US20140275688A1

US20140275688A1 - Methods for producing basestocks from renewable sources using dewaxing catalyst

Info

Publication number: US20140275688A1
Application number: US14/196,035
Authority: US
Inventors: Scott J. Weigel; Joseph Emmanuel Gatt; Darryl Donald Lacy; Randall D. Partridge; Kun Wang; Lei Zhang; Christine Nicole Elia; Jenna Lynn Walp
Original assignee: ExxonMobil Research and Engineering Co
Current assignee: ExxonMobil Technology and Engineering Co
Priority date: 2013-03-14
Filing date: 2014-03-04
Publication date: 2014-09-18
Also published as: WO2014158843A1; CA2896374A1; EP2970773A1; SG11201504958PA

Abstract

Provided are methods for producing a lube base stock and/or a fuel from a feedstock of biological origin, the method including: contacting the feedstock in the presence of a catalyst to produce a lube base stock and/or a fuel, wherein the catalyst comprises: a zeolite component selected from a zeolite having 10-member ring pores, a zeolite having 12-member ring pores and a combination thereof, 0.1 to 5 weight % of a hydrogenation component selected from Pt, Pd, Ag, Ni, Co, Mo, W, Rh, Re, Ru, Ir and a mixture thereof, and a hydrothermally stable binder component.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application Ser. No. 61/782,620 filed Mar. 14, 2013 and is herein incorporated by reference in its entirety.

FIELD

The present disclosure relates to catalysts for use in dewaxing and other hydrocarbon conversion processes and methods of using such catalysts. Specifically, this disclosure relates to a dewaxing catalyst comprising a zeolite component, a metal component for promoting hydrogenation and a hydrothermally stable binder component, and methods of using such catalysts.

BACKGROUND

Waxy feedstocks may be used to prepare basestocks having a high viscosity index (VI). However, in order to obtain a basestock having the low temperature properties suitable for most uses, it is usually necessary to dewax the feedstock. Dewaxing may be accomplished by means of a solvent or catalytically. Solvent dewaxing is a physical process whereby waxes are removed by contacting with a solvent, such as methyl ethyl ketone, followed by chilling to crystallize the wax and filtration to remove the wax. Catalytic dewaxing involves chemically converting the hydrocarbons leading to unfavorable low temperature properties to hydrocarbons having more favorable low temperature properties. Long chain normal paraffins and slightly branched paraffins readily solidify and thus result in generally unfavorable low temperature properties. Catalytic dewaxing is a process for converting these long chain normal paraffins and slightly branched paraffins to molecules having improved low temperature properties.
Catalytic dewaxing may be accomplished using catalysts that function primarily by cracking waxes to lower boiling products, or by catalysts that primarily isomerize waxes to more highly branched products. Catalysts that dewax by cracking decrease the yield of lubricating oils while increasing the yield of lower boiling distillates. Catalysts that isomerize do not normally result in significant boiling point conversion. Catalysts that dewax primarily by cracking are exemplified by the zeolites ZSM-5, ZSM-11, ZSM-12, beta and offretite. Catalysts that dewax primarily by isomerization are exemplified by the zeolites ZSM-22, ZSM-23, SSZ-32, ZSM-35, ZSM-48 and ZSM-50. To ensure adequate mechanical strength for use in a dewaxing reactor, such zeolite catalysts are generally combined with an inorganic oxide binder, such as alumina.
Catalysts are needed for the upgrading of renewable basestocks for fuels and lubricant applications. For example, a catalyst for fatty acid coupling helps production of a highly flexible feedstock. As shown in FIG. 1, this feedstock can then be hydrogenated and/or isomerized using conventional refinery processing, thereby producing high value products consisting of a mixture of fuels, high viscosity, and low viscosity lubricants. This product stream can easily be separated using conventional fractionation and distillation equipment.
The hydrogenation/isomerization catalyst for renewable feedstocks has several challenges to deal with: 1) a highly oxygenated feed (10% oxygen), 2) high heats of reaction, and 3) generation of water which is converted into steam in the reactor. The last challenge is of major concern to current dewaxing catalysts because steam can cause issues with the hydrothermal stability of the catalyst and can cause deactivation by dealuminating the zeolite catalyst and/or degradation of the oxide support/binder leading to agglomeration of the metal.
Conventional dewaxing catalysts are, however, susceptible to poisoning by contaminants in a feedstock. To mitigate the problem of catalyst poisoning and to allow effective dewaxing of feedstocks with very high levels of waxy materials, it is often desirable to be able to maximize the dewaxing activity of the catalyst. However, in seeking maximize activity, it is also important to maintain the mechanical strength of the catalyst.
U.S. Pat. No. 8,263,517 to Christine N. Elia describes a dewaxing catalyst comprising a zeolite with a low silica to alumina ratio in combination with a low surface area binder. The low surface area binder is believed to increase access to the active sites of the zeolite. Especially for bulky feeds, increased access to zeolite active sites is expected to lead to an overall increase in activity.
U.S. Patent Publication No. 2011/0192766 mentions a supported catalyst comprising a zeolite having a silica to alumina molar ratio of 500 or less, a first metal oxide binder having a crystallite size greater than 200 Å and a second metal oxide binder having a crystallite size less than 100 Å, wherein the second metal oxide binder is present in an amount less than 15 wt % of the total weight of the catalyst.

SUMMARY

The present disclosure relates to catalysts for use in dewaxing and other hydrocarbon conversion processes and methods of using such catalysts. In an embodiment, there is provided a method for producing a lube base stock and/or a fuel from a feedstock of biological origin, the method comprising: contacting the feedstock in the presence of a catalyst to produce a lube base stock and/or a fuel, wherein the catalyst comprises: a zeolite component selected from a zeolite having 10-member ring pores, a zeolite having 12-member ring pores and a combination thereof, 0.1 to 5 weight % of a hydrogenation component selected from Pt, Pd, Ag, Ni, Mo, Co, W, Rh, Re, Ru, Ir and a mixture thereof, and a hydrothermally stable binder component selected from silica, alumina, silica-alumina, titania, zirconia, tantalum oxide, tungsten oxide, molybdenum oxide, vanadium oxide, magnesium oxide, calcium oxide, yttrium oxide, lanthanum oxide, cerium oxide, niobium oxide, tungstated zirconia, cobalt molybdenum oxide, cobalt molybdenum sulfide, nickel molybdenum oxide, nickel molybdenum sulfide, nickel tungsten oxide, nickel tungsten sulfide, cobalt tungsten oxide, cobalt tungsten sulfide, nickel molybdenum tungsten oxide and nickel molybdenum tungsten sulfide, cobalt molybdenum tungsten oxide and cobalt molybdenum tungsten sulfide, wherein the weight ratio of the zeolite to the hydrothermally stable binder is 85:15 to 25:75.
In another embodiment, there is provided a method for producing a lube basestock and/or a fuel from a feedstock of biological origin, the method comprising: contacting the feedstock in the presence of a catalyst to produce a lube base stock and/or a fuel, wherein the catalyst comprises: a zeolite selected from ZSM-48, ZSM-23, ZSM-50, ZSM-5, ZSM-22, ZSM-11, ferrierite, faujasite, beta, ZSM-12, MOR, and a mixture thereof, and a hydrogenation component comprising at least three metals selected from the group consisting of Pt, Pd, Ag, Ni, Mo, Co, W, Rh, Re, and Ru, wherein at least one of the at least three metals is in either an oxide or sulfide form. In an aspect of the present embodiment, the catalyst further comprises a binder component.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a scheme illustrating process flow schematic for the conversion of renewable feedstocks to higher value fuels and lubes products where a catalyst of the present disclosure can be placed into the hydroisomerization unit.

FIG. 2 is a scheme illustrating process chemistry for the conversion of renewable feedstocks.

DETAILED DESCRIPTION

All numerical values within the detailed description and the claims herein are modified by “about” or “approximately” the indicated value, and take into account experimental error and variations that would be expected by a person having ordinary skill in the art.
The present disclosure provides a method for producing a lube base stock and/or a fuel from a feedstock of biological origin, the method comprising: contacting the feedstock in the presence of a catalyst to produce a lube base stock and/or a fuel, wherein the catalyst comprises a zeolite, a metal for promoting hydrogenation and a hydrothermally stable binder. In various embodiments, the zeolite is selected from selected from a zeolite having 10-member ring pores, a zeolite having 12-member ring pores and a combination thereof; the metal component is selected from the group consisting of Pt, Pd, Ag, Ni, Mo, W, Rh, Re, Ru and a mixture thereof; and the hydrothermally stable binder is selected from silica, alumina, silica-alumina, titania, zirconia, tantalum oxide, tungsten oxide, molybdenum oxide, vanadium oxide, magnesium oxide, calcium oxide, yttrium oxide, lanthanum oxide, cerium oxide, niobium oxide, tungstated zirconia, cobalt molybdenum oxide, cobalt molybdenum sulfide, nickel molybdenum oxide, nickel molybdenum sulfide, nickel tungsten oxide, nickel tungsten sulfide, cobalt tungsten oxide, cobalt tungsten sulfide, nickel molybdenum tungsten oxide and nickel molybdenum tungsten sulfide, cobalt molybdenum tungsten oxide and cobalt molybdenum tungsten sulfide. The catalysts provided herein have improved hydrothermal stability of the dewaxing catalysts which are, for example, used in conversion of renewable basestock. Also, the catalysts can minimize metal agglomeration, thereby improving catalytic selectivity and activity.
As shown in FIG. 2, a solid base catalyst such as La/ZrO₂converts natural oils via coupling reactions to ketone or acid functionalized feedstocks. The catalyst of the present disclosure is used in the next stage and is capable of doing the hydrogenation and/or isomerization in the presence of water and CO₂without significantly cracking the molecules to gaseous products.
In various embodiments, a weight ratio of the zeolite to the hydrothermally stable binder can be controlled. In an embodiment, for example, the weight ratio of the zeolite to the hydrothermally stable binder is 85:15 to 25:75, particularly, 80:20 to 65:35. In particular embodiments, the ratio is 80:20 or 65:35.
In another embodiment, there is provided a method for producing a lube base stock and/or a fuel from a feedstock of biological origin, the method comprising: contacting the feedstock in the presence of a catalyst to produce a lube base stock and/or a fuel, wherein the catalyst comprises: a zeolite selected from ZSM-48, ZSM-23, ZSM-50, ZSM-5, ZSM-22, ZSM-11, ferrierite, faujasite, beta, ZSM-12, MOR and a mixture thereof, and a hydrogenation component comprising at least three metals selected from the group consisting of Pt, Pd, Ag, Ni, Co, Mo, W, Rh, Re, and Ru, wherein at least one of the at least three metals is in either an oxide or sulfide form. The catalyst comprising a ternary metal component can be used in a conversion reaction without additional binder component. In an aspect of the present embodiment, the catalyst further comprises a hydrothermally stable binder.

