. Une solution de sulfate d'aluminium AI2(S04) est donc ajoutée en continu à la suspension chauffée obtenue à l'issue de la première étape de précipitation pendant 30 minutes à un débit de 7,2 ml/min à une solution d'aluminate de sodium NaAlOO selon un ratio massique base/acide = 1,86 de manière à ajuster le pH à une valeur de 9. La température du milieu réactionnel dans la deuxième étape est maintenue à 68°C.
Une suspension contenant un précipité d'alumine est obtenue.
La concentration finale en alumine visée étant de 45g/L, le débit des précurseurs sulfate d'aluminium AI2(S04) et aluminate de sodium NaAlOO contenant de l'aluminium introduit dans la deuxième étape de précipitations sont respectivement de 7,2 ml/min et de 8,8 ml/min.
Ces débits de précurseurs acide et basique contenant de l'aluminium permettent d'obtenir à l'issue de la deuxième étape de précipitation un taux d'avancement de 28%.
La suspension obtenue est ensuite soumise à une montée en température de 68 à 90°C.
La suspension subit ensuite une étape de traitement hydrothermal dans laquelle elle est maintenue à 90°C pendant 60 minutes.
La suspension obtenue est ensuite filtrée par déplacement d'eau sur un outil type Buchner fritté et le gel d'alumine obtenu est lavé 3 fois avec 5 L d'eau distillée. Le temps de filtration ainsi que les lavages est de 3h.
Les caractéristiques du gel d'alumine ainsi obtenu sont résumés dans le tableau 4.
Tableau 4 : caractéristiques du gel d'alumine obtenu selon l'exemple 2.
Un gel présentant un indice de dispersibilité de 100% est ainsi obtenu.
Le gel d'alumine obtenu est ensuite séché par atomisation avec une température d'entrée de 250 ° C et de sortie de 130 ° C. Le gel séché par aémisation est appelé Gel n ° 1.
Le gel d'alumine obtenu selon l'exemple 3 est séché dans une étude ventilée à 35°C pendant 4 jours. Le gel séché en étuve est appelé Gel n°2.
Les gels d'alumine séchés n°1 et 2 sont ensuite re^ectivement introduits dans un malaxeur de type Brabender en mélange avec une poudre de zéolithe USY présentant les caractéristiques décrites dans le tableau 2.
De l'eau acidifiée avec de l'acide nitrique à un taux d'acide total de 2 %, exprimé en poids par rapport à la masse de gel séché introduit dans le malaxeur, est ajoutée en 5 minutes, pendant un malaxage à 20 tours/min. Le malaxage acide est poursuivi pendant 10 minutes.
Une étape de neutralisation est ensuite réalisée par ajout d'une solution ammoniacale dans le malaxeur, à un taux de neutralisation de 20%, exprimé en poids d'ammoniaque par rapport à la quantité d'acide nitrique introduit dans le malaxeur pour l'étape d'acidification. Le malaxage est poursuivi pendant 3 minutes.
La pâte obtenue est ensuite extrudée à travers une filière de 2 mm trilobées. Les extrudés obtenus sont séchés à 100°C pendant une nuit puis calciné pendant 2 h à 600 °C.
Deux supports S2 et S3 comprenant chacun 20 % poids de la zéolithe USY-1 et 80% de gel d'alumine n°1 et 2 sont obtenus.
Les caractéristiques des supports S2 et S3 formés sont reportées dans le tableau 5 : Tableau 5 : caractéristiques des supports S2 et S3 obtenus selon l'exemple 2.
Exemple 3 : Préparation des catalyseurs C1 (non conforme). C2 (conforme). C3 (conforme), à partir respectivement des supports S1 à S3
Une solution composée d’oxyde de molybdène, d'hydroxycarbonate de nickel et d’acide phosphorique est ajoutée sur les supports S1 à S3 par imprégnation à sec afin d'obtenir une formulation de 2,5/15,0/2 exprimée en % poids d'oxydes par rapport à la quantité de matière sèche pour les catalyseurs C1 à C3 finaux. Après imprégnation à sec, les extrudés sont laissés à maturer en atmosphère saturée en eau pendant 12 h, puis ils sont séchés une nuit à 110°C puis finalement calciné à 450°C pendant 2 teures pour conduire aux catalyseurs C1 non-conformes et C2 et C3, conformes à l'invention.
Exemple 4 : Comparaison des catalyseurs C1 à C3 en hvdrocraauaae d'un distillât sous vide
Les catalyseurs dont les préparations sont décrites dans les exemples précédents sont utilisés dans les conditions de l'hydrocraquage à conversion élevée (60-100%). La charge pétrolière est un distillât sous vide hydrotraité sur un catalyseur commercial à base de nickel
et de molybdène sur alumine dont les principales caractéristiques sont données dans le Tableau 6.
Tableau 6 : Caractéristique de la charge hydrotraitée utilisée.
On ajoute à la charge hydrotraitée 0,6% poids d'aniline et 2% poids de diméthyl-disulfure afin de simuler les pressions partielles de H2S et de NH3, présente dans l’étape d'hydrocraquage, et générées lors de l’hydrotraitement préalable du DSV. La charge ainsi préparée est injectée dans l'unité de test d'hydrocraquage qui comprend un réacteur en lit fixe, à circulation ascendante de la charge ("up-flow"), dans lequel est introduit 50 ml de catalyseur. Les catalyseurs sont sulfurés par un mélange gasoil straight run additivé de 4%pds de diméthyldisulfure et 1,6%pds d’aniline à 350 °C. Notons que toute méthode de sulfuration in-situ ou ex-situ est convenable. Une fois la sulfuration réalisée, la charge décrite dans le tableau 10 peut être transformée. Les conditions opératoires suivantes sont fixées: pression totale de 14 MPa, vitesse volumique horaire de 1,5 h"1 et un rapport volumique H2/charge de 1000 Nl/I. La vitesse volumique horaire est définie comme le rapport du débit volumique de charge liquide entrant sur le volume de catalyseur introduit. Le rapport volumique H2/charge est obtenue par le rapport des débits volumiques en condition normale de température et de pression.
Les performances catalytiques sont exprimées en relatif par rapport à celles obtenues pour le catalyseur de référence non-conforme C1 par l’écart température qui permet d'atteindre un niveau de conversion brute de 70% (noté T70) et par les écarts de rendements en essence et en distillais moyens (carburéacteur et gazole) à cette même conversion brute. Ces performances catalytiques sont mesurées sur le catalyseur après qu'une période de stabilisation, généralement d’au moins 48 heures, ait été respectée.
La conversion brute CB est prise égale à : CB = % pds de 370 °C moins de l'effluent avec 370°C moins" représentant la fraction, distilée à une température inférieure ou égale à 370°C.
Le rendement en carburéacteur (kérosène, 150-250, ci dessous Rdt Kéro) est égal au % poids de composés ayant un point d’ébullition compris entre 150 et 250°C dans les effluents. Le rendement en gazole (250-380) est égal au % poids de composés ayant un point d’ébullition compris entre 250 et 380°C dansles effluents.
La température de réaction est fixée de façon à atteindre une conversion brute CB égale à 70% poids. Dans le Tableau 8, nous avons reporté la température de réaction et les rendements en distillât léger et moyens pour les catalyseurs décrits dans les exemples ci-dessus.
Tableau 8 : Performances catalytiques des catalyseurs C1 à C3 en hydrocraquage.
Les catalyseurs C2 et C3, conformes à l’invention présentent des performances catalytiques supérieures au catalyseur C1 non-conforme. En comparaison du catalyseur C1, les catalyseurs C2 et C3 montrent un gain de rendement en distillats moyens respectivement de 1,5 et 1,6 points. Enfin, il n’y a pas de différence significative de performance catalytique entre les catalyseurs C2 et C3 ce qui montre que le type de séchage du gel d’alumine conforme à l’invention n’a pas d’impact sur les performances catalytiques obtenues.
Technical area
The present invention relates to a process for hydrocracking hydrocarbonaceous feedstocks containing, for example, aromatic and / or olefinic and / or naphthenic and / or paraffinic compounds, whose feeds originating from the Fischer-Tropsch process and optionally containing metals, and / or or nitrogen, and / or oxygen and / or sulfur. The objective of the hydrocracking process is essentially the production of middle distillates, that is to say a kerosene cut having a boiling point between 150 and 250 ° C, and a gas oil section having a boiling point. between 250 and 380 ° C.
In particular, the present invention relates to the use in a hydrocracking process of a hydrocarbon feedstock of which at least 50% by weight of the compounds have an initial boiling point greater than 340 ° C. and an end boiling point. less than 540 ° C of a catalyst comprising at least one Group VIB metal and / or at least one Group VIII metal of the Periodic Table and a support comprising at least one zeolite having at least one series of channels whose opening is defined by a ring of 12 oxygen atoms (12MR), and at least one binder comprising at least one amorphous mesoporous alumina having a specific porous distribution said alumina having a very high connectivity with respect to the aluminas of the prior art. Said amorphous mesoporous alumina is advantageously shaped from an alumina gel having a high dispersibility, said alumina gel being itself obtained by precipitation of at least one aluminum salt according to a specific process.
More particularly, the present invention relates to the use in a hydrocracking process of said hydrocarbon feedstock of a catalyst comprising a support comprising at least one zeolite and at least one binder comprising at least one amorphous mesoporous alumina, shaped from an alumina gel, said alumina gel being prepared according to a method of preparation by specific precipitation, making it possible to obtain at least 40% by weight of alumina with respect to the total quantity of alumina formed at the end of the gel preparation process, the first precipitation step, the amount of alumina formed at the end of the first precipitation step can even reach 100%.
