Group 13-15 interstitial metal hydride catalysts and associated processes

Abstract

The present invention relates to the processing of hydrocarbon-containing feedstreams in the presence of an interstitial metal hydride comprised of at least one chemical element selected from Groups 3-11 (including the lanthanides, atomic numbers 58 to 71), and at least one chemical element selected from Groups 13-15 from the IUPAC Periodic Table of Elements. These interstitial metal hydrides, their catalysts and processes using these interstitial metal hydrides and catalysts of the present invention improve overall hydrogenation, product conversion, as well as sulfur reduction in hydrocarbon feedstreams.

1 . An interstitial metal hydride comprising at least a first chemical element selected from Groups 3-11 (including the lanthanides, atomic numbers 58 to 71), and at least a second chemical element selected from Groups 13-15 of the IUPAC Periodic Table of Elements. 
     
     
         2 . (canceled) 
     
     
         3 . (canceled) 
     
     
         4 . (canceled) 
     
     
         5 . The interstitial metal hydride of  claim 1 , wherein the second chemical element is selected from aluminum, gallium, indium, thallium, germanium, tin, lead, antimony and bismuth. 
     
     
         6 . (canceled) 
     
     
         7 . The interstitial metal hydride of  claim 1 , wherein the second chemical element is present in an amount of from 0.1 to 10 wt % based on the total weight of the interstitial metal hydride. 
     
     
         8 . (canceled) 
     
     
         9 . The interstitial metal hydride of  claim 1 , further comprised of a third chemical element selected from Groups 3-11 (including the lanthanides, atomic numbers 58 to 71). 
     
     
         10 . The interstitial metal hydride of  claim 9 , wherein the first chemical element is selected from a Group 4 element, and the third chemical element is selected from a Group 5 element of the IUPAC Periodic Table of Elements. 
     
     
         11 . (canceled) 
     
     
         12 . (canceled) 
     
     
         13 . The interstitial metal hydride of claim [[12]] 10, wherein the Group 4 element is selected from zirconium and titanium, and the Group 5 element is vanadium. 
     
     
         14 . (canceled) 
     
     
         15 . (canceled) 
     
     
         16 . The interstitial metal hydride of  claim 9 , wherein the first chemical element is selected from a first Group 4 element, and the third chemical element is selected from a second Group 4 element of the IUPAC Periodic Table of Elements. 
     
     
         17 . (canceled) 
     
     
         18 . (canceled) 
     
     
         19 . The interstitial metal hydride of  claim 16 , wherein the first Group 4 element is zirconium and the second Group 4 element is selected from titanium and hafnium. 
     
     
         20 . (canceled) 
     
     
         21 . (canceled) 
     
     
         22 . A catalyst comprised of an interstitial metal hydride, wherein the interstitial metal hydride is comprised of at least a first chemical element selected from Groups 3-11 (including the lanthanides, atomic numbers 58 to 71), and at least a second chemical element selected from Groups 13-15 of the IUPAC Periodic Table of Elements. 
     
     
         23 . The catalyst of  claim 22 , further comprised of a matrix comprised of a material selected from alumina, silica, titania, zirconia, and combinations thereof. 
     
     
         24 . The catalyst of  claim 23 , further comprised of a zeolite. 
     
     
         25 . The catalyst of  claim 23 , further comprised of at least one transition metal element selected from Mo, W, Fe, Co, Ni, Pd, and Pt. 
     
     
         26 . (canceled) 
     
     
         27 . (canceled) 
     
     
         28 . (canceled) 
     
     
         29 . (canceled) 
     
     
         30 . (canceled) 
     
     
         31 . A process comprising the steps of:
 a) contacting a hydrocarbon feedstream with a catalyst comprised of an interstitial metal hydride in the presence of hydrogen at process reaction conditions of at least 150° C. and at least 200 psig; and   b) obtaining an upgraded reaction product stream;   wherein the interstitial metal hydride is comprised of at least a first chemical element selected from Groups 3-11 (including the lanthanides, atomic numbers 58 to 71), and at least a second chemical element selected from Groups 13-15 of the IUPAC Periodic Table of Elements.   
     
     
         32 . The process of  claim 31 , wherein process reaction conditions are from about 200° C. to about 450° C. and from about 400 psig to about 2,500 psig. 
     
     
         33 . The process of  claim 31 , wherein step a) is performed in the presence of hydrogen with a hydrogen partial pressure of at least 150 psia. 
     
     
         34 . The process of  claim 31 , wherein the catalyst is further comprised of at least one transition metal element selected from Groups 6, 8, 9, and 10 of the IUPAC Periodic Table of Elements. 
     
     
         35 . (canceled) 
     
     
         36 . The process of  claim 31 , wherein the interstitial metal hydride is further comprised of a third chemical element selected from Groups 3-11 (including the lanthanides, atomic numbers 58 to 71). 
     
     
         37 . The process of  claim 31 , wherein the second chemical element of the interstitial metal hydride is selected from aluminum, gallium, indium, thallium, germanium, tin, lead, antimony and bismuth. 
     
     
         38 . (canceled) 
     
     
         39 . (canceled) 
     
     
         40 . (canceled) 
     
     
         41 . (canceled) 
     
     
         42 . (canceled) 
     
     
         43 . (canceled) 
     
     
         44 . (canceled) 
     
     
         45 . (canceled) 
     
     
         46 . The process of  claim 31 , wherein the process reaction conditions are at least 200° C. and at least 400 psig, and the hydrogen partial pressure during the process reaction is at least 350 psia. 
     
     
         47 . The process of  claim 31 , wherein the hydrocarbon feedstream and interstitial metal hydride are further subjected to radio frequency energy or microwave frequency energy while under the reaction conditions. 
     
     
         48 . The process of  claim 31 , wherein the hydrocarbon feedstream is a heavy hydrocarbon feedstream with an API gravity of less than 20 and a sulfur content of at least 1 wt % sulfur. 
     
     
         49 . The process of  claim 31 , wherein the hydrocarbon feedstream is comprised of a biofuel. 
     
     
         50 . The process of  claim 49 , wherein the hydrocarbon feedstream substantially consists of a biofuel. 
     
     
         51 . (canceled) 
     
     
         52 . (canceled) 
     
     
         53 . (canceled) 
     
     
         54 . (canceled) 
     
     
         55 . (canceled) 
     
     
         56 . (canceled) 
     
     
         57 . (canceled)