Zeolite Component

A zeolite to be employed in the present catalyst composition can be selected based on the intended use of the catalyst. When the catalyst is to be used in isomerization dewaxing, suitable zeolites include those having 10-membered ring pores and particularly those having unidirectional 10-membered ring pores. Examples of suitable zeolites include ZSM-48, ZSM-23, ZSM-50, ZSM-5, ZSM-22, ZSM-11, ferrierite and combinations thereof. Other suitable zeolites include those having 12-membered ring pores and examples of suitable zeolites include from faujasite, beta, ZSM-12, MOR and combinations thereof. Also, suitable zeolites include a combination of a zeolite having 10-membered ring pores and a zeolite having 12-membered ring pores: for example, a combination of beta and ZSM-48.
In particular embodiments, ZSM-48 or ZSM-23 is used as the zeolite component, and the catalysts are particularly useful in the isomerization dewaxing of lube oil basestocks. Such feedstocks are wax-containing feeds that boil in the lubricating oil range, typically having a 10% distillation point greater than 650° F. (343° C.), measured by ASTM D86 or ASTM D2887. Such feeds may be derived from a number of sources such as natural oils like seed oils and animal fats, oils derived from solvent refining processes such as raffinates, partially solvent dewaxed oils, deasphalted oils, distillates, vacuum gas oils, coker gas oils, slack waxes, foots oils and the like, and Fischer-Tropsch waxes.
In a particular embodiment, the zeolite component is ZSM-48. ZSM-48 crystals, as used herein, is described variously in terms of “as-synthesized” crystals that still contain the organic template; calcined crystals, such as Na-form ZSM-48 crystals; or calcined and ion-exchanged crystals, such as H-form ZSM-48 crystals. ZSM-48 crystals after removal of the structural directing agent have a particular morphology and a molar composition according to the general formula:
(n)SiO₂:Al₂O₃
where n is from 70 to 210. In another embodiment, n is 80 to 100. In yet another particular embodiment, n is 85 to 95. In still other embodiments, Si may be replaced by Ge and Al may be replaced by Ga, B, Fe, Ti, V, and Zr.
The as-synthesized form of ZSM-48 crystals is prepared from a mixture having silica, alumina, base and hexamethonium salt directing agent. In an embodiment, the molar ratio of structural directing agent:silica in the mixture is less than 0.05, less than 0.025, or less than 0.022. In another embodiment, the molar ratio of structural directing agent:silica in the mixture is at least 0.01, at least 0.015, or at least 0.016. In still another embodiment, the molar ratio of structural directing agent:silica in the mixture is from 0.015 to 0.025, preferably 0.016 to 0.022.
Particularly, the catalysts used in processes according to the disclosure have a zeolite component with a low ratio of silica to alumina. For example, for ZSM-48, the ratio of silica to alumina in the zeolite can be less than 200:1, less than 110:1, less than 100:1, less than 90:1, or less than 80:1. In a particular embodiment, the ratio of silica to alumina in the zeolite is less than 80:1, for example, particularly 70:1.

Hydrogenation Component

A hydrogenation component promotes the reaction of hydrogen with olefinic unsaturation in fatty acids, fatty acid dimers and oligomers, ketones, heavier oxygenates, and other intermediate reaction products. It further acts to reduce carbonyl, carboxyl, hydroxyl, and other oxygen containing groups to provide the saturated hydrocarbons as reaction products. Working in concert with other components in the dewaxing catalysts, it also provides isomerization functionality, helping to introduce sufficient branching in the final hydrocarbon products, where needed, to give basestocks with suitable pour point and low temperature properties.
Catalysts suitable for hydrogenation include metals such as Pt, Pd, Ag, Ni, Co, Mo, W, Rh, Re, Ru, Ir as well as binary or ternary mixtures thereof. In various embodiments, the metal hydrogenation component is a Group VIII noble metal. In non-limiting fashion, the metal hydrogenation component is Pt, Pd or a mixture thereof. In another embodiment, the metal hydrogenation component is a binary mixture, such as, for example, a combination of a non-noble Group VIII metal and a Group VI metal. Suitable combinations include Ni or Co with Mo or W, particularly Ni with Mo or W. In yet another embodiment, the hydrogenation component comprises at least three metals selected from the group consisting of Pt, Pd, Ag, Ni, Mo, Co, W, Rh, Re, and Ru, wherein at least one of the at least three metals is in either an oxide or sulfide form. In a particular embodiment, the metal component is (a) Ni, MoOx and WOx; or (b) Co. MoOx and WOx, wherein x is in the range of 0.5 to 3.
The metal hydrogenation component may be added to the catalyst in any convenient manner. One technique for adding the metal hydrogenation component is by incipient wetness. For example, after combining a zeolite and a hydrothermally stable binder, the combined zeolite and binder are extruded into catalyst particles. The catalyst particles are exposed to a solution containing a suitable metal precursor containing the Group VI or Group VIII metal. Alternatively, metal can be added to the catalyst by ion exchange, where a metal precursor is added to a mixture of zeolite (or zeolite and binder) prior to extrusion. The metal hydrogenation component may be steamed prior to use.
The amount of hydrogenation metal component may range from 0.1 to 5 wt %, based on catalyst. In an embodiment, the amount of metal component is at least 0.1 wt %, at least 0.25 wt %, at least 0.5 wt %, at least 0.6 wt %, or at least 0.75 wt %.

Hydrothermally Stable Binders

The catalyst needs to be stable in the presence of water especially when excessive water is generated during a conversion reaction. In various embodiments, a catalyst of the present disclosure comprises a binder component to increase mechanical strength and stability of the catalyst in the presence of water under effective hydrogenation conditions. Such a binder is referred to herein as a “hydrothermally stable binder.” Non-limiting examples of suitable binder components include silica, alumina, silica-alumina, titania, zirconia, tantalum oxide, tungsten oxide, molybdenum oxide, vanadium oxide, magnesium oxide, calcium oxide, yttrium oxide, lanthanum oxide, cerium oxide, niobium oxide, tungstated zirconia, cobalt molybdenum oxide, cobalt molybdenum sulfide, nickel molybdenum oxide, nickel molybdenum sulfide, nickel tungsten oxide, nickel tungsten sulfide, cobalt tungsten oxide, cobalt tungsten sulfide, nickel molybdenum tungsten oxide and nickel molybdenum tungsten sulfide, cobalt molybdenum tungsten oxide and cobalt molybdenum tungsten sulfide.
In an embodiment, a hydrothermally stable binder component is selected from binders capable of storing hydrogen, thereby keeping the metal in a reduced, highly dispersed state. Non-limiting examples of such binders include tungsten oxide, molybdenum oxide, vanadium oxide, and a mixture thereof.
In another embodiment, a hydrothermally stable binder component is a basic oxide, a binder capable of adsorbing carbon dioxide selectively or a binder which does not change to a denser phase upon exposure to steam and temperatures above 350° C. Non-limiting examples of such binders include magnesium oxide, calcium oxide, yttrium oxide, cerium oxide, niobium oxide, lanthanum oxide, zirconium oxide, and a mixture thereof.
In another embodiment, a hydrothermally stable binder component is a complex metal oxide used in hydroprocessing. Non-limiting examples of such binders include cobalt molybdenum oxide, cobalt molybdenum sulfide, nickel molybdenum oxide, nickel molybdenum sulfide, nickel tungsten oxide, nickel tungsten sulfide, nickel molybdenum tungsten oxide and nickel molybdenum tungsten sulfide.
In particular embodiments, the hydrothermally stable binder component is selected from lanthanum, cerium, niobium, nickel tungsten oxides, nickel tungsten sulfides, nickel molybdenum tungsten oxides, and nickel molybdenum tungsten sulfide.
A zeolite can be combined with a binder in any convenient manner. For example, a bound catalyst can be produced by starting with powders of both the zeolite and binder, combining and mulling the powders with added water to form a mixture, and then extruding the mixture to produce a bound catalyst of a desired size. Extrusion aids can also be used to modify the extrusion flow properties of the zeolite and binder mixture.
A catalyst comprising a ternary metal hydrogenation component has good hydrothermal stability with or without a binder. In an embodiment, to achieve improved stability, the catalyst may further comprise a binder selected from various metal oxides. Non-limiting examples of such binders include silica, alumina, silica-alumina, titania, zirconia, tantalum oxide, tungsten oxide, molybdenum oxide, vanadium oxide, magnesium oxide, calcium oxide, yttrium oxide, lanthanum oxide, cerium oxide, niobium oxide, titanium oxide, lanthanum oxide, zirconium oxide, tungstated zirconia, cobalt molybdenum oxide, cobalt molybdenum sulfide, nickel tungsten oxide, nickel tungsten sulfide, nickel molybdenum tungsten oxide, nickel molybdenum tungsten sulfide, and a mixture thereof. In particular embodiments, the hydrothermally stable binder is selected from lanthanum, cerium, niobium, nickel tungsten oxides, nickel tungsten sulfides, nickel molybdenum tungsten oxides, and nickel molybdenum tungsten sulfide.