PRIOR ART Hydrocracking of heavy oil cuts is a very important process of refining which makes it possible to produce, from excessively heavy and unrecognizable heavy feedstocks, lighter fractions such as gasolines, jet fuels and light gas oils that the refiner seeks to adapt his fuel. production to the structure of demand. Certain hydrocracking processes also make it possible to obtain a highly purified residue that can provide excellent bases for oils. Compared to catalytic cracking, the advantage of catalytic hydrocracking is to provide middle distillates of very good quality. Conversely, the gasoline produced has a much lower octane number than that resulting from catalytic cracking. Hydrocracking is a process which derives its flexibility from three main elements which are the operating conditions used, the types of catalysts employed and the fact that the hydrocracking of hydrocarbon feeds can be carried out in one or two stages.
The hydrocracking catalysts used in the hydrocracking processes are all of the bifunctional type associating an acid function with a hydrogenating function. The acid function is provided by supports whose surfaces generally vary from 150 2 -1 to 800 m 2g and having a surface acidity, such as halogenated aluminas (chlorinated or fluorinated in particular), the combinations of boron oxides and aluminum, amorphous silica-alumina and zeolites. The hydrogenating function is provided either by one or more metals of group VIB of the periodic table of elements, or by a combination of at least one metal of group VIB of the periodic table and at least one metal of group VIII. The equilibrium between the two acid and hydrogenating functions is one of the parameters which governs the activity and the selectivity of the catalyst. A weak acid function and a strong hydrogenating function give low active catalysts, operating at generally high temperature (greater than or equal to 390-400 ° C.), and at low feed space velocity (the WH expressed in volume of charge at treat per unit volume of catalyst and per hour is generally less than or equal to 2), but with a very good selectivity in middle distillates (jet fuels and diesel fuels). Conversely, a strong acid function and a low hydrogenating function give active catalysts, but with lower selectivities in middle distillates.
One type of conventional hydrocracking catalyst is based on moderately acidic amorphous supports, such as silica-aluminas, for example. These systems are used to produce medium distillates of good quality, and possibly, oil bases. These catalysts are for example used in one-step processes. The disadvantage of these catalysts based on amorphous support is their low activity.
Catalysts comprising, for example, zeolite Y of FAU structural type, or catalysts comprising, for example, a beta-type zeolite, have in turn a higher catalytic activity than silica-aluminas, but have selectivities in middle distillates (jet fuels and gas oils) lower. This difference is attributed to the difference in strength of acid sites on both types of materials. The prior art reports numerous works to improve the middle distillate selectivity of zeolite catalysts in hydrocracking processes. The latter are composed of a hydrogenation phase of very variable composition (different metals), generally deposited on a support containing a zeolite, most often zeolite Y. The hydrogenating phase is active in sulphide form.
For example, mention may be made of the work relating to the modification of zeolite Y, for example by dealumination by steaming or acid etching of zeolite Y, the use of composite catalysts, or the use of small crystals of Y zeolites. other patent applications such as the application WO2007 / 126419 describe the use of zeolite mixtures such as Beta and USY zeolites for improving the performance of hydrocracking catalysts.
In particular, US Pat. No. 7,790,652 describes a novel alumina support having a very specific porous distribution, which can be used as a catalyst support in a process for hydroconversion of heavy hydrocarbon feeds. Said support comprising alumina has an average pore diameter of between 100 and 140 Å, a size distribution whose width is less than 33 Å, a pore volume of at least 0.75 ml / g in which less than 5% of the pore volume of said support is present in pores with a diameter greater than 210 °.
Said support used in combination with a hydrogenating active phase makes it possible to obtain unexpected catalytic performances in the case where it is used in hydroconversion of heavy charges preferably having a majority of its components boiling at a temperature above 343 ° C. In particular, the heavy-lift hydroconversion process according to US Pat. No. 7,790,652 makes it possible to obtain a conversion of hydrocarbon compounds boiling at a temperature above 524 ° C. which is greatly improved compared to conversions obtained with conventional catalysts of the invention. prior art.
Said alumina support is prepared according to a method comprising a first step of forming an alumina dispersion by mixing, in a controlled manner, a first aqueous alkaline solution and a first aqueous acid solution, at least one of said solutions acidic and basic, or both comprising an aluminum compound. The acidic and basic solutions are mixed in such proportions that the pH of the resulting dispersion is between 8 and 11. The acidic and basic solutions are also mixed in quantities which make it possible to obtain a dispersion containing the desired quantity of alumina. in particular, the first step makes it possible to obtain 25 to 35% by weight of alumina with respect to the total amount of alumina formed at the end of the two precipitation stages. The first stage operates at a temperature of between 20 and 40 ° C. When the desired amount of alumina is formed, the temperature of the slurry is raised to a temperature between 45 and 70 ° C, and then the heated slurry is then subjected to a second precipitation step by contacting said slurry with a slurry. second aqueous alkaline solution and a second acidic aqueous solution, at least one or both of the two solutions comprising an aluminum compound. Similarly, the pH is adjusted between 8 and 10.5 by the proportions of the acid and basic solutions added and the remaining quantity of alumina to be formed in the second stage is provided by the amounts of the second acid and basic solutions added. The second step operates at a temperature of between 20 and 40 ° C. The alumina gel thus formed comprises at least 95% of boehmite. The dispersibility of the alumina gel thus obtained is not mentioned. The alumina gel is then filtered, washed and optionally dried according to methods known to those skilled in the art, without prior hydrothermal treatment step, to produce an alumina powder which is then shaped according to the known methods of the art. skilled in the art and then calcined to produce the final alumina support.
The first precipitation step of the preparation method of US Pat. No. 7,790,652 is limited to a low alumina production of between 25 and 35% by weight, since higher alumina production at the end of the first stage does not allow optimal filtration of the gel obtained. Moreover, the increase in the production of alumina in the first stage of the Shell patent would not allow the shaping of the gel thus obtained.
The Applicant has discovered that the use in a hydrocracking process of the hydrocarbon feedstock of a catalyst comprising at least one Group VIB metal and / or at least one Group VIII metal of the Periodic Table and a carrier comprising at least one minus a zeolite having at least one series of channels whose opening is defined by a ring of 12 oxygen atoms (12MR), and at least one binder comprising at least one amorphous mesoporous alumina prepared from a preparation process method for obtaining a highly dispersible alumina gel made it possible to improve the middle distillate selectivity while preserving or improving the catalytic activity of said zeolite catalysts, compared with hydrocracking catalysts of the prior art .
In particular, the use in the support of the catalyst, a binder comprising at least said specific alumina having a high connectivity by its preparation method, avoids overcracking of the treated feedstock and thus limit the production of light products not included in the middle distillate pools.
An object of the present invention is therefore to provide a process for the hydrocracking of at least one hydrocarbon feedstock of which at least 50% by weight of the compounds have an initial boiling point greater than 340 ° C. and a lower final boiling point. at 540 ° C employing at least one catalyst having improved catalytic performance, especially in terms of selectivity for middle distillates, while maintaining or improving the catalytic activity of said zeolite catalysts, with respect to hydrocracking catalysts, prior art.
Another object of the invention is to provide a process for hydrocracking said hydrocarbon feedstock making it possible to produce middle distillate bases, in particular a kerosene base and / or a diesel base, while limiting the production of light products that can not be incorporated into said bases. Summary and interest of the invention
The subject of the present invention is a process for the hydrocracking of at least one hydrocarbon feedstock of which at least 50% by weight of the compounds have an initial boiling point of greater than 300 ° C. and a final boiling point of less than 540 ° C. at a temperature between 200 ° C and 480 ° C, at a total pressure of between 1 MPa and 25 MPa with a volume ratio of hydrogen per volume of hydrocarbon feedstock of between 80 and 5000 liters per liter and at a volume velocity Hourly (WH) defined by the ratio of the volume flow rate of the liquid hydrocarbon feedstock by the volume of catalyst charged to the reactor of between 0.1 and 50 h -1, said process using at least one catalyst comprising at least one Group VIB metal and / or at least one metal of Group VIII of the Periodic Table and a support comprising at least one zeolite having at least one series of channels whose opening is defined by a ring of 12 oxygen atoms ( 12MR), and at least one binder comprising at least one amorphous mesoporous alumina, said support comprising at least said zeolite and at least said binder, being prepared according to at least the following steps: a) a precipitation step, in an aqueous reaction medium, at least one basic precursor selected from sodium aluminate, potassium aluminate, ammonia, sodium hydroxide and potassium hydroxide and at least one acidic precursor selected from aluminum, aluminum chloride, aluminum nitrate, sulfuric acid, hydrochloric acid, and nitric acid, wherein at least one of the basic precursors or acid comprises aluminum, the flow rate relative acidic and basic precursors is chosen so as to obtain a pH of the reaction medium of between 8.5 and 10.5 and the flow rate of the acidic and basic precursor (s) containing aluminum is adjusted so as to obtain a rate of progress of the first step of between 40 and 100%, the degree of progress being defined as the proportion of alumina formed during said first precipitation step relative to the total amount of alumina formed at the end of step c) the preparation process, said step operating at a temperature between 20 and 90 ° C, and for a period of between 2 minutes and 30 minutes, b) a hydrothermal treatment step of the suspension heated to a temperature of between 50 and 200 ° C for a time between 30 minutes and 5 hours to obtain an alumina gel, c) a filtration step of the suspension obtained at the end of step b) of hydrothermal treatment, followed by at least one washing step of the gel obtained, d) a step of drying the alumina gel obtained at the end of step c) to obtain a powder, e) a step of forming the powder obtained at the end of step d) in mixture with at least said zeo lithe having at least one series of channels whose opening is defined by a ring with 12 oxygen atoms (12MR) to obtain the raw material, f) a step of calcination of the raw material obtained at the end of the step e) at a temperature between 500 and 1000 ° C, with or without a flow of air containing up to 60% by volume of water.
