A PROCESS FOR THE MANUFACTURE OF LUBRICATING OILS

Abstract: A process for catalytically hydrodewaxing a hydrocarbon feedstock to produce high yields of low pour, high viscosity index hydrocracked lubricating oil stock comprises contacting the feedstock and hydrogen under dewaxing conditions with a catalyst composition comprising ZSM-22, a Group VIII metal and a support.

Description: This invention relates to a process for the manufacture of lubricating oils. Since lubricating oils are for the most part based on petroleum fractions boiling above about 230°C (450°F), the molecular weight of the hydrocarbon constituents is high and these constituents display almost all conceivable structures and structure types. The complexity of the molecular constitution of lubricating oils and its consequences are referred to in "Petroleum Refinery Engineering", by W. L. Nelson, McGraw Hill Book Company, Inc., New York, N.Y., 1958 (Fourth Edition). Although the broad principles involved in refining are qualitatively understood, the art is encumbered by quantitative uncertainties which require considerable resort to empiricism in practical refining. Underlying these quantitative uncertainties is the complexity of the molecular constitution of lubricating oils. Accordingly, the art of refining suitable petroleum crude oils to obtain a variety of lubricating oils which function effectively in diverse environments has become highly developed and complex. In general, the basic notion in lubricant refining is that a suitable crude oil, as shown by experience or by assay, contains a quantity of lubricant stock having a predetermined set of properties such as, for example, appropriate viscosity, oxidation stability, and maintenance of fluidity at low temperatures. The process of refining to isolate that lubricant stock consists of a set of subtractive unit operations which removes the unwanted components. The most important of these unit operations include distillation, solvent refining, and dewaxing, which basically are physical separation processes in the sense that if all the separated functions were recombined, one would reconstitute the crude oil. Unfortunately, crude oils suitable for the manufacture of lubes are becoming less available due to exhaustion of reserves, and the reliability of a steady, adequate supply from a known source is a matter of concern. The desirability of upgrading a crude fraction normally considered unsuitable for lubricant manufacture to one from which good yields of lubes can be obtained has long been recognized. The so-called "hydrocracking process", sometimes referred to in the art as "severe hydrotreating", has been proposed to accomplish such upgrading. In this process, a suitable fraction of a poor grade crude, such as a California crude, is catalytically reacted with hydrogen under pressure. The process is complex in that some of the oil is reduced in molecular weight and made unsuitable for lubes, but concurrently a substantial fraction of the polynuclear aromatics is hydrogenated to form naphthenes and paraffins. Process conditions and choice of catalyst are selected to provide an optimal conversion of the polynuclear aromatic content of the stock, since this component degrades the viscosity index and stability of the stock. Also, in the hydrocracking process, paraffins can be isomerized, imparting good viscosity index characteristics to the final lube product. For purposes of this invention, the term "hydrocracking" will be employed for the foregoing process step and to distinguish this step from the "hydrotreating" step to be described below, the purpose of the latter being to stabilize the lube base stock produced by hydrocracking. For purposes of this invention, the hydrocracking and hydrotreating steps may be distinguished also by the amount of hydrogen consumed, the hydrocracking step typically consuming 178-356 Nm³/m³ (1000-2000 SCF/bbl) while the hydrotreating step consumes only 18-36 Nm³/m³ (100-200 SCF/bbl). The hydrocracking process for increasing the availability of lube oils has an attractive feature that is not immediately apparent. Generally, the composition and properties of hydrocracked stocks are not particularly affected by the source and nature of the crude, i.e. they tend to be much more alike than fractions prepared from different crudes by conventional means. Thus, the process promises to free the refiner from dependence on a particular crude, with all of the advantages that this freedom implies. Hydrocracked lube stocks, however, tend to be unstable in the presence of air when exposed to sunlight. On such exposure, a sludge is formed, sometimes very rapidly and in fairly substantial amount. This tendency in a lubricating oil is unacceptable. Additionally, some hydrocracked lube oils tend to darken or to form a