Dewaxing Catalysts

A catalyst of this disclosure can be prepared by combining the three components, i.e., a zeolite, a hydrogenation component and a binder. Each of the three components can be selected from various components described herein, particularly choosing specific examples listed herein. In various embodiments, for example, the hydrogenation component is selected from Ni and Pt; the zeolite is ZSM-48 or ZSM-23; and the hydrothermally stable binder is selected from nickel molybdenum tungsten oxides, nickel molybdenum tungsten sulfide, WO₃, La₂O₃, CeO₂, and Nb₂O₅. Non-limiting examples of such catalysts include: (a) a catalyst comprising Ni, ZSM-48 and WO₃; (b) a catalyst comprising Ni, ZSM-23 and WO₃; (c) a catalyst comprising Pt, ZSM-48 and La₂O₃; (d) a catalyst comprising Pt, ZSM-48 and CeO₂; (e) a catalyst comprising Pt. ZSM-48 and Nb₂O₅; (f) a catalyst comprising Pt, ZSM-23 and La₂O₃; (g) a catalyst comprising Pt, ZSM-23 and CeO₂; (h) a catalyst comprising Pt, ZSM-23 and Nb₂O₅; (i) a catalyst comprising Pt, ZSM-48 and WO₃: and (j) a catalyst comprising Pt, ZSM-23 and WO₃, where each of (a) to (j) represents a catalyst comprising three components.
In a particular embodiment, the catalyst comprises 0.6 wt % Ni, ZSM-48 and WO₃, wherein the ratio of SiO₂:Al₂O₃is 80:1 or less, and wherein the weight ratio of ZSM-48 to WO₃is 8:2.
In another particular embodiment, the catalyst comprises 3 wt % Ni and 20 wt % W, ZSM-48 and alumina, wherein the ratio of SiO₂:Al₂O₃is 80:1 or less, and wherein the weight ratio of ZSM-48 to alumina is 65:35.
In yet another particular embodiment, the catalyst comprises 0.6 wt % Pt, ZSM-48 and Nb₂O₅, wherein the ratio of SiO₂:Al₂O₃is 80:1 or less, and wherein the weight ratio of ZSM-48 to Nb₂O₅is 8:2.
In yet another particular embodiment, the catalyst comprises 0.6 wt % Pt, ZSM-48 and La₂O₃, wherein the ratio of SiO₂:Al₂O₃is 80:1 or less, and wherein the weight ratio of ZSM-48 to La₂O₃is 8:2.
In yet another particular embodiment, the catalyst comprises 0.6 wt % Pt, ZSM-48 and CeO₂, wherein the ratio of SiO₂:Al₂O₃is 80:1 or less, and wherein the weight ratio of ZSM-48 to CeO₂is 8:2.
In yet another particular embodiment, the catalyst comprises 0.6 wt % Pt, CBV-901 and alumina, wherein the weight ratio of ZSM-48 to alumina is 8:2.
In yet another particular embodiment, the catalyst comprises 0.6 wt % Pt, ZSM-48 and TiO₂, wherein the ratio of SiO₂:Al₂O₃is 90:1 or less, and wherein the weight ratio of ZSM-48 to TiO₂is 65:35.
In yet another particular embodiment, the catalyst comprises 0.6 wt % Pt, ZSM-23 and alumina, wherein the weight ratio of ZSM-23 to alumina is 65:35.
In yet another particular embodiment, the catalyst comprises 0.6 wt % Pt, ZSM-48 and alumina, wherein the ratio of SiO₂:Al₂O₃is 90 or less, and wherein the weight ratio of ZSM-48 to alumina is 65:35.
When a catalyst comprises a ternary metal component, a zeolite is selected from ZSM-48, ZSM-23, ZSM-50, ZSM-5, ZSM-22, ZSM-11, ferrierite, faujasite, beta, ZSM-12, MOR and a mixture thereof, and a hydrogenation component comprises at least three metals selected from Pt, Pd, Ag, Ni, Co, Mo, W, Rh, Re, and Ru, wherein at least one of the at least three metals is in either an oxide or sulfide form. In an embodiment, the zeolite is ZSM-48 or ZSM-23; and the hydrogenation component comprises (a) Ni, MoOx and WOx or (b) Co, MoOx and WOx, wherein x is in the range of 0.5 to 3.
In a particular embodiment, the catalyst comprises ZSM-48 and a hydrogenation component comprising Ni, MoOx and WOx, where x is in the range of 0.5 to 3, wherein the ratio of SiO₂:Al₂O₃is 90 or less, and wherein the weight ratio of ZSM-48 to the hydrogenation component is 8:2.