One of the advantages of the present invention resides in the implementation, in a hydrocracking process of at least one hydrocarbon feedstock of which at least 50% by weight of the compounds have an initial boiling point greater than 340 ° C. and a point final boiling below 540 ° C, a zeolite catalyst comprising a binder comprising an alumina prepared according to a very specific process, from a highly dispersible alumina gel, itself obtained according to a preparation process well specific for shaping said gel. The alumina gel, at the origin of the alumina used as binder in the catalyst support, is prepared from a precipitation stage in which at least 40% by weight of alumina with respect to the total amount of alumina formed at the end of said process for preparing the gel are formed as of the first precipitation step. This method is achieved through the implementation of a hydrothermal treatment step and in particular a ripening step to obtain a support having improved filterability, and facilitating its shaping.
The process for preparing alumina makes it possible to obtain an alumina having a very connected porosity, that is to say having a very large number of adjacent pores. High connectivity represents an important advantage for the diffusion of the molecules of said charge to be treated during the implementation of the hydrocracking process according to the invention using this material. A better diffusion of the reagents makes it possible to have a more homogeneous concentration within the catalyst and thus allows a greater majority of the catalytic sites to work to the best of its possibilities.
Throughout the rest of the text, the connectivity of the alumina used as binder of the catalyst used in the process according to the invention is representative of the totality of the porosity of the alumina and in particular of the totality of the mesoporosity of the alumina, that is to say all the pores having an average diameter of between 2 and 50 nm.
Connectivity is a relative quantity measured according to the procedure described in the Seaton publication (Liu H., Zhang L., Seaton NA, Chemical Engineering Science, 47, 17-18, pp.4393-4404, 1992). This is a Monte Carlo simulation from nitrogen adsorption / desorption isotherms. These connectivity parameters are based on the theory of percolation. The connectivity is related to the numbers of adjacent pores and represents an advantage for the diffusion during the catalytic reactions of the molecules to be treated.
Throughout the rest of the text, the dispersibility index is defined as the weight of peptised alumina gel that can be dispersed by centrifugation in a polypropylene tube at 3600 G for 10 min.
Dispersibility is measured by dispersing 10% boehmite or alumina gel in a water slurry also containing 10% nitric acid based on the boehmite mass. Then, the suspension is centrifuged at 3600G rpm for 10 min. The collected sediments are dried at 100 ° C overnight and weighed.
The dispersibility rate, denoted ID, is obtained by the following calculation: ID (%) = 100% - mass of dried sediments (%).
Detailed Description of the Catalyst According to the Invention The invention relates to a process for the hydrotreatment of at least one hydrocarbon feedstock of which at least 50% by weight of the compounds have an initial boiling point greater than 340 ° C. and a boiling point final less than 540 ° C.
loads
A wide variety of fillers can be processed by the hydrocracking processes according to the invention. The feedstock used in the hydrocracking process according to the invention is a hydrocarbon feedstock of which at least 50% by weight of the compounds have an initial boiling point of greater than 300 ° C. and a final boiling point of less than 540 ° C. C, preferably at least 60% by weight, preferably at least 75% by weight and more preferably at least 80% by weight of the compounds have an initial boiling point greater than 300 ° C and a boiling point final less than 540 ° C.
The filler is advantageously chosen from LCOs (Light Cycle Oil), atmospheric distillates, vacuum distillates such as, for example, gas oils resulting from the direct distillation of the crude or from units. such as FCC, coker or visbreaking, feeds from aromatics extraction units of lubricating oil bases or from solvent dewaxing of lubricating oil bases, distillates from desulphurization or hydroconversion in fixed bed or bubbling bed of RAT (atmospheric residues) and / or RSV (vacuum residues) and / or deasphalted oils, and deasphalted oils, paraffins from the Fischer-Tropsch process, taken alone or mixed. The list above is not exhaustive. Said fillers preferably have a boiling point T5 greater than 300 ° C., preferably greater than 340 ° C., ie 95% of the compounds present in the feed have a boiling point greater than 300 ° C. and preferably more than 340 ° C.
The nitrogen content of the feedstocks treated in the processes according to the invention is advantageously greater than 500 ppm by weight, preferably between 500 and 10,000 ppm by weight, more preferably between 700 and 4000 ppm by weight and even more preferably between 1000 and 1000 ppm by weight. and 4000 ppm weight. The sulfur content of the fillers treated in the processes according to the invention is advantageously between 0.01 and 5% by weight, preferably between 0.2 and 4% by weight and even more preferably between 0.5 and 3%. % weight
The charge may optionally contain metals. The cumulative nickel and vanadium content of the feeds treated in the processes according to the invention is preferably less than 1 ppm by weight.
The charge may optionally contain asphaltenes. The asphaltene content is generally less than 3000 ppm by weight, preferably less than 1000 ppm by weight, more preferably less than 200 ppm by weight.
According to the invention, the process for hydrocracking said hydrocarbon feedstock according to the invention is carried out at a temperature of between 200 ° C. and 480 ° C., at a total pressure of between 1 MPa and 25 MPa with a ratio volume of hydrogen per volume of hydrocarbon feedstock of between 80 and 5000 liters per liter and at a Time Volume Velocity (WH) defined by the ratio of the volume flow rate of the liquid hydrocarbon feedstock to the volume of catalyst charged to the reactor between 0, 1 and 50 h'1.
Preferably, the hydrocracking process according to the invention operates in the presence of hydrogen, of between 250 and 480 ° C., in a preferred manner between 320 and 450 ° C., very preferably between 330 and 435 ° C., under a pressure between 2 and 25 MPa, preferably between 3 and 20 MPa, at a space velocity of between 0.1 and 20 h -1, preferably 0.1 and 6 h -1, preferably between 0.2 and 3 h -1, and the amount of hydrogen introduced is such that the volume ratio liter of hydrogen / liter of hydrocarbon is between 100 and 2000 L / L.
These operating conditions used in the processes according to the invention generally make it possible to achieve pass conversions, products having boiling points below 340 ° C., and better still below 370 ° C., greater than 15% by weight and even more preferably between 20 and 95 wt%.
Preferably, the catalyst comprises at least one Group VIB metal and at least one Group VIII metal of the Periodic Table, taken alone or as a mixture, said catalyst being a sulphide phase catalyst.
Preferably, the Group VIB metals of the Periodic Table are selected from the group consisting of tungsten and molybdenum, alone or as a mixture. According to a preferred embodiment, the Group VIB metal is molybdenum. In another preferred embodiment, the Group VIB metal is tungsten.
Preferably, the non-noble metals of Group VIII of the Periodic Table are selected from the group consisting of cobalt and nickel, taken alone or as a mixture. According to a preferred embodiment, the non-noble group VIII metal is cobalt. According to another preferred embodiment, the non-noble group VIII metal is nickel.
Preferably, said catalyst comprises at least one Group VIB metal in combination with at least one Group VIII non-noble metal, the Group VIII non-noble metals being selected from the group consisting of cobalt and nickel, taken alone or in combination. and the Group VIB metals being selected from the group consisting of tungsten and molybdenum, alone or in a mixture. Advantageously, the following combinations of metals are used: nickel-molybdenum, cobalt-molybdenum, nickel-tungsten, cobalt-tungsten, the preferred combinations are: nickel-molybdenum, cobalt-molybdenum, cobalt-tungsten, nickel-tungsten and still more preferably nickel-molybdenum and nickel-tungsten.
In the case where the catalyst comprises at least one Group VIB metal in combination with at least one Group VIII non-noble metal, the Group VIB metal content is advantageously comprised, in oxide equivalent, of between 5 and 40% by weight per relative to the total mass of said catalyst, preferably between 10 and 35% by weight and very preferably between 15 and 30% by weight and the non-noble metal content of group VIII is advantageously comprised, in oxide equivalent, between 0 , 5 and 10% by weight relative to the total mass of said catalyst, preferably between 1 and 8% by weight and very preferably between 1.5 and 6% by weight.
In the case where the catalyst comprises at least one Group VIB metal in combination with at least one Group VIII non-noble metal, said catalyst is a sulphurized catalyst.
It is also possible to use combinations of three metals, for example nickel-cobalt-molybdenum, nickel-molybdenum-tungsten, nickel-cobalt-tungsten. Advantageously, the following combinations of metals are used: nickel-niobium-molybdenum, cobalt-niobium-molybdenum, nickel-niobium-tungsten, cobalt-niobium-tungsten, the preferred combinations being: nickel-niobium-molybdenum, cobalt -niobium-molybdenum. It is also possible to use combinations of four metals, for example nickel-cobalt-niobium-molybdenum.
The catalyst may also advantageously contain: from 0 to 50% by weight of oxide, preferably from 0.1 to 15% by weight and even more preferably from 0.1 to 10% by weight relative to the weight total of the catalyst of at least one doping element selected from the group consisting of silicon, boron and phosphorus, and preferably phosphorus 4 - from 0 to 60% by weight, preferably from 0.1 to 50% by weight , and even more preferably from 0.1 to 40% by weight of oxide relative to the total mass of the catalyst, of at least one element selected from group VB and preferably niobium and optionally at 20% by weight, preferably from 0.1 to 15% by weight and even more preferably from 0.1 to 10% by weight of oxide relative to the total mass of the catalyst of at least one selected element in group VIIA, preferably fluorine.
According to the invention, the support of the catalyst used in the process according to the invention comprises at least at least one zeolite having at least one series of channels, the opening of which is defined by a ring with 12 oxygen atoms (12MR) and at least one binder comprising at least one amorphous mesoporous alumina, said support comprising and preferably consisting of, preferably: 1 to 80% by weight, preferably 1 to 70% by weight, even more preferably from 5 to 50% by weight, and very preferably from 5 to 40% by weight of said zeolite relative to the total weight of said support, from 20 to 99% by weight, preferably from 30 to 99% by weight, 50 to 95% by weight, and very preferably 60 to 95% by weight relative to the total weight of said support, of at least said binder.