haze. Several methods have been proposed to correct the above-described instability. U.S. Patent 4,031,016 proposes to add certain antioxidants to the hydrocracked oil. A second proposed approach is to hydrotreat the hydrocrackate. Variants of this approach are described in U.S. Patent 3,666,657 which teaches a sulfided mixture of an iron group metal and a Group VI metal for the hydrotreating stage; U.S. Patent 3,530,061 which utilizes a hydrotreating catalyst having one or more elements from Group IIB, VIB and VIII at hydrogen pressure up to about 800 kPa (100 psig); and U.S. Patent 4,162,962 which teaches to hydrotreat the hydrocrackate at a temperature in the 200°C to 300°C range with a catalyst of prescribed pore size. U.S. Patent 3,530,061 teaches a non-cracking support for the hydrotreating stage. U.S. Patent 3,852,207 teaches hydrotreating with a noble metal hydrogenation component supported on an oxide. Hydrocracked lubricating oils generally have an unacceptably high pour point and require dewaxing. Solvent dewaxing is a well-known and effective process but expensive. More recently catalytic methods for dewaxing have been proposed. U.S. Reissue Patent 28,398 describes a catalytic dewaxing process wherein a particular crystalline zeolite is used. To obtain lubricants and specialty oils with outstanding resistance to oxidation, it is often necessary to hydrotreat the oil after catalytic dewaxing, as illustrated by U.S. Patent 4,137,148. U.S. Pat. Nos. 4,283,271, 4,283,272 and 4,414,097 describe processes for producing dewaxed lubricating oil base stacks including hydrocracking a hydrocarbon feedstock, catalytically dewaxing the hydrocrackate and hydrotreating the dewaxed hydrocrackate. These latter patents, recognized as advances in the art, describe use of catalyst compositions comprising zeolite ZSM-5, ZSM-11 and ZSM-23 for the dewaxing phase. U.S. Patent application Serial No. 587,327 filed March 7, 1984, a division of U.S. Serial No, 373,451 filed April 30, 1982, describes ZSM-22 and its use in gas oil dewaxing and lube stock dewaxing. It is inferentially evident from the foregoing background material that, in general, the manufacture of modern high quality lubricants requires that the crude be treated in a sequence of fairly complex and costly steps. It is further evident that there is a need for processes which can efficiently provide such lubricants from interchangeable and readily available low grade crudes. It is an object of the present invention to provide an improved process for the manufacture of lubricating oils. Accordingly, the invention resides in a process for hydrodewaxing a hydrocarbon feedstock boiling above about 288°C (550°F), to produce a dewaxed lubricating oil base stock, comprising contacting the feedstock in the presence of hydrogen, with a supported catalyst composition comprising 20 to 50 percent by weight of a support material; 0.1 to 3 weight percent of at least one Group VIII metal and the remainder being a porous crystalline zeolite having a silica to alumina mole ratio of at least about 20, wherein the zeolite exhibits the X-ray diffraction lines set out in Table A and wherein contact of said feedstock with said supported catalyst composition is effected at a pressure of from 1480 to 20786 kPa (200 psig to 3000 psig); a temperature of from 260°C to 482°C; a feedstock LHSV ranging from 0.2 to 20 and a hydrogen feed rate of 89 to 3560 Nm³ hydrogen/m³ feedstock (500 to 20,000 standard cubic feet of hydrogen per barrel of feedstock). Various advantages are inherent in the process of the invention. The yield of dewaxed oil is higher than those of prior art methods. The viscosity index (VI) of the dewaxed oil produced in accordance with the invention is higher than that obtained by methods employing other catalyst compositions containing zeolites in dewaxing. Activity and selectivity, as measured by viscosity index and lube yield at a given pour point, of the catalyst composition are superior. In addition, the hydrodewaxing conditions include temperatures which are comparable to those of hydrocracking. Accordingly, when the feedstock processed in accordance with the invention has been previously subjected to hydrocracking, the need for quenching the hydrocracking effluent prior to dewaxing is minimized thereby resulting in substantial energy savings. In the accompanying drawings, Figure 1 is a flow diagram illustrating a process according to one example of the invention, Figure 2 is a plot of lube product yield in weight percent v. product pour point, Figure 3 is a plot of product viscosity index v. product pour point, Figure 4 is a plot of lube product yield v. product pour point, and Figure 5 is a plot of product viscosity index v. product pour point. Referring to Figure 1, the process shown involves initially