Feedstocks

In one embodiment, a process for producing a lube basestock and/or a fuel hydrocarbon from a feedstock of biological origin, the method comprising: contacting the feedstock in the presence of a catalyst which comprises a zeolite component, a hydrogenation component and a hydrothermally stable binder. The feedstock of biological origin normally comprises one or more components selected from the group consisting of fatty acids, fatty acid esters, fatty alcohols, fatty olefins, mono-glycerides, di-glycerides, tri-glycerides, phospholipids and saccharolipids. Optionally water can be co-fed with the biological feedstock, with the water content of 0.5-5 wt % of the total feed.
Feedstocks for the process are drawn from renewable sources of biological origin, e.g., plant, algae or animal (including insect) origin. Animal, algae and plant oils containing tri-glycerides, as well as partially processed oils containing mono-glycerides and di-glycerides are included in this group. Another source of feedstock is phospholipids or saccharolipids containing fatty acid esters in their structure, such as phosphatidyl choline and the like present in plant cell walls. Carbon numbers for the fatty acid component of such feedstocks are generally in the range of C₁₂or greater, up to C₃₀.
Other components of the feed can include a) plant fats, plant oils, plant waxes; animal fats, animal oils, animal waxes; fish fats, fish oils, fish waxes, and mixtures thereof; b) free fatty acids or fatty acids obtained by hydrolysis, acid trans-esterification or pyrolysis reactions from plant fats, plant oils, plant waxes, animal fats, animal oils, animal waxes, fish fats, fish oils, fish waxes, and mixtures thereof; c) esters obtained by trans-esterification from plant fats, plant oils, plant waxes, animal fats, animal oils, animal waxes, fish fats, fish oils, fish waxes, and mixtures thereof, d) esters obtained by esterification of free fatty acids of plant, animal and fish origin with alcohols, and mixtures thereof; e) fatty alcohols obtained as reduction products of fatty acids from plant fats, plant oils, plant waxes, animal fats, animal oils, animal waxes, fish fats, fish oils, fish waxes, and mixtures thereof, and f) waste and recycled food grade fats and oils, and fats, oils and waxes obtained by genetic engineering, and mixtures thereof.
Examples of vegetable oils that can be used in accordance with this disclosure include, but are not limited to rapeseed (canola) oil, soybean oil, coconut oil, sunflower oil, palm oil, palm kernel oil, peanut oil, linseed oil, tall oil, corn oil, castor oil, jatropha oil, jojoba oil, olive oil, flaxseed oil, camelina oil, safflower oil, babassu oil, tallow oil and rice bran oil. Vegetable oils as referred to herein can also include processed vegetable oil material as a portion of the feedstock. Non-limiting examples of processed vegetable oil material include fatty acids and fatty acid alkyl esters. Alkyl esters typically include C₁-C₅alkyl esters. One or more of methyl, ethyl, and propyl esters are desirable.
Examples of animal fats that can be used in accordance with the disclosure include, but are not limited to, beef fat (tallow), hog fat (lard), turkey fat, fish fat/oil, and chicken fat. The animal fats can be obtained from any suitable source including restaurants and meat production facilities.
Animal fats as referred to herein also include processed animal fat material. Non-limiting examples of processed animal fat material include fatty acids and fatty acid alkyl esters. Alkyl esters typically include C₁-C₅alkyl esters. In particular embodiments, alkyl esters are one or more of methyl, ethyl, and propyl esters.
Algae oils or lipids can typically be contained in algae in the form of membrane components, storage products, and/or metabolites. Certain algal strains, particularly microalgae such as diatoms and cyanobacteria, can contain proportionally high levels of lipids. Algal sources for the algae oils can contain varying amounts, e.g., from 2 wt % to 40 wt % of lipids, based on total weight of the biomass itself.
Algal sources for algae oils can include, but are not limited to, unicellular and multicellular algae. Examples of such algae can include a rhodophyte, chlorophyte, heterokontophyte, tribophyte, glaucophyte, chlorarachniophyte, euglenoid, haptophyte, cryptomonad, dinoflagellum, phytoplankton, and the like, and combinations thereof. In one embodiment, algae can be of the classes Chlorophyceae and/or Haptophyta. Specific species can include, but are not limited to, Neochloris oleoabundans, Scenedesmus dimorphus, Euglena gracilis, Phaeodactylum tricornutum, Pleurochrysis carterae, Prymnesium parvum, Tetraselmis chui, and Chlamydomonas reinhardtii. Additional or alternate algal sources can include one or more microalgae of the Achnanthes, Amphiprora, Amphora, Ankistrodesmus, Asteromonas, Boekelovia, Borodinella, Botryococcus, Bracteococcus, Chaetoceros, Carteria, Chlamydomonas, Chlorococcum, Chlorogonium, Chlorella, Chroomonas, Chrysosphaera, Cricosphaera, Crypthecodinium, Cryptomonas, Cyclotella, Dunaliella, Ellipsoidon, Emiliania, Eremosphaera, Ernodesmius, Euglena, Franceia, Fragilaria, Gloeothamnion, Haematococcus, Halocafeteria, Hymenomonas, Isochrysis, Lepocinclis, Micractinium, Monoraphidium, Nannochloris, Nannochloropsis, Navicula, Neochloris, Nephrochloris, Nephroselmis, Nitzschia, Ochromonas, Oedogonium, Oocystis, Ostreococcus, Pavlova, Parachlorella, Pascheria, Phaeodactylum, Phagus, Platymonas, Pleurochrysis, Pleurococcus, Prototheca, Pseudochlorella, Pyramimonas, Pyrobotrys, Scenedesmus, Skeletonema, Spyrogyra, Stichococcus, Tetraselmis, Thalassiosira, Viridiella, and Volvox species, and/or one or more cyanobacteria of the Agmenellum, Anabaena, Anabaenopsis, Anacystis, Aphanizomenon, Arthrospira, Asterocapsa, Borzia, Calothrix, Chamaesiphon, Chlorogloeopsis, Chroococcidiopsis, Chroococcus, Crinalium, Cyanobacterium, Cyanobium, Cyanocystis, Cyanospira, Cyanothece, Cylindrospermopsis, Cylindrospermum, Dactylococcopsis, Dermocarpella, Fischerella, Fremyella, Geitleria, Geitlerinema, Gloeobacter, Gloeocapsa, Gloeothece, Halospirulina, lyengariella, Leptolyngbya, Limnothrir, Lyngbya, Microcoleus, Microcystis, Myxosarcina, Nodularia, Nostoc, Nostochopsis, Oscillatoria, Phormidium, Planktothrix, Pleurocapsa, Prochlorococcus, Prochloron, Prochlorothrix, Pseudanabaena, Rivularia, Schizothrix, Scytonema, Spirulina, Stanieria, Starria, Stigonema, Symploca, Synechococcus, Synechocystis, Tolypothrir, Trichodesmium, Tychonema, and Xenococcus species.
Other feeds usable in the present disclosure can include any of those that comprise primarily triglycerides and free fatty acids (FFAs). The triglycerides and FFAs typically contain aliphatic hydrocarbon chains in their structure having from 8 to 36 carbons, particularly from 10 to 26 carbons, for example from 14 to 22 carbons. Types of triglycerides can be determined according to their fatty acid constituents. The fatty acid constituents can be readily determined using Gas Chromatography (GC) analysis. This analysis involves extracting the fat or oil, saponifying (hydrolyzing) the fat or oil, preparing an alkyl (e.g., methyl) ester of the saponified fat or oil, and determining the type of (methyl) ester using GC analysis. In one embodiment, a majority (i.e., greater than 50%) of the triglyceride present in the lipid material is made of C₁₀to C₂₆fatty acid constituents, based on total triglyceride present in the lipid material. Further, a triglyceride is a molecule having a structure identical to the reaction product of glycerol and three fatty acids. Thus, although a triglyceride is described herein as being comprised of fatty acids, it should be understood that the fatty acid component does not necessarily contain a carboxylic acid hydrogen. If triglycerides are present, a majority of triglycerides present in the feed can particularly be comprised of C₁₂to C₂₂fatty acid constituents, based on total triglyceride content. Other types of feed that are derived from biological raw material components can include fatty acid esters, such as fatty acid alkyl esters (e.g., FAME and/or FAEE).
For reactions with feedstocks having a relatively higher degree of unsaturation, an acidic catalyst can be used to promote dimerization and oligomerization. The dimers and oligomers are branched or having cyclic structures, so that subsequent hydrogenation under the action of the hydrogenation catalyst produces saturated branched or cyclized hydrocarbons than can be naturally very low in wax and require little if any dewaxing. If the feedstock is highly saturated, action of a basic catalyst produces straight chain products that are subsequently hydrogenated to relatively straight chain hydrocarbons that normally require some dewaxing to make them suitable lube stocks. Dewaxing can be provided by the hydrogenation catalyst, as further described below.
One method for characterizing the triglycerides in a feedstock is based on the number of carbons in the side chains. While some feedstocks may have consistent numbers of carbons in each side chain, such as in a tristearin feedstock, many types of triglycerides will have variations in chain length between molecules and even within molecules. In order to characterize these variations, the average number of carbons per side chain in the triglycerides can be determined. By definition, a triglyceride contains three side chains. Each side chain contains a number of carbons, as mentioned above. By averaging the number of carbons in each side chain for the triglycerides in a feedstock, an average side chain length can be determined. The average number of carbons (also referred to as average carbon number) per side chain in the feedstock can be used as a comparative value for characterizing products. For example, the average number of carbons per side chain in the feedstock can be compared with the average number of carbons in hydrocarbons generated by converting and/or isomerizing the triglyceride-containing feedstock.
In various aspects, the production of fatty acid coupling products and corresponding hydrogenated products is based on processing of triglycerides within the feed. Thus, the presence of at least some triglycerides within the feed is desirable. The feed can include at least 10 wt % of feed based on a renewable source or sources, such as at least 25 wt %. In particular embodiments, the renewable portion of the feed is at least 50 wt %, or at least 75 wt %, or at least 90 wt %, or at least 95 wt %. Such higher amounts of feed from a renewable source provide an advantage based on the greater amount of renewable material. Additionally or alternately, the feed can be entirely a feed from a renewable source, or the feed can include 99 wt % or less of a feed based on a renewable source, or 90 wt %/o or less, or 75 wt % or less, or 50 wt % or less.
Higher amounts of feed from a renewable source provide an advantage based on the greater amount of renewable material, as well as potentially including a greater amount of triglycerides. Feeds with lower amounts of renewable materials may have other processing advantages. Such advantages can include improved flow characteristics within a reaction system, as renewable feeds often have a relatively high viscosity compared to conventional diesel or lubricant feeds in a refinery. Additionally, deoxygenation of a renewable feed can generate a substantial amount of heat due to formation of highly favorable products from a free energy standpoint, such as H₂O and CO₂. For a typical catalyst bed with a bed length of 25 to 30 feet (9 to 10 meters), it may be preferable to have a temperature increase across the bed of 100° F. (55° C.) or less. If deoxygenation of a renewable feed with high oxygen content is performed using a sufficiently reactive catalyst, an exotherm of greater than 100° F. across the catalyst bed can be generated. Blending a renewable feed with a portion that does not contain oxygen can reduce the exotherm generated across a catalyst bed used for performing deoxygenation.
Thus the feedstock can contain a number of components. It can be supplied as a solution in a suitable solvent (particularly a non-reactive solvent such as a hydrocarbon), or the feedstock can be supplied neat. The main reactions are thought to be coupling or oligomerizing the fatty acid components (which produces intermediate products of suitable carbon number to be useful as diesel fuel and lube base stocks upon hydrogenation), and hydrogenating the resulting products to remove functional groups and produce a saturated hydrocarbon.
The feed may contain various amount of mineral feed as diluent. The advantages of increased mineral feed content are largely due to dilution of the renewable feed, as the processing conditions effective for deoxygenation of a renewable feed will have a low or minimal impact on a typical hydroprocessed mineral feed. Therefore, while the deoxygenation conditions are effective for deoxygenation of renewable feeds at a variety of blend ratios with mineral feeds, it may be preferable to have at least 75 wt % of the feed from a renewable source, such as at least 90 wt % or at least 95 wt %.
One option for increasing the renewable content of a feed while retaining some of the benefits of adding a feed with reduced oxygen content is to use recycled product from processing of renewable feed as a diluent. A recycled product from processing a renewable feed is still derived from a renewable source, and therefore such a recycled product is counted as a feed portion from a renewable source. Thus, a feed containing 60% renewable feed that has not been processed and 40% of a recycled product from processing of the renewable feed would be considered as a feed that includes 100% of feed from a renewable source. As an example, at least a portion of the product from processing of a renewable feed can be a diesel boiling range product. Such a recycled diesel boiling range product will be deoxygenated, and therefore incorporation of the recycled diesel boiling range product in the feed will reduce the exotherm generated during deoxygenation. Adding a recycled diesel boiling range product is also likely to improve the cold flow properties of a renewable feed. More generally, any convenient product from processing of a renewable feed can be recycled for blending with the renewable feed in order to improve the cold flow properties and/or reduce the oxygen content of the input flow to a deoxygenation process. If a recycled product flow is added to the input to a deoxygenation process, the amount of recycled product can correspond to at least 10 wt % of the feed to the deoxygenation process, such as at least 25 wt %, or at least 40 wt %. Additionally or alternately, the amount of recycled product in a feed can be 60 wt % or less, such as 50 wt % or less, 40 wt % or less, or 25 wt % or less.
With regard to triglyceride content, the feedstock can include at least 10 wt %, such as at least 25 wt %, and particularly at least 40 wt %, or at least 60 wt %, or at least 80 wt %. Additionally or alternately, the feed can be composed entirely of triglycerides, or the triglyceride content of the feed can be 90 wt % or less, such as 75 wt % or less, or 50 wt % or less. The methods described herein are suitable for conversion of triglycerides to lubricant and diesel products in a single reactor, so higher contents of triglycerides may be advantageous. However, to the degree that a recycle loop is used to improve the feed flow properties or reduce the reaction exotherm across catalyst beds, lower triglyceride contents may be beneficial.
While feed dilution can be used to control the exotherm generated across a catalyst bed used for deoxygenation, it is noted that some processing options can also impact the exotherm. One alternative is to use a less reactive catalyst, so that a larger amount of catalyst is needed at a given liquid hourly space velocity (LHSV) in order to deoxygenate a feed to a desired level. Another option is to reduce the amount of hydrogen provided for the deoxygenation process. Still another option could be to introduce additional features into a reactor to assist in cooling and/or transporting heat away from a deoxygenation catalyst bed. In combination with selecting an appropriate amount of product recycle and/or blending of another non-oxygenated feed, a desired combination of a flow characteristics and heat generation during deoxygenation can be achieved.
Oxygen is the major heteroatom component in renewable base feeds. A renewable feedstream based on a vegetable oil, prior to hydrotreatment, includes up to 10 wt % oxygen, for example up to 12 wt % or up to 14 wt %. Such a renewable feedstream, also called a biocomponent feedstream, normally includes at least 1 wt % oxygen, for example at least 2 wt %, at least 3 wt %, at least 4 wt %, at least 5 wt %, at least 6 wt %, or at least 8 wt %. Further, the renewable feedstream, prior to hydrotreatment, can include an olefin content of at least 3 wt %, for example at least 5 wt % or at least 10 wt %.
Biocomponent based feedstreams have a wide range of nitrogen and/or sulfur contents depending on the feed sources. For example, a feedstream based on a vegetable oil source can contain up to 300 wppm nitrogen. In some embodiments, the sulfur content can be 500 wppm or less, for example 100 wppm or less, 50 wppm or less, or 10 wppm or less, where wppm stands for parts per million by weight.