The zeolite used in the support of the catalyst is advantageously chosen from zeolites of structural type FAU, BEA, ISV, IWR, IWW, MEI, UWY, taken alone or as a mixture and preferably from the zeolites of structural type FAU and BEA, taken alone or in mixture.
In a preferred embodiment, the zeolite is chosen from zeolite Y and zeolite beta taken alone or as a mixture, and preferably the zeolite is zeolite Y or USY.
Said zeolites are advantageously defined in the classification "Atlas of Zeolite Framework Types, 6th revised edition", Ch. Baerlocher, LB Mc Cusker, D.FI. Oison, 6th Edition, Elsevier, 2007, Elsevier ".
The zeolite used according to the invention may advantageously have undergone treatments in order to stabilize it or to create mesoporosity. These modifications are advantageously carried out by at least one of the dealumination techniques known to those skilled in the art, and for example hydrothermal treatment or acid attack.
According to the invention, the support of the catalyst used in the process according to the present invention is advantageously prepared according to the preparation process comprising at least the following steps: a) at least one precipitation step, in an aqueous reaction medium, from at least one basic precursor selected from sodium aluminate, potassium aluminate, ammonia, sodium hydroxide and potassium hydroxide and at least one acidic precursor selected from aluminum sulphate, aluminum chloride, aluminum nitrate, sulfuric acid, hydrochloric acid, and nitric acid, wherein at least one of the basic precursors or acid comprises aluminum, the relative flow rate of the precursors acid and basic is chosen so as to obtain a pH of the reaction medium of between 8.5 and 10.5 and the flow rate of the acidic and basic precursor (s) containing aluminum is adjusted so as to obtain a degree of progress. of the first step of between 40 and 100%, the degree of progress being defined as the proportion of alumina formed during said first precipitation step relative to the total amount of alumina formed at the end of the the precipitation steps, said step operating at a temperature between 20 and 90 ° C, and for a time between 2 minutes and 30 minutes, b) a hydrothermal treatment step of the suspension heated to a temperature between 50 and 200 ° C for a time between 30 minutes and 5 hours to obtain an alumina gel, c) a filtration step of the suspension obtained at the end of step b) of hydrothermal treatment, followed by at least one washing step of the gel obtained, d) a step of drying the alumina gel obtained at the end of step c) to obtain a powder, e) a step of forming the powder obtained at the end of step d)) in mixture with at least said zeolite having at least one series of channels whose opening is defined by a ring with 12 oxygen atoms (12MR) to obtain the raw material, f) a step of calcination of the raw material obtained at the end of the step e) at a temperature between 500 and 1000 ° C, with or without a flow of air containing up to 60% by volume of water.
In the case where the progress rate of said precipitation step a) is 100%, said precipitation step a) generally makes it possible to obtain an alumina suspension having an Al 2 O 3 concentration of between 20 and 100 g. / L, preferably between 20 and 80 g / l, preferably between 20 and 50 g / l.
The mixture in the aqueous reaction medium of at least one basic precursor and at least one acidic precursor requires either that at least the basic precursor or the acidic precursor comprises aluminum, or that the two precursors basic and acidic include aluminum.
Basic precursors comprising aluminum are sodium aluminate and potassium aluminate. The preferred basic precursor is sodium aluminate.
Acidic precursors comprising aluminum are aluminum sulphate, aluminum chloride and aluminum nitrate. The preferred acidic precursor is aluminum sulphate.
Preferably, the aqueous reaction medium is water.
Preferably, said step a) operates with stirring.
Preferably, said step a) is carried out in the absence of organic additive.
The acidic and basic precursors, whether they contain aluminum or not, are mixed, preferably in solution, in the aqueous reaction medium, in such proportions that the pH of the resulting suspension is between 8.5 and 10. 5.
According to the invention, it is the relative flow rate of the acidic and basic precursors that they contain aluminum or not, which is chosen so as to obtain a pH of the reaction medium of between 8.5 and 10.5.
In the preferred case where the basic and acidic precursors are respectively sodium aluminate and aluminum sulphate, the mass ratio of said basic precursor to said acidic precursor is advantageously between 1.6 and 2.05.
For the other basic and acidic precursors, whether they contain aluminum or not, the base / acid mass ratios are established by a curve of neutralization of the base by the acid. Such a curve is easily obtained by those skilled in the art.
Preferably, said precipitation step a) is carried out at a pH of between 8.5 and 10 and very preferably between 8.7 and 9.9.
The acidic and basic precursors are also mixed in amounts to obtain a suspension containing the desired amount of alumina, depending on the final concentration of alumina to be achieved. In particular, said step a) makes it possible to obtain 40 to 100% by weight of alumina with respect to the total amount of alumina formed at the end of the precipitation stage or steps.
According to the invention, it is the flow rate of the aluminum-containing acidic and basic precursor (s) which is adjusted so as to obtain a first step advancement rate of between 40 and 100%, the rate of advancement being defined as the proportion of alumina formed during said step a) of precipitation relative to the total amount of alumina formed at the end of the precipitation step or steps.
Preferably, the rate of progress of said precipitation step a) is between 45 and 90% and preferably between 50 to 85%. In the case where the advancement rate obtained at the end of the precipitation step a) is less than 100%, a second precipitation step is necessary in order to increase the amount of alumina formed. In this case, the advancement rate being defined as being the proportion of alumina formed during said step a) of precipitation relative to the total amount of alumina formed at the end of the two precipitation steps of the preparation process according to the invention.
Thus, depending on the concentration of alumina targeted at the end of the precipitation step (s), preferably between 20 and 100 g / l, the quantities of aluminum to be provided by the acidic and / or basic precursors are calculated and the flow rate of the precursors is adjusted according to the concentration of said added aluminum precursors, the amount of water added to the reaction medium and the rate of progress required for the precipitation step or steps.
The flow rate of the acid-containing and / or basic precursor (s) containing aluminum depends on the size of the reactor used and thus on the quantity of water added to the reaction medium.
Preferably, said precipitation step a) is carried out at a temperature of between 10 and 45 ° C., preferably between 15 and 45 ° C., more preferably between 20 and 45 ° C. and very preferably between 20 and 45 ° C. 40 C.
It is important that said precipitation step a) operates at a low temperature. In the case where said preparation process according to the invention comprises two precipitation stages, the precipitation step a) is advantageously carried out at a temperature below the temperature of the second precipitation stage.
Preferably, said precipitation step a) is carried out for a period of between 5 and 20 minutes, and preferably of 5 to 15 minutes.
According to the invention, said preparation process comprises a hydrothermal treatment step b) of the suspension obtained at the end of the precipitation step a), said hydrothermal treatment step operating at a temperature of between 60 and 200 ° C. C for a period of between 30 minutes and 5 hours.
Preferably, said hydrothermal treatment step b) is a ripening step.
Preferably, said hydrothermal treatment step b) operates at a temperature between 65 and 150 ° C, preferably between 65 and 130 ° C, preferably between 70 and 110 ° C, very preferably between 70 and 95 ° C.
Preferably, said hydrothermal treatment step b) is carried out for a duration of between 40 minutes and 5 hours, preferably between 40 minutes and 3 hours, and preferably between 45 minutes and 2 hours. second optional precipitation step
According to a preferred embodiment, in the case where the advancement rate obtained at the end of the precipitation step a) is less than 100%, said preparation method preferably comprises a second precipitation step.
Said second precipitation step makes it possible to increase the proportion of alumina produced.
In the case where a second precipitation step is carried out, a heating step of the suspension obtained at the end of the precipitation step a) is advantageously carried out between the two precipitation stages.
Preferably, said step of heating the suspension obtained at the end of step a), carried out between said step a) and the second precipitation step operates at a temperature of between 20 and 90 ° C., preferably between 30 and 80 ° C, preferably between 30 and 70 ° C and very preferably between 40 and 65 ° C.
Preferably, said heating step is carried out for a period of between 7 and 45 minutes and preferably between 7 and 35 minutes.
Said heating step is advantageously carried out according to all the heating methods known to those skilled in the art.
According to said preferred embodiment, said preparation method comprises a second step of precipitating the suspension obtained at the end of the heating step, said second step operating by adding to said suspension at least one basic precursor chosen from sodium aluminate, potassium aluminate, ammonia, sodium hydroxide and potassium hydroxide and at least one acidic precursor selected from aluminum sulphate, aluminum chloride, aluminum nitrate, sulfuric acid, hydrochloric acid, and nitric acid, wherein at least one of the basic precursors or acid comprises aluminum, the relative flow rate of the acidic and basic precursors is selected from in order to obtain a pH of the reaction medium of between 8.5 and 10.5 and the flow rate of the aluminum-containing acidic and basic precursor (s) is adjusted so as to obtain a progress rate of the second stage of between 0.degree. e 60%, said progress rate of the second step being defined as the proportion of alumina formed during said second precipitation step relative to the total amount of alumina formed at the end of the step or steps of precipitation, said step operating at a temperature between 40 and 90 ° C, and for a period of between 2 minutes and 50 minutes.
As in the first precipitation step a), the addition to the heated suspension of at least one basic precursor and at least one acidic precursor requires either that at least the basic precursor or the acidic precursor comprises aluminum, that the two basic precursors and acid include aluminum.
Basic precursors comprising aluminum are sodium aluminate and potassium aluminate. The preferred basic precursor is sodium aluminate.
Acidic precursors comprising aluminum are aluminum sulphate, aluminum chloride and aluminum nitrate. The preferred acidic precursor is aluminum sulphate.
Preferably, said second precipitation step operates with stirring.
Preferably, said second step is carried out in the absence of organic additive.
The acidic and basic precursors, whether they contain aluminum or not, are mixed, preferably in solution, in the aqueous reaction medium, in such proportions that the pH of the resulting suspension is between 8.5 and 10. 5.