introducing a suitable hydrocarbon feed via line 1 together with hydrogen via line 2 to a hydrocracker 3. Hydrocracker 3 includes a catalytic hydrocracking zone maintained at conditions effective to convert in a single pass at least 20% of the feed to materials boiling below the initial boiling point of said feed. Such conditions for the hydrocracking step are summarized in Table I: TABLE I A wide variety of hydrocracking catalysts are contemplated as suitable for use in the hydrocracker 3. Such catalysts will in general possess an acid function and a hydrogenation function, exemplified by a porous acidic oxide such as a silica alumina or silica zirconia associated with a nickel-tungsten or palladium or platinum, or cobalt-molybdenum or nickel-molybdenum component. In general, a Group VIII metal or a combination of a Group VI and a Group VIII metal, as the oxides or sulfides thereof, deposited on silica alumina or silica zirconia, may serve as the hydrocracking catalyst. The hydrocracking itself may be conducted in two or more stages, with pretreatment of the raw feed as part of the first stage. The effluent from the hydrocracker 3 including excess hydrogen may be contaminated with free hydrogen sulfide and in some cases with ammonia, since the hydrocracking step, in addition to saturating aromatic compounds, also is accompanied by desulfurization and denitrogenation. This effluent is therefore passed via line 4 to a high pressure gas-liquid separator (G/L Sep) 5 wherein the hydrocrackate is separated from contaminated hydrogen. The contaminated hydrogen is then passed from separator 5 via line 6 to a high pressure sorption section 7 wherein a substantial fraction of the hydrogen sulfide and of the ammonia are removed via line 8. The hydrogen from sorption unit 7 is passed via line 9 to a high pressure separator section 10 wherein it is separated from light hydrocarbons which are removed via line 11. The hydrocrackate separated in separator section 5 is passed via line 12 to catalytic dewaxing section 13 along with makeup hydrogen introduced via line 14. It is important to note that the only hydrogen supplied to the catalytic dewaxer section 13 is fresh hydrogen having a hydrogen sulfide partial pressure of less than about 35 kPa (about 5 psia) and less than 100 ppm of ammonia. The amount of hydrogen supplied via line 14 may be up to about the amount consumed in the process. Thus, all of the makeup hydrogen may be supplied via line 14. Alternatively, if it is desired to supply to the catalytic dewaxer 13 less than the makeup requirement of the system, the remainder may be supplied to the hydrocracker via line 15, or at any other point in the system. Process conditions in the catalytic dewaxer 13 are summarized in Table II TABLE II Since each of the hydrocracking and hydrodewaxing operations may produce oils unstable to air and/or to light, it is desirable to perform a hydrotreating operation subsequent to the hydrodewaxing operation. To undertake the hydrotreating operation, the effluent from the catalytic dewaxer 13, including excess hydrogen, is passed via line 16 to hydrotreater unit 17. Catalytic hydrotreater 17 contains a hydrotreating catalyst typically one or more metals from Group VIII (e.g. cobalt and nickel) and Group VI (e.g. molybdenum and tungsten) of the Periodic Table of Elements supported by an inorganic oxide such as, for example, alumina or silica-alumina. Conditions in the hydrotreater unit 17 are summarized in Table III: TABLE III By disposing the catalytic dewaxing step between the hydrocracking and stabilization step in the manner described in this embodiment, a very efficient over-all process results with the production of a stabilized and dewaxed hydrocracked lubricating oil stock. The effluent from the hydrotreater unit is passed via line 18 to a high pressure separation section 10 wherein it is treated to separate light hydrocarbons, which are removed together with a hydrogen bleed via line 11. Also separated is the hydrocarbon mixture comprising a stabilized and dewaxed hydrocracked lubricating oil stock, which is recovered via line 19. The hydrocarbon mixture containing the lubricating oil stock is passed via line 19 to another unit (not shown) for recovery of the lubricating oil stock. The makeup and recycle hydrogen separated in section 10 is passed via line 20 to compressor 21 to raise its pressure and then passed via line 2 to the hydrocracker 3. Preferably, the pressure in line 20, which is downstream from pump 21, and the pressure in line 2, which is upstream of pump 21, do not differ by more than about 5300 kPa (about 750 psig). It will be recognized by those skilled in the art that various separation steps conducted at high pressure may be advantageously incorporated in the process flow diagram of Figure 1. For example, a