Reaction Conditions and Process Configurations

Hydrogen is present throughout the reactor, and is consumed by the reactants during the hydrogenation step. Advantageously, it was found that the presence of hydrogen did not adversely affect the fatty acid coupling reactions believed to be catalyzed primarily by the acidic or basic catalysts. During the fatty acid coupling, hydrogen transfer reactions can lead to formation of coke molecules, which can cause catalyst deactivation. In various embodiments, the presence of hydrogen can inhibit hydrogen transfer and improve catalyst life. In an embodiment, water is added to the renewable feed.
Temperature and pressure of the reactor and reactants is selected depending on the throughput and turnover required. Non-limiting examples of temperatures include 100 to 500° C., 200 to 400° C., and 250 to 400° C. Hydrogen partial pressure is used in the range of from 1.8 to 34.6 MPag (250 to 5000 psig) or 4.8 to 20.8 MPag, by way of non-limiting example. Also in non-limiting fashion, a liquid hourly space velocity is from 0.2 to 10 v/v/hr, or 0.5 to 3.0, and a hydrogen circulation rate is 35.6 to 1781 m³/m³(200 to 10,000 scf/B), particularly 178 to 890.6 m³/m³(1,000 to 5000 scf/B). Further non-limiting examples of conditions are given in working examples.
Loading of the catalyst is 1 to 30% by weight of the weight of the feedstock in the reactor, for example 2 to 20%, or 5 to 10% by weight. The reaction time or residence time can range from 5 minutes to 50 hours depending on types of catalysts used, reaction temperature and the amount (wt %) of catalyst in the reactor. In a particular embodiment, a residence time is 10 minutes to 10 hours. Shorter residence time gives better efficiency for reactor usage. Longer residence time ensures high conversion to pure hydrocarbons. Usually an optimized reactor time is most desirable.
In various embodiments, the duration of the reaction (or the average residence time in the reactor for a continuous process) is 1-48 hours, 1-20 hours, 12-36 hours, or 24-30 hours. In various embodiments, the reactions are carried out in a fixed bed reactor, a continuous stir tank reactor, or a batch reactor. In any of these operations, it is advantageous to maintain partial pressure of hydrogen above 300 psi, above 400 psi, above 500 psi, above 600 psi, or above 700 psi. During conversion, carbon dioxide and water generated from the action of the acidic or basic catalyst on the feedstock fatty acids are present in gaseous form, and thus increase the total reactor pressure. Under this condition, it can be important to maintain hydrogen partial pressure. By way of non-limiting example, this can be achieved by intermittently purging the reactor gas and re-charging with hydrogen gas in batch or CSTR operation. Alternatively, in a fixed bed operation, this can be achieved by withdrawing reactor gas at different locations along the fixed bed reactor; or alternatively by stage injection of hydrogen. Other means to maintain hydrogen pressure are also possible.
Where needed, the hydrogenation catalyst can introduce branches into the final hydrocarbon products to provide a dewaxing function. For triglycerides with only saturated fatty acid side chains, the combination of fatty acid coupling (particularly using a basic material as the first catalyst) and hydrogenation will be relatively unbranched hydrocarbons. For triglycerides with both saturated and unsaturated fatty acid side chains, the combination of fatty acid coupling and hydrogenation will be mixtures of branched hydrocarbons (containing one or more branches of various lengths in the range of 1 to 10 carbons) and naphthenics substituted with various lengths of hydrocarbon chains. Of course, if the side chains of the triglycerides contain other types of heteroatoms, such as nitrogen or sulfur, other types of molecules may be generated.
For triglycerides with side chains containing between 12 and 22 carbon atoms, the stacked bed configuration of the fatty acid coupling catalyst and hydrogenation catalyst will result in production of hydrocarbon molecules that boil in the lubricant boiling range as a primary product, with some production of hydrocarbon molecules that boil in the diesel boiling range. The lubricant boiling range molecules correspond to fatty acid coupling products that were formed during conversion of the triglycerides in the feedstock. These fatty acid coupling products are subsequently hydrogenated and isomerized. However, while the process of converting triglycerides will typically occur at percentages approaching 100%, less than all of the side chains in the triglycerides may result in formation of coupling products. Instead, at least a portion of the side chains from the triglycerides will reach the hydrogenation catalyst without combining with another side chain to form a lubricant boiling range molecule. These uncombined side chains are also deoxygenated and isomerized by the hydrogenation catalyst, resulting in diesel boiling range molecules. Thus, a stacked bed arrangement for the catalysts would be expected to generate a majority portion of lubricant boiling range molecules from a triglyceride feed and a minority portion of diesel boiling range molecules.
In order to provide a general way of characterizing the hydrocarbons resulting from conversion, hydrogenation, and isomerization of a triglyceride feed, the average number of carbons (i.e., average carbon number) in hydrogenated molecules derived from triglycerides can be compared with the average number of carbons in the fatty acid side chains of the triglycerides. The average number of carbons in hydrocarbon molecules derived from triglycerides in a feed can be at least 1.5 times the average number of carbons in the fatty acid side chains of the corresponding triglycerides, such as at least 1.75 time the average number of carbons in the fatty acid side chains or at least 1.9 times the average number of carbons in the fatty acid side chains.
In a particular embodiment, the average carbon number of hydrocarbons produced by conversion of feedstock based triglycerides or other fatty esters is two times or more that of the fatty acid components of the feedstock. The first catalyst is believed to increase carbon number in the product by a factor of approximately two or more comparing to the carbon numbers of the fatty acid side chains in the feed, by the process of coupling (oligomerization, ketonization, and aldol condensation).

Further Processing

The product of the reaction described herein is a mixture of hydrocarbons, largely saturated, having a carbon number in the diesel fuel and lube base stock range. If desired, the reaction product can be hydrofinished by subjecting it to low pressure hydrogen. This process can clean up residual unsaturations and oxygenates that may result when the products are being heated in the presence of the hydrogenation catalyst, which can have some cracking power given that it may contain an acidic carrier such as a zeolite. The hydrofinishing can be carried out either in a fixed-bed or in an autoclave reactor. The catalyst can be either noble metal (Pd, Pt, Rh, Ru, Ir, or combination thereof) or non-noble metal (Co, Ni. Fe), particularly supported on a support such as clay, alumina, aluminosilicate, silica, titania and zirconia. The weight hourly space velocity can be in the range of 0.5 to 10 h⁻¹, under a hydrogen pressure in the range of ambient to 30 MPag, and a temperature from 150° C. to 400° C. The resulting product can then be further processed by distillation to separate out any diesel fuel from the lube base stock.

EXAMPLES

Example 1

0.6 wt % Pt Impregnated 80/20 Steamed H-ZSM-48/WOx

The title catalyst (0.6 wt % Pt impregnated 80/20 ZSM-48/WOx) was prepared by the following method: material is first extruded as 80 wt % 70:1 SiO₂:Al₂O₃ZSM-48 and 20 wt % tungsten oxide (designated as WOx). Charge the tungsten oxide to a Lancaster Muller and dry mull for 3 minutes. Dilute 28.6 TEAOH (Tetraethylamonium Hydroxide) in 66.1 g of de-ionized water and slowly add to the WOx. The WOx was mixed by hand in a beaker due to the low volume of material. Wet mull the mixture for 3 minutes. Add the ZSM-48 crystal to the peptized WOx and mull 10 minutes. Dilute 57.2 of TEAOH in 627.3 g of deionized water and add to the mull mix over a five minute period. Wet mull the mixture for 20 minutes or until the desired consistency is achieved. Extrude the mull mixture on a 2″ Bonnot extruder using 1/16″ quadrulobe die inserts.
Pre-calcine the bound zeolite in flowing N₂at 950° F. (510° C.) for three hours to start removing the structure directing agent from the zeolite. Ammonium-exchange the formed material two times (5 ml of 1 M NH₄NO₃solution per gram of catalyst) under ambient conditions to remove the alkali cations from the structure. After completing the second exchange wash the material with de-ionized water for one hour. Dry at 250° F. (121° C.) overnight in a forced draft oven. To create the acid form of the catalyst, calcine the extrudate in air for 6 hours at 1,000° F. (538° C.) in air.
Place the acid form of the catalyst into a vertical steamer. Bring catalyst up to 650° F. (343° C.) in air and hold at temperature for 30 minutes. Switch from air to steam over a 30-minute period. Ramp the temperature of the steamer to 700° F. (371° C.), allow the temperature in the bed to stabilize, and hold for 3 hours at 700° F. in 100% steam. Cool down in air and remove the catalyst from the steamer.
Impregnate the steamed acid form of the catalyst using a tetraamine platinum nitrate solution via spray impregnation targeting a metal loading of 0.6 wt % Pt. Spray in the impregnating solution slowly; after the solution has been applied continue mixing for 20 minutes to insure that the solution is uniformly distributed across all of the extrudates. Dry at ambient conditions in an open dish. Dry for 2 hours in a forced air oven at 250° F. Complete the impregnation by calcining the extrudate in air at 680° F. (360° C.) for three hours.
The finished catalyst had 0.56 wt % Pt on catalyst. Dispersion of Pt was measure by H₂chemisorption, a H/Pt molar ratio of 4.02 was observed, indicating high degree of Pt dispersion (equivalent to smaller Pt particles on catalyst).

Example 2

80/20 H-ZSM-48/NiMoWOx

The title catalyst (80/20 H-ZSM-48/NiMoWOx) was prepared by the following method: charge the NiMoWOx to a Lancaster Muller and dry mull for 3 hours. Dilute 28.6 g of 35 wt % TEAOH in 66.1 g of de-ionized water. Slowly add the solution to the NiMoWOx. Wet mull the mixture for 3 minutes. Add the ZSM-48 crystal to the peptized NiMoWOx and mull 10 minutes. Dilute 57.2 g of 35 wt % TEAOH in 680.2 g of de-ionized water. Add the solution to the mull mix over a five minute period. Wet mull for 20 minutes or until reasonable consistency is achieved. Extrude the mull mix on a 2″ Bonnot extruder equipped with a die plate using 1/16″ quadrulobe die inserts. Dry in a forced air oven at 250° F. to dry the extrudate.
Pre-calcine the extrudate in flowing nitrogen at 950° F. for 3 hours. Ammonium-exchange the extrudate two times under ambient conditions (5 ml of 1 N NH₄NO₃solution per gram of catalyst). After the completion of two exchanges, wash with DI water for 1 hour at room temperature, drain, and dry under ambient conditions. Dry at 250° F. overnight in a forced draft oven. Heat the extrudate under nitrogen to 752° F. (300° C.) for three hours. Lower the temperature of the oven to 700° F. and begin introducing air over a three hour period. The final air calcination should be completed at 1,000° F. under air for 10 hours.
Loadings of metal on the finished catalyst were 3.45 wt % W, 2.41 wt % Ni, and 1.92 wt % Mo.

Example 3

3 wt % Ni and 20 wt % W Impregnated 65/35 ZSM-48/Alumina (V-300)

The title catalyst (3 wt % Ni and 20 wt % W impregnated 65/35 ZSM-48/V-300) was prepared by the following method: charge 1,639 g of ZSM-48 (SiO₂:Al₂O₃=70:1) crystal to the muller and mull for 10 minutes. Add 1153 g of Versal-300 alumina to the muller and mull for 10 minutes. Slowly add 1547 g of de-ionized water to mull mix while mulling. Mull the mixture for 40 minutes or until a reasonable mixture consistency is achieved. Extrude the mixture on the 2″ Bonnot extruder using a die plate with 1/20″ quadrulobe inserts. After extrusion, dry at 250° F. in a forced draft oven.
Pre-calcine the extrudate prepared above for 3 hours at 1,000° F. in flowing nitrogen. After calcining the extrudate under inert conditions, exchange the material two times with ammonium nitrate (5 ml of 1 N NH₄NO₃solution per gram of catalyst). After the second exchange wash the material with de-ionized water for 1 hour at room temperature, drain, and blow dry with air. Dry the exchanged material in a forced draft oven at 250° F. overnight. Calcine the ammonium form of the extrudate for 6 hours at 1,000° F. in air to create the acid form of the catalyst.
Impregnate the extrudate with 20 wt % W using ammonium metatungstate hydrate using a rotary spray impregnation technique. For example, 500 g of extrudate would be impregnated with 134 g of ammonium metatungstate hydrate dissolved in water. After the material is sprayed onto the catalyst the catalyst should be mixed for an additional 30 minutes to improve the homogeneity of the metal dispersion. Dry the extrudate for 4 hours at ambient conditions in a pan. Dry the catalyst overnight in a forced draft oven at 250° F. Calcine the extrudates in air at 900° F. for 1 hour.
The resulting catalyst had 14 wt % tungsten and 3 wt % Ni as measured by XRF analysis.