As in step a) of precipitation, it is the relative flow rate of the acidic and basic precursors that they contain aluminum or not, which is chosen so as to obtain a pH of the reaction medium of between 8, 5 and 10.5.
In the preferred case where the basic and acidic precursors are respectively sodium aluminate and aluminum sulphate, the mass ratio of said basic precursor to said acidic precursor is advantageously between 1.6 and 2.05.
For the other basic and acidic precursors, whether they contain aluminum or not, the base / acid mass ratio is established by a curve of neutralization of the base by the acid. Such a curve is easily obtained by those skilled in the art.
Preferably, said second precipitation step is carried out at a pH of between 8.5 and 10 and preferably between 8.7 and 9.9.
The acidic and basic precursors are also mixed in amounts to obtain a suspension containing the desired amount of alumina, depending on the final concentration of alumina to be achieved. In particular, said second precipitation step makes it possible to obtain 0 to 60% by weight of alumina with respect to the total amount of alumina formed at the end of the precipitation stage or steps.
Just as in step a) of precipitation, it is the flow rate of the acidic and basic precursor (s) containing aluminum which is adjusted so as to obtain a progress rate of the second stage of between 0 and 60.degree. %, the feed rate being defined as the proportion of alumina formed in said second precipitation step relative to the total amount of alumina formed from the precipitation step or steps.
Preferably, the rate of progress of said precipitation step a) is between 10 and 55% and preferably between 15 and 55%, the degree of progress being defined as the proportion of alumina formed during said second precipitation step relative to the total amount of alumina formed at the end of the two precipitation steps of the preparation process according to the invention.
Thus, depending on the concentration of alumina targeted at the end of the precipitation step (s), preferably between 20 and 100 g / l, the quantities of aluminum to be provided by the acidic and / or basic precursors are calculated and the flow rate of the precursors is adjusted according to the concentration of said added aluminum precursors, the amount of water added to the reaction medium and the rate of progress required for each of the precipitation steps.
As in step a) of precipitation, the flow rate of the acid-containing precursor (s) and / or base (s) containing aluminum depending on the size of the reactor used and thus the amount of water added to the reaction medium. For example, if one works in a 3 L reactor and that 1L alumina suspension Al203 final concentration of 50 g / l is targeted, the target rate of advancement is 50% for the first step of precipitation. Thus, 50% of the total alumina must be provided during step a) of precipitation. The precursors of aluminas are sodium aluminate at a concentration of 155 g / l of Al 2 O 3 and aluminum sulphate at a concentration of 102 g / l of Al 2 O 3. The precipitation pH of the first step is set at 9.5 and the second at 9. The amount of water added to the reactor is 622 ml.
For the first step a) of precipitation operating at 30 ° C and for 8 minutes, the flow rate of aluminum sulfate should be 10.5 ml / min and the sodium aluminate flow rate is 13.2 ml / min . The mass ratio of sodium aluminate to aluminum sulfate is therefore 1.91.
For the second precipitation stage, operating at 70 ° C., for 30 minutes, the aluminum sulfate flow rate should be 2.9 ml / min and the sodium aluminate flow rate is 3.5 ml / min. The mass ratio of sodium aluminate to aluminum sulfate is therefore 1.84.
Preferably, the second precipitation step is carried out at a temperature between 40 and 80 ° C, preferably between 45 and 70 ° C and very preferably between 50 and 70 ° C.
Preferably, the second precipitation step is carried out for a period of between 5 and 45 minutes, and preferably of 7 to 40 minutes.
The second precipitation step generally makes it possible to obtain an alumina suspension having an Al 2 O 3 concentration of between 20 and 100 g / l, preferably between 20 and 80 g / l, preferably between 20 and 50 g / l.
In the case where said second precipitation step is carried out, said preparation process also advantageously comprises a second step of heating the suspension obtained at the end of said second precipitation step to a temperature of between 60 and 95 ° C. and preferably between 50 and 90 ° C.
Preferably, said second heating step is carried out for a period of between 7 and 45 minutes.
Said second heating step is advantageously carried out according to all the heating methods known to those skilled in the art.
Said second heating step makes it possible to increase the temperature of the reaction medium before subjecting the suspension obtained in hydrothermal treatment step b).
According to the invention, the process for preparing alumina according to the invention also comprises a step c) of filtering the suspension obtained at the end of step b) of hydrothermal treatment, followed by at least one step washing the gel obtained. Said filtration step is carried out according to the methods known to those skilled in the art.
The filterability of the suspension obtained at the end of step a) of precipitation or of the two precipitation stages is improved by the presence of said final hydrothermal treatment step b) of the suspension obtained, said hydrothermal treatment step promoting the productivity of the process according to the invention as well as an extrapolation of the process at the industrial level.
Said filtration step is advantageously followed by at least one washing step with water and preferably from one to three washing steps, with a quantity of water equal to the amount of filtered precipitate. The sequence of steps a) and c) and optionally of the second precipitation step, the second heating step and the optional filtration step, makes it possible to obtain a specific alumina gel having a dispersibility greater than 70%, a crystallite size of between 1 and 35 nm and a sulfur content of between 0.001% and 2% by weight and a sodium content of between 0.001% and 2% by weight, the weight percentages being expressed relative to the total mass of alumina gel.
The alumina gel thus obtained has a dispersibility index between 70 and 100%, preferably between 80 and 100%, very preferably between 85 and 100% and even more preferably between 90 and 100%.
Preferably, the alumina gel thus obtained has a crystallite size of between 2 and 35 nm.
Preferably, the alumina gel thus obtained comprises a sulfur content of between 0.001% and 1% by weight, preferably between 0.001 and 0.40% by weight, very preferably between 0.003 and 0.33% by weight, and more preferably between 0.005 and 0.25% by weight.
Preferably, the alumina gel thus obtained comprises a sodium content of between 0.001% and 1% by weight, preferably between 0.001 and 0.15% by weight, very preferably between 0.0015 and 0.10% by weight. , and 0.002 and 0.040% by weight.
In particular, the alumina gel or the boehmite in powder form according to the invention is composed of crystallites whose size, obtained by the Scherrer formula in X-ray diffraction according to the crystallographic directions [020] and [120] are respectively between 2 and 20 nm and between 2 and 35 nm.
Preferably, the alumina gel according to the invention has a crystallite size in the crystallographic direction [020] of between 1 to 15 nm and a crystallite size in the crystallographic direction [120] of between 1 to 35 nm.
X-ray diffraction on alumina or boehmite gels was performed using the conventional powder method using a diffractometer.
Scherrer's formula is a formula used in X-ray diffraction on powders or polycrystalline samples which connects the width at half height of the diffraction peaks to the size of the crystallites. It is described in detail in the reference: Appl. Cryst. (1978). 11, 102-113 Scherrer after sixty years: A survey and some new results in the determination of crystallite size, JI Langford and AJC Wilson.
The alumina gel thus prepared and having a high degree of dispersibility facilitates the shaping step of said gel according to all the methods known to those skilled in the art and in particular by extrusion kneading, by granulation and by the technique known as oil drop according to the English terminology.
According to the invention, the alumina gel obtained at the end of the filtration step c) is dried in a drying step d) to obtain a powder.
Said drying step is advantageously carried out at a temperature of between 20 and 50 ° C. and for a period of time comprised between 1 day and 3 weeks or by atomization.
In the case where said drying step d) is carried out at a temperature of between 20 and 50 ° C. and for a period of time ranging from 1 day to 3 weeks, said drying step d) may advantageously be carried out in a closed oven and ventilated, preferably said drying step operates at a temperature between 25 and 40 ° C, and for a period of between 3 days and two weeks.
In the case where said drying step d) is carried out by atomization, the cake obtained at the end of the hydrothermal treatment step optionally followed by a filtration step is resuspended. Said suspension is then sprayed in fine droplets, in a vertical cylindrical chamber in contact with a stream of hot air to evaporate the water according to the principle well known to those skilled in the art. The powder obtained is driven by the heat flow to a cyclone or a bag filter that will separate the air from the powder. Preferably, in the case where said drying step d) is carried out by atomization, the atomization is carried out according to the operating protocol described in the publication Asep Bayu Dani Nandiyanto, Kikuo Okuyama, Advanced Powder Technology, 22, 1-19 , 2011.
The alumina powder thus prepared is a mesoporous alumina with controlled mesoporosity having good thermal and chemical stability, having a centered, uniform and controlled mesopore size distribution.
Said alumina has a specific surface area and a porous distribution calibrated and adapted to its use in a process for hydrocracking said hydrocarbon feedstock.
Preferably, the mesoporous alumina is devoid of micropores.
Preferably, the support advantageously has a specific surface area greater than 100 m 2 / g, and a mesoporous volume greater than or equal to 0.5 ml / g, preferably greater than or equal to 0.6 ml / g.
The mesoporous volume is defined as the volume included in the pores having a mean diameter of between 2 and 50 nm and is measured from the mercury intrusion method.
Preferably, the alumina thus prepared and used in the invention is a non-mesostructured alumina.
Preferably, the amorphous mesoporous alumina thus prepared and used in the invention has a connectivity (Z) greater than 2.7, preferably a connectivity (Z) of between 2.7 and 10, preferably of between 2, 8 and 10, very preferably between 3 and 9, more preferably between 3 and 8 and even more preferably between 3 and 7.
According to the invention, the powder obtained at the end of the drying step d) is shaped in a step e)) in a mixture with at least said zeolite having at least one series of channels whose opening is defined by a ring of 12 oxygen atoms (12MR) to obtain a raw material.
By raw material is meant the material shaped and having not undergone any heat treatment steps.
Said zeolite modified or not used in the support may be, without limitation, for example in the form of powder, milled powder, suspension, suspension having undergone deagglomeration treatment. Thus, for example, the zeolite can advantageously be slurried acidulated or not at a concentration adjusted to the final zeolite content referred to the support. This suspension commonly called a slip is then advantageously mixed with the precursors of the matrix.