high pressure separation unit may be located in line 12 or line 16, for example, to remove a low molecular weight fraction of hydrocarbon not suitable for inclusion in the final lubricant base stock, thereby reducing the hydrocarbon load to subsequent sections. The catalyst composition used in dewaxing section 13 comprises 47 to 80 weight percent the zeolite ZSM-22, in combination with the Group VIII metal(s) and support material. The composition and preparation of the dewaxing catalyst will be described in detail below. ZSM-22 is a highly siliceous zeolite which can be prepared from a reaction mixture comprising a source of silica, an alkali metal oxide or an alkaline earth metal oxide, e.g., sodium, potassium, cesium, calcium or strontium, water, and alumina. In addition, the reaction mixture will preferably contain a template or directing agent. The template or directing agent may be selected from a variety of organic compounds. Amines and alcohols may act as such template or directing agents. Preferred directing agents are the alkane diamines or their salts and the dialkylammonium compounds. When the organic compound is alkane diamine the reaction mixture will have a composition, in terms of mole ratios of oxides, falling within the following ratios: wherein RN is a C₂-C₁₂ alkane diamine of the formula H₂N-(CH₂) n -NH₂ (abbreviated C n DN), n = 2 to 12, and preferably is 5 to 8, and M is an alkali metal or an alkaline earth metal. Suitable diamines are, e.g., ethanediamine, propanediamine, butanediamine, pentanediamine, hexanediamine, heptanediamine, octane-diamine, nonanediamine, decanediamine, undecanediamine, duodecane-diamine. In the as-synthesized form, the ZSM-22 has a calculated composition, in terms of moles of oxides, after dehydration, per 100 moles of silica, as follows: ( 0.02 to 10)RN:(0 to 2)M 2/n O:(0 to 5)Al₂O₃:100SiO₂ wherein RN is a C₂-C₁₂ alkane diamine and M is an alkali metal or an alkaline earth metal having a valence n, e.g., Na, K, CS, Li, Ca or Sr. Suitable dialkylammonium compounds which may be used as the organic compound acting as the template or directing agent are those in which each of the alkyl groups is the same or different and each alkyl group has two (2) to eight (8) carbon atoms, e.g., ethyl, propyl, butyl, pentyl, hexyl, heptyl or octyl. In the as synthesized form, using a dialkylammonium source, the ZSM-22 has a calculated composition, in terms of moles of oxides, after dehydration, per 100 moles of silica, as follows: (0.01-2.0)Q₂O:(0-2.0)M 2/n O:(0-5)Al₂O₃:100 SiO₂ wherein Q₂O is theoxide form of said dialkylammonium. It is believed that either polyalkylene polyamines or methanol in appropriate mole ratios, based on the moles of reactants, may also be used as the directing agent to produce ZSM-22. The reaction mixture is maintained at crystallization temperature until crystals of the ZSM-22 zeolite are formed. Thereafter, the crystals are separated from the liquid by any conventional means, washed and recovered. Crystallization can be carried out under either static or stirred conditions in a reactor vessel, e.g., a polypropylene jar, teflon lined or stainless steel autoclaves, at 80°C (176°F) to about 210°C (410°F) for 6 hours to 150 days. Thereafter, the crystals are separated from the liquid and recovered. The composition can be prepared utilizing materials which supply the appropriate oxide. Such materials include aluminates, alumina, silicates, sodium silicate, silica hydrosol, silica gel, silicia acid, sodium, potassium or cesium hydroxide, and an alkane diamine. The reaction mixture can be prepared either batchwise or continuously. Crystal size and crystallization time of the crystalline material varies with the nature of the reaction mixture employed and the crystallization conditions. As set forth above, the ZSM-22 zeolite can be prepared at a relatively wide range of SiO₂/Al₂O₃ ratios of 20 to infinity. However, it has been found that larger alkali metal cations, e.g., K⁺ and Cs⁺, are preferably used at the SiO₂/Al₂O₃ ratios of 20 to 90 to obtain ZSM-22 crystals substantially free of impurities or other zeolites. The potassium (K⁺) cation is preferred at such low SiO₂/Al₂O₃ ratios because cesium (Cs) appears to decrease the reaction rate. At the SiO₂/Al₂O₃ ratios of 90 or above, e.g., 90 to 200, smaller cations, e.g., sodium (Na⁺) cations, are preferably used to produce substantially 100% crystalline ZSM-22. The highly siliceous ZSM-22 zeolite comprises crystalline, three-dimensional continuous framework, silicon-containing structures or crystals which result when all the oxygen atoms in the tetrahedra are mutually shared between tetrahedral atoms of silicon or aluminum, and which can exist with a network of mostly SiO₂, i.e., exclusive of any intracrystalline cations. ZSM-22 has a calculated