Example 4

0.6 wt % Ni Impregnated 80/20 Steamed H-ZSM-48/WOx

The title catalyst (0.6 wt % Ni impregnated 80/20 ZSM-48/WOx) was prepared by the following method: the 80:20 ratio of ZSM-48 and WOx extrudate formed in Example 1 is impregnated with 0.6 wt % Ni instead of 0.6 wt % Pt. Impregnate the steamed acid form of the catalyst using a nickel nitrate hexahydrate solution via spray impregnation targeting a metal loading of 0.6 wt % Ni. Spray in the impregnating solution slowly; after the solution has been applied continue mixing for 30 minutes to insure that the solution is uniformly distributed across all of the extrudates. Dry the extrudate for 4 hours at ambient conditions in a pan. Dry the catalyst overnight in a forced draft oven at 250° F. Calcine the extrudates in air at 900° F. for 3 hours. The finished catalyst contained 0.69 wt % Ni.

Example 5

0.6 wt % Pt Impregnated 80/20 Steamed H-ZSM-48/Niobium Oxide

The title catalyst (0.6 wt % Pt impregnated 80/20 ZSM-48/niobium oxide) was prepared by the following method: material is first extruded as 80 wt % 70:1 SiO₂:Al₂O₃ZSM-48 and 20 wt % niobium oxide. Charge the niobium oxide to a Lancaster Muller and dry mull for 3 minutes. Dilute 17.1 g of 35 wt %/o TEAOH in 39.7 g of de-ionized water and slowly add to the niobium oxide. Wet mull the mixture for 3 minutes. Add the ZSM-48 crystal to the peptized niobium oxide and mull for 10 minutes. Dilute 34.3 g of 35 wt % TEAOH in 356.2 g of deionized water and add to the mull mix over a five minute period. Wet mull the mixture for 20 minutes or until the desired consistency is achieved. Extrude the mull mixture on a 2″ Bonnot extruder using 1/16″ quadrulobe die inserts.
Pre-calcine the bound zeolite in flowing N₂at 950° F. for three hours to start removing the structure directing agent from the zeolite. Ammonium-exchange the formed material two times (5 ml of 1 M NH₄NO₃solution per gram of catalyst) under ambient conditions to remove the alkali cations from the structure. After completing the second exchange wash the material with de-ionized water for one hour. Dry at 250° F. overnight in a forced draft oven. To create the acid form of the catalyst, calcine the extrudate in air for 6 hours at 1,000° F. in air.
Place the acid form of the catalyst into a vertical steamer. Bring catalyst up to 650° F. in air and hold at temperature for 30 minutes. Switch from air to steam over a 30-minute period. Ramp the temperature of the steamer to 700° F., allow the temperature in the bed to stabilize, and hold for 3 hours at 700° F. in 100% steam. Cool down in air and remove the catalyst from the steamer.
Impregnate the steamed acid form of the catalyst using a tetraamine platinum nitrate solution via spray impregnation targeting a metal loading of 0.6 wt % Pt. Spray in the impregnating solution slowly; after the solution has been applied continue mixing for 20 minutes to insure that the solution is uniformly distributed across all of the extrudates. Dry at ambient condition in an open dish. Dry for 2 hours in a forced air oven at 250° F. Complete the impregnation by calcining the extrudate in air at 680° F. for three hours.
H₂chemisorption revealed a Pt dispersion of H/Pt=0.73.

Example 6

0.6 wt % Pt Impregnated 80/20 Steamed H-ZSM-48/La₂O₃

The title catalyst (0.6 wt % Pt impregnated 80/20 ZSM-48/La₂O₃) was prepared by the following method: the material is first extruded as 80 wt % 70:1 SiO₂:Al₂O₃ZSM-48 and 20 wt % lanthanum oxide. Charge 125 g of lanthanum oxide to a Lancaster Muller and dry mull for 3 minutes. Dilute 17.1 g of 35 wt % TEAOH in 29.7 g of de-ionized water and slowly add the solution to the lanthanum oxide. Wet mull the mixture for 3 minutes. Add the ZSM-48 crystal to the peptized lanthanum oxide and mull 10 minutes. Dilute 34.3 g of 35 wt % TEAOH in 356.2 g of deionized water and add to the mull mix over a five-minute period. Wet mull the mixture for 20 minutes or until the desired consistency is achieved. Extrude the mull mixture on a 2″ Bonnot extruder using 1/16″ quadrulobe die inserts.
Pre-calcine the bound zeolite in flowing N₂at 950° F. for three hours to start removing the structure directing agent from the zeolite. Ammonium-exchange the formed material two times (5 ml of 1 M NH₄NO₃solution per gram of catalyst) under ambient conditions to remove the alkali cations from the structure. After completing the second exchange wash the material with de-ionized water for one hour. Dry at 250° F. overnight in a forced draft oven. To create the acid form of the catalyst, calcine the extrudate in air for 6 hours at 1,000° F. in air.
Place the acid form of the catalyst into a vertical steamer. Bring catalyst up to 650° F. in air and hold at temperature for 30 minutes. Switch from air to steam over a 30-minute period. Ramp the temperature of the steamer to 700° F., allow the temperature in the bed to stabilize, and hold for 3 hours at 700° F. in 100% steam. Cool down in air and remove the catalyst from the steamer.
Impregnate the steamed acid form of the catalyst using a tetraamine platinum nitrate solution via spray impregnation targeting a metal loading of 0.6 wt % Pt. Spray in the impregnating solution slowly; after the solution has been applied continue mixing for 20 minutes to insure that the solution is uniformly distributed across all of the extrudates. Dry at ambient conditions in an open dish. Dry for 2 hours in a forced air oven at 250° F. Complete the impregnation by calcining the extrudate in air at 680° F. for three hours.
The finished catalyst had 0.56 wt % Pt on catalyst. H₂chemisorption revealed a Pt dispersion of H/Pt=1.18.

Example 7

0.6 wt % Pt Impregnated 80/20 Steamed H-ZSM-48/CeO₂

The title catalyst (0.6 wt % Pt impregnated 80/20 ZSM-48/CeO₃) was prepared by the following method: the material is first extruded as 80 wt % 70:1 SiO₂:Al₂O₃ZSM-48 and 20 wt % cerium oxide. Charge 122 g of cerium oxide to a Lancaster Muller and dry mull for 3 minutes. Dilute 17.1 g of 35 wt % TEAOH in 39.7 g of de-ionized water and slowly add the solution to the cerium oxide. Wet mull the mixture for 3 minutes. Add the ZSM-48 crystal to the peptized lanthanum oxide and mull 10 minutes. Dilute 34.3 g of 35 wt % TEAOH in 419.7 g of deionized water and add to the mull mix over a five-minute period. Wet mull the mixture for 20 minutes or until the desired consistency is achieved. Extrude the mull mixture on a 2″ Bonnot extruder using 1/16″ quadrulobe die inserts.
Pre-calcine the bound zeolite in flowing N₂at 950° F. for three hours to start removing the structure directing agent from the zeolite. Ammonium-exchange the formed material two times (5 ml of 1 M NH₄NO₃solution per gram of catalyst) under ambient conditions to remove the alkali cations from the structure. After completing the second exchange wash the material with de-ionized water for one hour. Dry at 250° F. overnight in a forced draft oven. To create the acid form of the catalyst, calcine the extrudate in air for 6 hours at 1,000° F. in air.
Place the acid form of the catalyst into a vertical steamer. Bring catalyst up to 650° F. in air and hold at temperature for 30 minutes. Switch from air to steam over a 30-minute period. Ramp the temperature of the steamer to 700° F., allow the temperature in the bed to stabilize, and hold for 3 hours at 700° F. in 100% steam. Cool down in air and remove the catalyst from the steamer.
Impregnate the steamed acid form of the catalyst using a tetraamine platinum nitrate solution via spray impregnation targeting a metal loading of 0.6 wt % Pt. Spray in the impregnating solution slowly; after the solution has been applied continue mixing for 20 minutes to insure that the solution is uniformly distributed across all of the extrudates. Dry at ambient conditions in an open dish. Dry for 2 hours in a forced air oven at 250° F. Complete the impregnation by calcining the extrudate in air at 680° F. for three hours.
The finished catalyst had 0.42 wt % Pt on catalyst. H₂chemisorption revealed a Pt dispersion of H/Pt=0.78.

Example 8

0.6 wt % Pt Impregnated 80/20 CBV-901/Alumina

The title catalyst (0.6 wt % Pt impregnated 80/20 CBV-901/alumina) was prepared by the following method: The material is first extruded as a 80 wt % CBV-901 and 20 wt % Versal 300 alumina composite using the following procedure. Charge 808 g of CBV-901 USY crystal to a Lancaster Muller and dry mull for 5 minutes. Dilute 10 g of acetic acid with 690 g of de-ionized water. Dissolve 5 g of polyvinylacetate (PVA) in the acetic acid solution. Slowly add the acid/PVA solution to the zeolite over 5 minutes and mull the mixture for 10 minutes. Add 275 g of Versal-300 alumina to the muller and mull for an additional 10 minutes. Add the remaining 173 g of de-ionized water to the mull mix over 3 minutes and mull 3 minutes or until reasonable consistency is achieved. Extrude the mull mixture on a 2″ Bonnot extruder using 1/16″ quadrulobe die inserts. Dry the extrudates at 250° F. Calcine the dried extrudates in air at 1,000° F. for 6 hours.
Impregnate the acid form of the catalyst using a tetraamine platinum nitrate solution via spray impregnation targeting a metal loading of 0.6 wt % Pt. Spray in the impregnating solution slowly; after the solution has been applied continue mixing for 20 minutes to insure that the solution is uniformly distributed across all of the extrudates. Dry at ambient conditions in an open dish. Dry for 2 hours in a forced air oven at 250° F. Complete the impregnation by calcining the extrudate in air at 680° F. for three hours.