Preferably, said shaping step e) is carried out by extrusion kneading, by pelletization, by the method of dropwise coagulation (oil-drop), by rotary plate granulation or by any other method well known to man. of career.
In a very preferred manner, said shaping step e) is carried out by extrusion kneading.
According to the invention, the raw material obtained at the end of the shaping step e) is then subjected to a f) calcination step at a temperature of between 500 and 1000 ° C., for a period of time between 2 and 10 hours, with or without airflow containing up to 60% water volume.
Preferably, said calcining step f) operates at a temperature of between 540 ° C. and 850 ° C.
Preferably, said f) calcination step operates for a period of between 2h and 10h.
Said f) calcination step allows the transition of the boehmite to the final alumina.
The catalyst support thus obtained after the forming and calcining steps e) and f) comprises and preferably consists of at least said zeolite and at least one binder comprising at least said amorphous mesoporous alumina.
The catalyst used in the hydrocracking process according to the invention is then advantageously obtained by adding the elements constituting the active phase.
The elements of groups VIB and / or the non-noble elements of group VIII, optionally the doping elements chosen from phosphorus, boron, silicon and optionally the elements of groups VB and VIIA may optionally be introduced, in whole or in part, at any stage of the preparation, during the synthesis of the matrix, preferably during the shaping of the support, or very preferably after the shaping of the support by any method known to those skilled in the art. They can be introduced after forming the support and after or before the drying and calcining of the support.
According to a preferred embodiment of the present invention, all or part of the elements of the groups VIB, and / or the non-noble elements of the group VIII and optionally the doping elements chosen from phosphorus, boron, silicon and possibly the elements of the groups VB , and VIIA may be introduced during the shaping of the support, for example, during the mixing step of the modified zeolite with a wet alumina gel.
According to another preferred embodiment of the present invention, all or part of the elements of the groups VIB, and / or the non-noble elements of the group VIII and optionally the doping elements chosen from phosphorus, boron, silicon and possibly the elements of the groups VB, and VI IA may be introduced by one or more impregnation operations of the shaped and calcined support, by a solution containing the precursors of these elements. In a preferred manner, the support is impregnated with an aqueous solution. The impregnation of the support is preferably carried out by the "dry" impregnation method well known to those skilled in the art.
In the case where the catalyst of the present invention contains a non-noble metal of group VIII, the metals of group VIII are preferably introduced by one or more impregnation operations of the shaped and calcined support, after those of group VIB or at the same time as these.
According to another preferred embodiment of the present invention, the deposition of boron and silicon can also be carried out simultaneously using, for example, a solution containing a boron salt and a silicon-type silicon compound.
The catalyst used in the hydrocracking process according to the invention can advantageously be additive. In this case, at least one organic additive is added as defined above and preferably introduced into the impregnating solution containing the precursors of the active phase or in a subsequent impregnation step. Impregnation of the elements of the group VB and preferably niobium may advantageously be facilitated by addition of oxalic acid and optionally ammonium oxalate in the solutions of niobium oxalate. Other compounds can be used to improve the solubility and facilitate the impregnation of niobium as is well known to those skilled in the art.
When at least one doping element, P and / or B and / or Si, is introduced, its distribution and location can be determined by techniques such as the Castaing microprobe (distribution profile of the various elements), electron microscopy. transmission coupled to an analysis X of the catalyst components, or else by restoring a distribution map of the elements present in the catalyst by electron microprobe.
For example, among the sources of molybdenum and tungsten, it is possible to use oxides and hydroxides, molybdic and tungstic acids and their salts, in particular ammonium salts such as ammonium molybdate, ammonium heptamolybdate, ammonium tungstate, phosphomolybdic acid, phosphotungstic acid and their salts, silicomolybdic acid, silicotungstic acid and their salts. Oxides and ammonium salts such as ammonium molybdate, ammonium heptamolybdate and ammonium tungstate are preferably used.
Sources of non-noble group VIII elements that can be used are well known to those skilled in the art. For example, for non-noble metals, use will be made of nitrates, sulphates, hydroxides, phosphates, halides, for example chlorides, bromides and fluorides, carboxylates, for example acetates and carbonates.
The preferred phosphorus source is orthophosphoric acid H 3 PO 4, but its salts and esters such as ammonium phosphates are also suitable. The phosphorus may for example be introduced in the form of a mixture of phosphoric acid and a basic organic compound containing nitrogen such as ammonia, primary and secondary amines, cyclic amines, compounds of the family of pyridine and quinolines and compounds of the pyrrole family. Tungstophosphoric or tungstomolybdic acids can be used.
The phosphorus content is adjusted, without limiting the scope of the invention, so as to form a mixed compound in solution and / or on the support for example tungsten-phosphorus or molybdenum-tungsten-phosphorus. These mixed compounds may be heteropolyanions. These compounds may be Anderson heteropolyanions, for example.
The boron source may be boric acid, preferably orthoboric acid H3B03, biborate or ammonium pentaborate, boron oxide, boric esters. The boron may for example be introduced in the form of a mixture of boric acid, hydrogen peroxide and a basic organic compound containing nitrogen such as ammonia, primary and secondary amines, cyclic amines, compounds of the family of pyridine and quinolines and compounds of the pyrrole family. Boron may be introduced for example by a boric acid solution in a water / alcohol mixture.
Many sources of silicon can be used. Thus, it is possible to use ethyl orthosilicate Si (OEt) 4, siloxanes, polysiloxanes, silicones, silicone emulsions, halide silicates, such as ammonium fluorosilicate (NH4) 2SiF6 or fluorosilicate. sodium Na2SiF6. Silicomolybdic acid and its salts, silicotungstic acid and its salts can also be advantageously employed. The silicon may be added, for example, by impregnation of ethyl silicate in solution in a water / alcohol mixture. Silicon can be added, for example, by impregnating a silicon-type silicon compound or silicic acid suspended in water.
Group VB element sources that can be used are well known to those skilled in the art. For example, among the sources of niobium, it is possible to use the oxides, such as diniobium pentoxide Nb205, niobic acid Nb2O5.H20, niobium hydroxides and polyoxoniobates, niobium alkoxides of formula Nb (OR1) 3 where R1 is an alkyl radical, niobium oxalate Nb0 (HC204) 5, ammonium niobate. Niobium oxalate or ammonium niobate is preferably used.
Sources of VIIA group elements that can be used are well known to those skilled in the art. For example, the fluoride anions can be introduced in the form of hydrofluoric acid or its salts. These salts are formed with alkali metals, ammonium or an organic compound. In the latter case, the salt is advantageously formed in the reaction mixture by reaction between the organic compound and the hydrofluoric acid. It is also possible to use hydrolysable compounds which can release fluoride anions in water, such as ammonium fluorosilicate (NH4) 2 SiF6, silicon tetrafluoride SiF4 or sodium tetrafluoride Na2SiF6. The fluorine may be introduced for example by impregnation with an aqueous solution of hydrofluoric acid or ammonium fluoride.
The catalysts used in the process according to the invention advantageously have the form of spheres or extrudates. It is however advantageous that the catalyst is in the form of extrudates with a diameter of between 0.5 and 5 mm and more particularly between 0.7 and 2.5 mm. The shapes are cylindrical (which can be hollow or not), cylindrical twisted, multilobed (2, 3, 4 or 5 lobes for example), rings. The cylindrical shape is preferably used, but any other shape may be used. The catalysts according to the invention may optionally be manufactured and used in the form of crushed powder, tablets, rings, balls, wheels.
The Group VIB and / or Group VIII metals of said catalyst are present in sulphide form.
Prior to the injection of the feedstock, the catalysts used in the processes according to the present invention are subjected beforehand to a sulphurization treatment making it possible, at least in part, to convert the metal species into sulphide before they are brought into contact with the feedstock. treat. This activation treatment by sulfurization is well known to those skilled in the art and can be performed by any method already described in the literature either in-situ, that is to say in the reactor, or ex-situ.
A conventional sulphurization method well known to those skilled in the art consists in heating the catalyst in the presence of hydrogen sulphide (pure or for example under a stream of a hydrogen / hydrogen sulphide mixture) at a temperature of between 150 and 800 ° C. preferably between 250 and 600 ° C, usually in a crossed-bed reaction zone.
The hydrocracking process according to the invention can advantageously be implemented according to all the embodiments known in the prior art.
Said method can advantageously be implemented in one or two stages, in one or more reactor (s), fixed bed or bubbling bed. The invention is illustrated by the following examples, which in no way present a limiting character.
Examples:
Example 1 (Comparative) Preparation of a Support S1 (Non-Conforming) Comprising an Alumina Prepared According to US Pat. No. 7,754,562 Shaped with a Y Zeolite
In a first step, the synthesis of a non-compliant alumina gel is carried out in that Example 2 is carried out according to the preparation method described in patent US Pat. In particular, the process for preparing the alumina gel according to Example 2 does not include a heat treatment step of the suspension obtained at the end of the precipitation steps and in that the first precipitation step a) does not produce an amount of alumina greater than 40% relative to the total amount of alumina formed at the end of the second precipitation step.
The synthesis is carried out in a 7L reactor and a final suspension of 5L in two precipitation stages. The amount of water added to the reactor is 3868 ml.
The final alumina concentration is 30g / L.
A first step of co-precipitation of aluminum sulphate Al 2 (SO 4) and of sodium aluminate NaAlOO is carried out at 30 ° C. and pH = 9.3 for a period of 8 minutes. The concentrations of the aluminum precursors used are as follows: Al 2 (SO 4) = 102 g / l in Al 2 O 3 and NaAlOO at 155 g / l in Al 2 O 3. The agitation is 350 rpm throughout the synthesis.