Example 9

0.6 wt % Pt Impregnated 65/35 Steamed H-ZSM-48/TiO₂

The title catalyst (0.6 wt % Pt impregnated 65/35 ZSM-48/TiO₂) was prepared by the following method: the material is first extruded as 65 wt % 90:1 SiO₂:Al₂O₃ZSM-48 and 35 wt % titanium oxide. Charge the ZSM-48 to the muller and mull for 10 minutes. Add 214 g of DT-51 titania to muller and mull for 10 minutes. Slowly add 488 g of de-ionized water to mull mix while mulling. Mull the mixture for 30 minutes or until the mixture reaches the desired consistency to extrude properly. Extrude mixture on a 2″ Bonnot extruder equipped with a die plate using 1/16″ quadrulobe inserts. Dry the extrudate at 250° F. in a forced draft oven.
Pre-calcine the bound zeolite in flowing N₂at 1,000° F. for 3 hours to start removing the structure directing agent from the zeolite. Ammonium-exchange the formed material two times (5 ml of 1 M NH₄NO₃solution per gram of catalyst) under ambient conditions to remove the alkali cations from the structure. After completing the second exchange wash the material with de-ionized water for one hour. Dry at 250° F. overnight in a forced draft oven. To create the acid form of the catalyst, calcine the extrudate in air for 6 hours at 1,000° F. in air.
Place the acid form of the catalyst into a vertical steamer. Bring catalyst up to 700° F. in air and hold at temperature for 30 minutes. Switch from air to steam over a 30-minute period. Ramp the temperature of the steamer to 890° F., allow the temperature in the bed to stabilize, and hold for 3 hours at 890° F. in 100% steam. Cool down in air and remove the catalyst from the steamer.
Impregnate the steamed acid form of the catalyst using a tetraamine platinum nitrate solution via spray impregnation targeting a metal loading of 0.6 wt % Pt. Spray in the impregnating solution slowly; after the solution has been applied continue mixing for 20 minutes to insure that the solution is uniformly distributed across all of the extrudates. Dry at ambient conditions in an open dish. Dry for 2 hours in a forced air oven at 250° F. Complete the impregnation by calcining the extrudate in air at 680° F. for 3 hours.
H₂chemisorption revealed a Pt dispersion of H/Pt=0.76.

Example 10

0.6 wt % Pt Impregnated 65/35 H-ZSM-23/Alumina

The title catalyst (0.6 wt % Pt impregnated 65/35 ZSM-23/alumina) was prepared by the following method: the material is first extruded as 65 wt % ZSM-23 and 35 wt % Versal 300 alumina. Charge the 433 g of ZSM-23 crystal to muller and dry mull for 15 minutes. Add the 248 g of Versal 300 alumina to the muller and dry mull for an additional 10 minutes. Slowly add 451.3 g of de-ionized water to the mull mix over 5 minutes and mull the mixture for 10 minutes or until reasonable consistency. Extrude the mixture on a 2″ Bonnot extruder equipped with a die plate using 1/16″ quadrulobe inserts. Dry the extrudate at 250° F. in a forced draft oven.
Pre-calcine the bound zeolite in flowing N₂at 1,000° F. for 3 hours to start removing the structure directing agent from the zeolite. Ammonium-exchange the formed material two times (5 ml of 1 M NH₄NO₃solution per gram of catalyst) under ambient conditions to remove the alkali cations from the structure. After completing the second exchange wash the material with de-ionized water for one hour. Dry at 250° F. overnight in a forced draft oven. To create the acid form of the catalyst, calcine the extrudate in air for 8 hours at 1,000° F. in air.
Impregnate the acid form of the catalyst using a tetraamine platinum nitrate solution via spray impregnation targeting a metal loading of 0.6 wt % Pt. Spray in the impregnating solution slowly; after the solution has been applied continue mixing for 20 minutes to insure that the solution is uniformly distributed across all of the extrudates. Dry at ambient conditions in an open dish. Dry for 2 hours in a forced air oven at 250° F. Complete the impregnation by calcining the extrudate in air at 680° F. for 3 hours.
The finished catalyst had 0.52 wt % Pt on catalyst. H₂chemisorption revealed a Pt dispersion of H/Pt=1.25.

Example 11

0.6 wt % Pt Impregnated 65/35 H-ZSM-48/Alumina

The title catalyst (0.6 wt % Pt impregnated 65/35 ZSM-48/alumina) was prepared by the following method: add 245 lbs. of ZSM-48 SiO₂/Al₂O₃90 to the muller. Mull the mixture for ten minutes. Add 162 lbs. of Versal 300 alumina. Mull the mixture for ten minutes after adding all of the alumina. Add 292 lbs. of de-ionized water while mulling. Mull the mixture for forty minutes or until reasonable consistency is achieved. Extrude the mixture on an extruder equipped with a die plate using 1/16″ quadrulobe inserts. Dry the extrudate at 250° F. in a forced draft oven.
Pre-calcine the bound zeolite in flowing N₂at 980° F. for 3 hours to start removing the structure directing agent from the zeolite. Ammonium-exchange the formed material two times (5 ml of 1 M NH₄NO₃solution per gram of catalyst) under ambient conditions to remove the alkali cations from the structure. After completing the second exchange wash the material with de-ionized water for one hour. Dry at 250° F. overnight in a forced draft oven. To create the acid form of the catalyst, calcine the extrudate in air for 6 hours at 980° F. in air.
Place the acid form of the catalyst into a vertical steamer. Bring catalyst up to 650° F. in air and hold at temperature for 30 minutes. Switch from air to steam over a 30-minute period. Ramp the temperature of the steamer to 890° F., allow the temperature in the bed to stabilize, and hold for 3 hours at 890° F. in 100% steam. Cool down in air and remove the catalyst from the steamer.
Impregnate the steamed acid form of the catalyst using a tetraamine platinum nitrate solution via spray impregnation targeting a metal loading of 0.6 wt % Pt. Spray in the impregnating solution slowly; after the solution has been applied continue mixing for 20 minutes to insure that the solution is uniformly distributed across all of the extrudates. Dry at ambient conditions in an open dish. Dry for 2 hours in a forced air oven at 250° F. Complete the impregnation by calcining the extrudate in air at 680° F. for three hours.

Example 12

Steaming of the 0.6 wt % Pt Impregnated 65/35 ZSM-48/TiO₂

Place the Pt form of the catalyst from Example 8 into a vertical steamer. Bring catalyst up to 950° F. in air and hold at temperature for 30 minutes. Switch from air to steam over a 30 minute period. Ramp the temperature of the steamer to 1,000° F., allow the temperature in the bed to stabilize, and hold for 24 hours at 1,000° F. in 100% steam. Cool down in air and remove the catalyst from the steamer.

Example 13

Steaming of the 0.6 wt % Pt Impregnated 65/35 ZSM-23/Alumina

Place the Pt form of the catalyst from Example 10 into a vertical steamer. Bring catalyst up to 950° F. in air and hold at temperature for 30 minutes. Switch from air to steam over a 30 minute period. Ramp the temperature of the steamer to 1,000° F., allow the temperature in the bed to stabilize, and hold for 24 hours at 1,000° F. in 100% steam. Cool down in air and remove the catalyst from the steamer.
Catalyst candidates were first screened through a “severe steaming process” which consisted of steaming each potential lead at 1,000° F. for 24 hours in order to examine the effects that exposure to water at high temperatures would have on the crush strength and metal dispersion of each material. Pt dispersions were measured by H₂chemisorption. A promising lead candidate for this application would maintain its crush strength with minimal metal agglomeration. Catalyst from Example 11 was included in the study as a point of reference. The results of the severe steaming study are shown in Table 1.

TABLE 1

Summary of Steaming Study Results

	Crush Strength	Crush Strength
	before steaming	after steaming	H/Pt before	H/Pt after
Example	(lb/in)	(lb/in)	steaming	steaming

1	18.06	25.33	0.49	0.43
8	152.31	129.38	1.37	0.172
9	30.69	25.75	0.76	0.2
10	79.01	78.52	1.26	0.407
11	156.05	132.35	1.31	0.195

It can be seen that the catalyst of Example 1 maintained metal dispersion (indicted by H/Pt) and showed slightly higher crush strength after severe steaming.

Example 14

Catalytic Testing for Dewaxing of Oxygenated Feeds

Catalytic testing was conducted on a High Pressure Heated Orbital Shaker high-throughput experimentation device, which is a collection of small batch reactors contained in a heated, high pressure enclosure. Individual batch reactors consist of a 40 mm deep well with an internal volume of 5.15 cm³each. Each individual well was charged with a catalyst along with 18-pentatriacontanone feed and run at 800 psig H₂, 350° C., and WHSV of 1 to 2 hr⁻¹over a course of 24 hours. Without being bound to any theory or structural details, the reaction is schematically represented below. The results are shown in Table 2.

TABLE 2

Catalytic testing results

			Total	Pendant
	Con-	Epsilon	Pendant	Methyl	# Side		Free
Ex-	version	Carbon,	Groups,	Groups,	Chains/	Carbon	Carbon
ample	(%)	mole %	mole %	mole %	Molecule	#	Index

1	91	22.03	9.44	7.17	1.87	26.08	5.75
2	98	10.23	10.94	8.24	2.44	29.57	3.03
3	91	22.55	7.95	5.72	1.52	26.47	5.97
5	99	10.19	13.35	9.70	2.28	23.54	2.40
6	100	22.07	10.04	7.86	2.33	29.64	6.54
7	100	12.13	12.76	9.43	2.28	24.16	2.93
9	100	8.41	13.15	10.08	2.96	29.40	2.47
11	100	4.75	14.22	10.41	2.68	25.78	1.22