A solution of aluminum sulphate Al.sub.2 (SO.sub.4) is continuously added for 8 minutes at a flow rate of 19.6 ml / min to a sodium aluminate solution NaAlO.sub.2 in a weight ratio base / acid = 1.80 to adjust the pH to a value of 9.3. The temperature of the reaction medium is maintained at 30 ° C.
A suspension containing a precipitate of alumina is obtained.
The final concentration of alumina targeted being 30 g / l, the flow rate of aluminum sulphate precursors Al 2 (SO 4) and aluminum aluminate NaAlOO containing aluminum introduced in the first precipitation stage are respectively 19.6 ml / min. and 23.3 ml / min.
These flow rates of acid and basic precursors containing aluminum make it possible to obtain at the end of the first precipitation step a degree of progress of 30%.
The suspension obtained is then subjected to a temperature rise of 30 to 57 ° C.
A second step of co-precipitation of the suspension obtained is then carried out by adding aluminum sulphate Al.sub.2 (SO.sub.4) at a concentration of 102 g / l of Al.sub.2 O.sub.3 and of sodium aluminate NaAlO.sub.2 at a concentration of 155 g / l. in Al203. A solution of aluminum sulphate Al.sub.2 (SO.sub.4) is therefore added continuously to the heated suspension obtained at the end of the first precipitation step for 30 minutes at a flow rate of 12.8 ml / min at an aluminate solution. sodium NaAlOO in a base / acid mass ratio = 1.68 so as to adjust the pH to a value of 8.7. The temperature of the reaction medium in the second step is maintained at 57 ° C.
A suspension containing a precipitate of alumina is obtained.
The final concentration of alumina targeted being 30 g / l, the flow rate of aluminum sulphate precursors Al 2 (SO 4) and aluminum aluminate NaAlOO containing aluminum introduced in the second precipitation stage are respectively 12.8 ml / min. and 14.1 ml / min.
These flow rates of aluminum-containing basic and basic precursors make it possible to obtain at the end of the second precipitation stage a 70% degree of advance.
The suspension thus obtained does not undergo a ripening step.
The suspension obtained is then filtered by displacement of water on a sintered Buchner type tool and the alumina gel obtained is washed 3 times with 5 L of distilled water at 70 ° C. Filtration time and washes are 4 hours.
The characteristics of the alumina gel thus obtained are summarized in Table 1.
Table 1: characteristics of the alumina gel obtained according to Example 1.
The alumina gel is then spray-dried with an inlet temperature of 250 ° C and an exit temperature of 130 ° C.
The dried alumina gel is introduced into a Brabender type mixer mixed with a USY zeolite powder having the characteristics described in Table 2.
Table 2: Characteristic of the USY zeolite.
Acidified water with nitric acid at a total acid content of 2%, expressed by weight relative to the mass of dried gel introduced into the kneader, is added in 5 minutes, during a 20-minute mixing. / min. The acid mixing is continued for 10 minutes. A neutralization step is then carried out by adding an ammoniacal solution in the kneader, at a neutralization rate of 20%, expressed by weight of ammonia relative to the amount of nitric acid introduced into the kneader for the stage. acidification. The kneading is continued for 3 minutes.
The paste obtained is then extruded through a 2 mm trilobal die. The support is obtained after shaping and extrusion by mixing 20% by weight of the zeolite USY-1 with 80% of alumina gel.
The extrudates obtained are dried at 100 ° C. for one night and then calcined for 2 hours at 600 ° C.
The characteristics of the support formed are shown in Table 3:
Table 3: Characteristics of the support S1 obtained according to Example 1.
EXAMPLE 2 (According to the Invention) Preparation of the Supports S2 and S3 (Compliant) Comprising an Alumina Prepared According to the Invention and a USY-1 Zeolite
First, the synthesis of two supports S2 and S3 is carried out according to a preparation method according to the invention in a 7L reactor and a final 5L suspension in 3 steps, two precipitation stages followed by a ripening stage. .
The final alumina concentration is 45g / L. The amount of water added to the reactor is 3267 ml. The agitation is 350 rpm throughout the synthesis.
A first step of co-precipitation in water, aluminum sulphate Al 2 (SO 4) and sodium aluminate NaAlO 2 is carried out at 30 ° C. and pH = 9.5 for a period of 8 minutes. The concentrations of the aluminum precursors used are as follows: Al 2 (SO 4) = 102 g / l in Al 2 O 3 and NaAlOO at 155 g / l in Al 2 O 3.
A solution of aluminum sulphate Al 2 (SO 4) is added continuously for 8 minutes at a flow rate of 69.6 ml / min to a solution of sodium aluminate NaAlOO at a flow rate of 84.5 ml / min in a ratio mass base / acid = 1.84 so as to adjust the pH to a value of 9.5. The temperature of the reaction medium is maintained at 30 ° C.
A suspension containing a precipitate of alumina is obtained.
The final concentration of alumina targeted being 45 g / l, the flow rate of aluminum sulphate precursors Al 2 (SO 4) and aluminum aluminate NaAlOO containing aluminum introduced in the first precipitation stage are respectively 69.6 ml / min. and 84.5 ml / min.
These flow rates of aluminum-containing acidic and basic precursors make it possible to obtain at the end of the first precipitation step an advancement rate of 72%.
The resulting suspension is then subjected to a temperature rise of 30 to 68 ° C.
A second step of co-precipitation of the suspension obtained is then carried out by adding aluminum sulphate Al.sub.2 (SO.sub.4) at a concentration of 102 g / l of Al.sub.2 O.sub.3 and of sodium aluminate NaAlO.sub.2 at a concentration of 155 g / l in Al.sub.2 O.sub.3. . A solution of aluminum sulphate Al.sub.2 (SO.sub.4) is therefore added continuously to the heated suspension obtained at the end of the first precipitation step for 30 minutes at a flow rate of 7.2 ml / min to an aluminate solution. sodium NaAlOO in a mass ratio base / acid = 1.86 so as to adjust the pH to a value of 9. The temperature of the reaction medium in the second step is maintained at 68 ° C.
A suspension containing a precipitate of alumina is obtained.
As the final concentration of alumina is 45 g / l, the flow rate of aluminum sulphate precursors Al 2 (SO 4) and aluminum aluminate NaAlOO containing aluminum introduced in the second precipitation stage are respectively 7.2 ml / min. and 8.8 ml / min.
These flow rates of acid and basic precursors containing aluminum make it possible to obtain at the end of the second precipitation stage a progress rate of 28%.
The resulting suspension is then subjected to a temperature rise of 68 to 90 ° C.
The slurry then undergoes a hydrothermal treatment step in which it is held at 90 ° C for 60 minutes.
The suspension obtained is then filtered by displacement of water on a sintered Buchner type tool and the alumina gel obtained is washed 3 times with 5 L of distilled water. Filtration time and washes is 3h.
The characteristics of the alumina gel thus obtained are summarized in Table 4.
Table 4: characteristics of the alumina gel obtained according to Example 2.
A gel having a dispersibility index of 100% is thus obtained.
The alumina gel obtained is then spray-dried with an inlet temperature of 250 ° C. and an outlet temperature of 130 ° C. The gel dried by aeration is called Gel No. 1.
The alumina gel obtained according to Example 3 is dried in a ventilated study at 35 ° C. for 4 days. The dried gel in an oven is called Gel No. 2.
The dried alumina gels Nos. 1 and 2 are then introduced into a Brabender-type mixer in a mixture with a USY zeolite powder having the characteristics described in Table 2.
Acidified water with nitric acid at a total acid content of 2%, expressed by weight relative to the mass of dried gel introduced into the kneader, is added in 5 minutes, during a 20-minute mixing. / min. The acid mixing is continued for 10 minutes.
A neutralization step is then carried out by adding an ammoniacal solution in the kneader, at a neutralization rate of 20%, expressed by weight of ammonia relative to the amount of nitric acid introduced into the kneader for the stage. acidification. The kneading is continued for 3 minutes.
The paste obtained is then extruded through a 2 mm trilobal die. The extrudates obtained are dried at 100 ° C. overnight and then calcined for 2 hours at 600 ° C.
Two supports S2 and S3 each comprising 20% by weight of the zeolite USY-1 and 80% of alumina gel No. 1 and 2 are obtained.
The characteristics of the supports S2 and S3 formed are reported in Table 5: Table 5: characteristics of the supports S2 and S3 obtained according to Example 2.
Example 3: Preparation of C1 catalysts (non-compliant). C2 (compliant). C3 (compliant), respectively from the supports S1 to S3
A solution composed of molybdenum oxide, nickel hydroxycarbonate and phosphoric acid is added to the supports S1 to S3 by dry impregnation to obtain a formulation of 2.5 / 15.0 / 2 expressed in% weight of oxides relative to the amount of dry matter for the final catalysts C1 to C3. After dry impregnation, the extrudates are allowed to mature in a saturated water atmosphere for 12 hours, then dried overnight at 110 ° C and finally calcined at 450 ° C for 2 hours to yield non-compliant C1 and C2 catalysts. and C3, according to the invention.
EXAMPLE 4 Comparison of catalysts C1 to C3 in hydrocracking of a vacuum distillate
The catalysts whose preparations are described in the preceding examples are used under the conditions of high conversion hydrocracking (60-100%). The petroleum feedstock is a hydrotreated vacuum distillate over a commercial nickel-based catalyst
and molybdenum on alumina, the main characteristics of which are given in Table 6.
Table 6: Characteristic of the hydrotreated load used.
0.6% by weight of aniline and 2% by weight of dimethyl disulfide are added to the hydrotreated feed in order to simulate the partial pressures of H2S and NH3, present in the hydrocracking step, and generated during hydrotreatment the DSV. The feed thus prepared is injected into the hydrocracking test unit which comprises a fixed-bed reactor with up-flow of the feed ("up-flow") into which 50 ml of catalyst is introduced. The catalysts are sulphurized with an additonal straight-run gas oil mixture of 4% by weight of dimethyl disulphide and 1.6% by weight of aniline at 350 ° C. It should be noted that any in situ or ex situ sulphurization method is suitable. Once the sulphurization is complete, the charge described in Table 10 can be transformed. The following operating conditions are fixed: total pressure of 14 MPa, hourly volume velocity of 1.5 h -1 and a volume ratio H2 / load of 1000 Nl / l The hourly space velocity is defined as the ratio of the volume flow rate of the load. liquid entering the volume of catalyst introduced.The volume ratio H2 / load is obtained by the ratio of flow rates in normal condition of temperature and pressure.
The catalytic performances are expressed in relative relation to those obtained for the non-compliant reference catalyst C1 by the temperature difference which makes it possible to reach a gross conversion level of 70% (denoted T70) and by the differences in yields in gasoline and middle distillates (jet fuel and diesel) at this same gross conversion. These catalytic performances are measured on the catalyst after a period of stabilization, generally at least 48 hours, has been observed.
The gross conversion CB is taken as: CB =% wt. 370 ° C minus the effluent with 370 ° C minus "representing the fraction, distilled at a temperature of less than or equal to 370 ° C.
The yield of jet fuel (kerosene, 150-250, below Yt Kero) is equal to the weight% of compounds having a boiling point between 150 and 250 ° C in the effluents. The yield of gas oil (250-380) is equal to the weight% of compounds having a boiling point of between 250 and 380 ° C. in the effluents.
The reaction temperature is set so as to reach a gross conversion CB equal to 70% by weight. In Table 8 we have reported the reaction temperature and the yields of light and medium distillates for the catalysts described in the examples above.
Table 8: Catalytic Performance of Catalysts C1 to C3 in Hydrocracking
The catalysts C2 and C3, in accordance with the invention have higher catalytic performance than the non-compliant catalyst C1. In comparison with the catalyst C1, the catalysts C2 and C3 show a gain in yield of middle distillates respectively of 1.5 and 1.6 points. Finally, there is no significant difference in catalytic performance between the C2 and C3 catalysts, which shows that the type of drying of the alumina gel according to the invention has no impact on the catalytic performances obtained. .

权利要求:
Claims (12)
[1" id="c-fr-0001]
A process for the hydrocracking of at least one hydrocarbon feedstock of which at least 50% by weight of the compounds have an initial boiling point of greater than 300 ° C. and a final boiling point of less than 540 ° C. at a temperature comprised between between 200 ° C and 480 ° C, at a total pressure of between 1 MPa and 25 MPa with a volume ratio of hydrogen per volume of hydrocarbon feedstock of between 80 and 5000 liters per liter and at a defined hourly volume velocity (WH) by the ratio of the volume flow rate of the liquid hydrocarbon feedstock by the volume of catalyst charged to the reactor of between 0.1 and 50 h -1, said process using at least one catalyst comprising at least one Group VIB metal and / or at least one a metal of Group VIII of the Periodic Table and a support comprising at least one zeolite having at least one series of channels whose Opening is defined by a ring of 12 oxygen atoms (12MR), and at least one binder comprising comprising at least one amorphous mesoporous alumina, said support comprising at least said zeolite and at least said binder, being prepared according to at least the following steps: a) a step of precipitation, in an aqueous reaction medium, of at least one basic precursor chosen among sodium aluminate, potassium aluminate, ammonia, sodium hydroxide and potassium hydroxide and at least one acid precursor selected from aluminum sulphate, aluminum chloride, aluminum nitrate, sulfuric acid, hydrochloric acid, and nitric acid, in which at least one of the basic or acidic precursors comprises aluminum, the relative flow rate of the acidic and basic precursors is chosen in such a way as to obtain a pH of the reaction medium of between 8.5 and 10.5 and the flow rate of the aluminum-containing acidic and basic precursor (s) is adjusted so as to obtain a degree of progress of the first stage comprised between 40 th 100%, the rate of progress being defined as the proportion of alumina formed during said first precipitation step relative to the total amount of alumina formed at the end of step c) of the preparation process said step operating at a temperature between 20 and 90 ° C, and for a period of between 2 minutes and 30 minutes, b) a step of hydrothermal treatment of the suspension heated to a temperature between 50 and 200 ° C for a period of duration between 30 minutes and 5 hours to obtain an alumina gel, c) a filtration step of the suspension obtained at the end of the hydrothermal treatment step b), followed by at least one step of washing the gel obtained, d) a step of drying the alumina gel obtained at the end of step c) to obtain a powder, e> a step of shaping the powder obtained at the end of step d) in admixture with at least said zeolite having at least one e series of channels whose opening is defined by a ring with 12 oxygen atoms (12MR) to obtain the raw material, f) a step of calcination of the raw material obtained at the end of step e) at a temperature between 500 and 1000 ° C, in the presence or absence of a flow of air containing up to 60% by volume of water.
[2" id="c-fr-0002]
2. The method of claim 1 wherein the group VIB element is selected from the group consisting of tungsten and molybdenum, alone or in mixture.
[3" id="c-fr-0003]
3. Method according to one of claims 1 or 2 wherein the non-noble element of group VIII is selected from the group formed by cobalt and nickel, alone or in mixture.
[4" id="c-fr-0004]
4. Method according to one of claims 1 to 3 wherein said catalyst comprises at least one group VIB metal in combination with at least one non-noble group VIII metal, the group VIB metal content being, in oxide equivalent between 5 and 40% by weight relative to the total weight of said catalyst and the non-noble metal content of group VIII being in oxide equivalent between 0.5 and 10% by weight relative to the total mass of said catalyst .
[5" id="c-fr-0005]
5. Method according to one of claims 1 to 4 wherein the zeolite used in the catalyst support is selected from zeolites of the structural type FAU, BEA, ISV, IWRS lyVVVj MEI, UWY, pfiées alone or in mixture.
[6" id="c-fr-0006]
6. Process according to claim 5, in which the zeolite is chosen from zeolites of structural type FAU and BEA, taken alone or as a mixture.
[7" id="c-fr-0007]
7. Process according to claim 6, in which the zeolite is chosen from zeolite Y and zeolite beta, taken alone or as a mixture.
[8" id="c-fr-0008]
8. Method according to one of claims 1 to 7 wherein the rate of progress of said precipitation step a) is between 45 and 90%.
[9" id="c-fr-0009]
9. Method according to one of claims 1 to 8 wherein in the case where the advancement rate obtained at the end of the first step a) of precipitation is less than 100%, said preparation process comprises a second step precipitation a ') after the first precipitation step,
[10" id="c-fr-0010]
10. The method of claim 9 wherein a step of heating the suspension obtained at the end of step a) of precipitation is carried out between the two precipitation steps a) and a '), said heating step operating at a temperature between 20 and 90 ° C and for a period of between 7 and 45 minutes,
[11" id="c-fr-0011]
11. Method according to one of claims 9 to 10 wherein said second precipitation step a ') of the suspension obtained at the end of the heating step, operates by ai ° ut in said suspension of at least one basic precursor selected from sodium aluminate, potassium aluminate, ammonia, sodium hydroxide and potassium hydroxide and at least one acidic precursor selected from aluminum sulfate, sodium chloride, aluminum, alumina nitrate, sulfuric acid, hydrochloric acid, and nitric acid, wherein at least one of the basic or acidic precursors comprises aluminum, the relative flow rate of the acid precursors and basic is chosen so as to obtain a pH of the reaction medium of between 8.5 and 10.5 and the flow rate of the acidic and basic precursor (s) containing aluminum is adjusted so as to obtain a progress rate of the second step between 0 and 60%, said progress rate of the second step being defined as being the proportion of alumina formed in Al 2 O 3 equivalent during said second precipitation step a ') relative to the total amount of alumina formed at the end of step a') of the process of preparation, said second step a ') operating at a temperature between 40 and 90 ° C, and for a period of between 2 minutes and 50 minutes.
[12" id="c-fr-0012]
12. Method according to one of claims 1 to 11 wherein said hydrocarbon feeds are selected from light gas oils from a catalytic skimming unit, atmospheric distillates, vacuum distillates, feeds from extraction units. aromatics of lubricating oil bases or derived from solvent dewaxing of lubricating oil bases, distillates from processes for desulphurization or hydroconversion to fixed bed or ebullated bed of atmospheric residues and / or vacuum residues and / or deasphalted oils, deasphalted oils and paraffins from the Fischer-Tropsch process, alone or as a mixture.

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优先权:

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申请号 | 申请日 | 专利标题

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FR1561975A|FR3044677B1|2015-12-08|2015-12-08|METHOD FOR HYDROCRACKING HYDROCARBON LOADS USING A CATALYST COMPRISING A ZEOLITHE AND AMORPHOUS MESOPOROUS ALUMINA|

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FR1561975|2015-12-08|FR1561975A| FR3044677B1|2015-12-08|2015-12-08|METHOD FOR HYDROCRACKING HYDROCARBON LOADS USING A CATALYST COMPRISING A ZEOLITHE AND AMORPHOUS MESOPOROUS ALUMINA|

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CN201680072135.6A| CN108603126A|2015-12-08|2016-11-16|Use the method comprising zeolite and the catalyst hydrogenation crack hydrocarbon feeds of amorphous mesoporous aluminas|

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PCT/EP2016/077788| WO2017097551A1|2015-12-08|2016-11-16|Method for hydrocracking hydrocarbon feedstocks using a catalyst comprising a zeolite and an amorphous mesoporous alumina|

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US16/060,069| US10723960B2|2015-12-08|2016-11-16|Method for hydrocracking hydrocarbon feedstocks using a catalyst comprising a zeolite and an amorphous mesoporous alumina|

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JP2018529044A| JP2019504144A|2015-12-08|2016-11-16|Process for hydrocracking hydrocarbon feedstocks using a catalyst comprising zeolite and amorphous mesoporous alumina|