Under the conditions tested, all catalysts disclosed herein effectively dewaxed the ketone feed (conversions of ketone >90%) giving liquid products.
The products were characterized using quantitative ¹³C NMR. Quantitative ¹³C NMR spectra were obtained using Cr(acac)3 as a relaxation aid during acquisition. For example, all normal paraffins with carbon numbers greater than C₉have only five inequivalent carbon NMR absorptions, corresponding to the terminal methyl carbons (α), methylene carbons at the second, third, and fourth positions from the molecular ends (β, γ and δ, respectively), and the other carbon atoms along the backbone that have a common shift (ε). The intensities of α, β, γ and δ are equal and the intensity of ε carbons depends on the length of the molecule. Similarly, side branches on the backbone of an iso-paraffin have unique chemical shifts and the presence of side-chain causes a unique shift at the tertiary site on the backbone to which it is anchored. It also perturbs the chemical shifts within three sites of the tertiary site, imparting unique chemical shifts (α′, β′ and γ′) to the adjacent sites when they occur in the center of a long backbone. The number of free ends of molecules can be estimated by measuring the number of α, β, γ and δ carbons. Unique shifts also enable measuring the number of pendant side-chains of different length (which are called P-Me, P-Et, P-Pr, and P-Bu). The molecular ends that have a side branch at the 2, 3, 4, or 5 sites (which are called T-Me, T-Et, T-Pr and T-Bu) can also be measured. The branching features are particularly valuable in characterizing lube basestocks.
The products can be characterized by the “Free Carbon Index”, which represents the measure of carbon atoms in an average molecule that are epsilon carbons:
FCI=(% epsilon carbons)×(Carbon Number)/100,
where the Carbon Number is determined by ¹³C NMR as following:
Carbon Number=2/((mole % α carbon+mole % T-Me carbon+mole % T-Et carbon+mole % T-Pr carbon)/100)
¹³C NMR also revealed that the products are significantly free of carbonyl carbon, consistent with high conversions seen by GC. The dewaxed products had, on average, 1-3 side chain per molecule, indicating effective dewaxing of the ketone feed.
All documents described herein are incorporated by reference herein, including any priority documents and/or testing procedures to the extent they are not inconsistent with this text. As is apparent from the foregoing general description and the specific embodiments, while forms of the disclosure have been illustrated and described, various modifications can be made without departing from the spirit and scope of the disclosure. Accordingly, it is not intended that the disclosure be limited thereby. Likewise, the term “comprising” is considered synonymous with the term “including” for purposes of Australian law.
When numerical lower limits and numerical upper limits are listed herein, ranges from any lower limit to any upper limit are contemplated.
While the illustrative embodiments of the disclosure have been described with particularity, it will be understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the spirit and scope of the disclosure. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the examples and descriptions set forth herein but rather that the claims be construed as encompassing all the features of patentable novelty which reside in the present disclosure, including all features which would be treated as equivalents thereof by those skilled in the art to which the disclosure pertains.

Claims

What is claimed is:

1. A method for producing a lube base stock and/or a fuel from a feedstock of biological origin, the method comprising:

contacting the feedstock in the presence of a catalyst to produce a lube base stock and/or a fuel,

wherein the catalyst comprises:

a zeolite component selected from a zeolite having 10-member ring pores, a zeolite having 12-member ring pores and a combination thereof,

0.1 to 5 weight % of a hydrogenation component selected from Pt, Pd, Ag, Ni, Mo, Co, W, Rh, Re, Ru, Ir and a mixture thereof, and

a hydrothermally stable binder component selected from silica, alumina, silica-alumina, titania, zirconia, tantalum oxide, tungsten oxide, molybdenum oxide, vanadium oxide, magnesium oxide, calcium oxide, yttrium oxide, lanthanum oxide, cerium oxide, niobium oxide, tungstated zirconia, cobalt molybdenum oxide, cobalt molybdenum sulfide, nickel molybdenum oxide, nickel molybdenum sulfide, nickel tungsten oxide, nickel tungsten sulfide, cobalt tungsten oxide, cobalt tungsten sulfide, nickel molybdenum tungsten oxide and nickel molybdenum tungsten sulfide, cobalt molybdenum tungsten oxide and cobalt molybdenum tungsten sulfide,

wherein the weight ratio of the zeolite component to the hydrothermally stable binder component is 85:15 to 25:75.

2. The method of claim 1, wherein the method produces jet fuel, diesel fuel, or gasoline.

3. The method of claim 1, wherein the method produces lube base stock.

4. The method of claim 1, wherein the feedstock of biological origin comprises one or more components selected from the group consisting of fatty acids, fatty acid esters, fatty alcohols, fatty olefins, mono-glycerides, di-glycerides, tri-glycerides, phospholipids and saccharolipids.

5. The method of claim 1, further comprising providing hydrogen.

6. The method of claim 1, further comprising adding water to the feedstock of biological origin.

7. The method of claim 1, wherein the weight ratio of the zeolite component to the hydrothermally stable binder component is 80:20 to 65:35.

8. The method of claim 1, wherein the hydrogenation component is selected from Pt, Pd, Ni, Mo, W and a binary mixture thereof.

9. The method of claim 1, wherein the zeolite component is selected from ZSM-48, ZSM-23, ZSM-50, ZSM-5, ZSM-22, ZSM-11, ferrierite, faujasite, beta, ZSM-12, MOR and a combination thereof.

10. The method of claim 1, wherein the zeolite component is a combination of beta and ZSM-48.

11. The method of claim 1, wherein the zeolite component is ZSM-48 or ZSM-23, wherein the ratio of SiO₂:Al₂O₃is 100 or less.

12. The method of claim 1, wherein the hydrothermally stable binder component is selected from tungsten oxide, molybdenum oxide, vanadium oxide, and a mixture thereof

13. The method of claim 1, wherein the hydrothermally stable binder component is selected from magnesium oxide, calcium oxide, yttrium oxide, cerium oxide, niobium oxide, lanthanum oxide, zirconium oxide, and a mixture thereof.

14. The method of claim 1, wherein the hydrothermally stable binder component is selected from cobalt molybdenum oxide, cobalt molybdenum sulfide, nickel molybdenum oxide, nickel molybdenum sulfide, nickel tungsten oxide, nickel tungsten sulfide, nickel molybdenum tungsten oxide and nickel molybdenum tungsten sulfide.

15. The method of claim 1, wherein the hydrothermally stable binder component is lanthanum, cerium, niobium, nickel tungsten oxides, nickel tungsten sulfides, nickel molybdenum tungsten oxides, and nickel molybdenum tungsten sulfide.

16. The method of claim 1, wherein the hydrogenation component is Ni or Pt; the zeolite component is ZSM-48 or ZSM-23; and the hydrothermally stable binder component is nickel molybdenum tungsten oxides, nickel molybdenum tungsten sulfide, WO₃, La₂O₃, CeO₂, or Nb₂O₅.

17. The method of claim 1, wherein the catalyst comprises a mixture selected from:

(a) Ni, ZSM-48 and WO₃; (b) Ni, ZSM-23 and WO₃(c) Pt, ZSM-48 and La₂O₃;

(b) Pt, ZSM-48 and CeO₂; (e) Pt, ZSM-48 and Nb₂O₅; (f) Pt, ZSM-23 and La₂O₃;

(c) Pt, ZSM-23 and CeO₂; (h) Pt, ZSM-23 and Nb₂O₅;

(d) Pt, ZSM-48 and WO₃; and (j) Pt, ZSM-23 and WO₃.

18. The method of claim 1, wherein the catalyst is selected from:

(i) a catalyst comprising 0.6 weight % Ni, ZSM-48 and WO₃, wherein the ratio of SiO₂:Al₂O₃is 80:1 or less, and wherein the weight ratio of ZSM-48 to WO₃is 8:2;

(ii) a catalyst comprising 3 weight % Ni and 20% W, ZSM-48 and alumina, wherein the ratio of SiO₂:Al₂O₃is 80:1 or less, and wherein the weight ratio of ZSM-48 to alumina is 65:35;

(iii) a catalyst comprising 0.6 weight % Pt, ZSM-48 and Nb₂O₅, wherein the ratio of SiO₂:Al₂O₃is 80:1 or less, and wherein the weight ratio of ZSM-48 to Nb₂O₅is 8:2;

(iv) a catalyst comprising 0.6 weight % Pt, ZSM-48 and La₂O₃, wherein the ratio of SiO₂:Al₂O₃is 80:1 or less, and wherein the weight ratio of ZSM-48 to La₂O₃is 8:2;

(v) a catalyst comprising 0.6 weight % Pt, ZSM-48 and CeO₂, wherein the ratio of SiO₂:Al₂O₃is 80:1 or less, and wherein the weight ratio of ZSM-48 to CeO₂is 8:2;

(vi) a catalyst comprising 0.6 weight % Pt, CBV-901 and alumina, wherein the weight ratio of ZSM-48 to alumina is 8:2;

(vii) a catalyst comprising 0.6 weight % Pt, ZSM-48 and TiO₂, wherein the ratio of SiO₂:Al₂O₃is 90:1 or less, and wherein the weight ratio of ZSM-48 to TiO₂is 65:35;

(viii) a catalyst comprising 0.6 weight % Pt, ZSM-23 and alumina, wherein the weight ratio of ZSM-23 to alumina is 65:35; and

(ix) a catalyst comprising 0.6 weight % Pt, ZSM-48 and alumina, wherein the ratio of SiO₂:Al₂O₃is 90 or less, and wherein the weight ratio of ZSM-48 to alumina is 65:35.

19. A method for producing a lube basestock and/or a fuel from a feedstock of biological origin, the method comprising:

wherein the catalyst comprises:

a zeolite component selected from ZSM-48, ZSM-23, ZSM-50, ZSM-5, ZSM-22, ZSM-11, ferrierite, faujasite, beta, ZSM-12, MOR, and a mixture thereof, and

a hydrogenation component comprising at least three metals selected from the group consisting of Pt, Pd, Ag, Ni, Mo, Co, W, Rh, Re, and Ru, wherein at least one of the at least three metals is in either an oxide or sulfide form.

20. The method of claim 19, wherein the feedstock of biological origin comprises one or more components selected from the group consisting of fatty acids, fatty acid esters, fatty alcohols, fatty olefins, mono-glycerides, di-glycerides, tri-glycerides, phospholipids and saccharolipids.

21. The method of claim 19, wherein the zeolite is ZSM-48 or ZSM-23; and the hydrogenation component comprises (a) Ni, MoOx and WOx or (b) Co, MoOx and WOx, wherein x is in the range of 0.5 to 3.

22. The method of claim 19, wherein the catalyst comprises ZSM-48 and a hydrogenation component comprising Ni, MoOx and WOx, wherein x is in the range of 0.5 to 3,

wherein the ratio of SiO₂:Al₂O₃is 90:1 or less, and

wherein the weight ratio of ZSM-48 to the hydrogenation component is 8:2.

23. The method of claim 19, wherein the catalyst further comprises a binder selected from silica, alumina, silica-alumina, titania, zirconia, tantalum oxide, tungsten oxide, molybdenum oxide, vanadium oxide, magnesium oxide, calcium oxide, yttrium oxide, lanthanum oxide, cerium oxide, niobium oxide, titanium oxide, zirconium oxide, tungstated zirconia, cobalt molybdenum oxide, cobalt molybdenum sulfide, nickel molybdenum oxide, nickel molybdenum sulfide, nickel tungsten oxide, nickel tungsten sulfide, nickel molybdenum tungsten oxide, nickel molybdenum tungsten sulfide, and a mixture thereof.

24. The method of claim 23, wherein the binder is selected from silica, alumina, silica-alumina, titania, zirconia, yttrium oxide, lanthanum oxide, cerium oxide, niobium oxide, and a mixture thereof.