composition, in terms of moles of inorganic oxides, after dehydration and removal of the organic template or directing agent, per 100 moles of silica, as follows: (0 to 2)M 2/n O:(0 to 5)Al₂O₃:100SiO₂ wherein M is an alkali metal or an alkaline earth metal having a valence n, e.g., Na, K, Cs, Li, Ca or Sr and n is 1 or 2. ZSM-22 can further be identified by its sorptive characteristics and its X-ray diffraction pattern. Thus, ZSM-22 zeolite has a definite X-ray diffraction pattern, set forth below in Table A, which distinguishes it from other crystalline materials. TABLE A These values were determined by standard techniques. The radiation was the K-alpha doublet of copper and a diffractometer equipped with a scintillation counter and an associated computer were used. The peak heights, I, and the positions as a function of 2 theta, where theta is the Bragg angle, were determined using algorithms on the computer associated with the spectrometer. From these, the relative intensities, 100 I/I₀, where I₀ is the intensity of the strongest line or peak, and d (obs.) the interplaner spacing in angstroms (A), corresponding to the recorded lines, were determined. In Table I, the relative intensities are given in terms of the following symbols vs = very strong, s = strong, m = medium, w = weak, etc. It should be understood that this X-ray diffraction pattern is characteristic of all the species of ZSM-22 zeolite compositions. Ion exchange of the alkali or alkaline earth metal cations in the as-synthesized material with other ions results in a zeolite which reveals substantially the same X-ray diffraction pattern as that of Table 1 with some minor shifts in interplanar spacing and variations in relative intensity. Other minor variations can occur, depending on the silica to alumina ratio of the particular sample, as well as its degree of thermal treatment. The ZSM-22 zeolite freely sorbs normal hexane and has a pore dimension greater than about 4 Angstroms. In addition, the structure of the zeolite provides constrained access to larger molecules, which is conveniently measured by determination of the constraint index of the zeolite. The term "constraint index" and a method of its determination are described in, for example, U.S. Patent No. 4,016,218. ZSM-22 has a constraint index of about 8.6 at 800°F (427°C). The sorption of hydrocarbons by ZSM-22 is summarized in Table B. Sorption capacities for n-hexane (normal hexane), cyclohexane, and water are about 4% by weight, or about one third that of ZSM-5. Cyclohexane and o-xylene sorption is relatively slow, making it difficult to determine equilibrium capacities. TABLE B The n-hexane/o-xylene ratios may vary under different conditions, as illustrated by the data of Table C, below: TABLE C The ZSM-22 zeolite, as synthesized, tends to crystallize as agglomerates of elongated crystals having the size of 0.5 to 2.0 microns. Ballmilling fractures these crystals into smaller size crystallites (about 0.1 microns) without significant loss of crystallinity. The zeolite can be formed into a wide variety of particle shapes. Generally speaking, the particles can be in the form of a powder, a granule, or a molded product, such as an extrudate having particle size sufficient to pass through a 2 mesh (Tyler) screen and be retained on a 400 mesh (Tyler) screen. In cases where the catalyst is molded, such as by extrusion, the crystals can be extruded before drying or partially dried and then extruded. The as-synthesized zeolite may be conveniently converted into the hydrogen, the univalent or multivalent cationic forms by base exchanging the zeolite to remove the sodium cations by such ions as hydrogen (from acids), ammonium, alkylammonium and arylammonium including RNH₃ R₃NH⁺, R₂NH₂ and R₄N⁺ where R is alkyl or aryl, provided that steric hindrance does not prevent the cations from entering the cage and cavity structure of the ZSM-22 type crystalline zeolite. The hydrogen form of the zeolite, used in the dewaxing process of the invention, is prepared, for example, by base exchanging the sodium form with,e.g., ammonium chloride or hydroxide whereby the ammonium ion is substituted for the sodium ion. The composition is then calcined at a temperature of, e.g., 1000°F (about 540°C) causing evolution of ammonia and retention of the hydrogen proton in the composition. Other replacing cations include cations of the metals of the Periodic Table, particularly metals other than sodium, most preferably metals of Group IIA, e.g., zinc, and Groups IIIA, IVA, IB, IIB, IIIB, IVB, VIB and Group VIII of the Periodic Table, and rare earth metals and manganese. Ion exchange of the zeolite can be accomplished conventionally, e.g., by admixing the zeolite with a solution of a cation to be introduced into the zeolite. Ion exchange with various metallic and non-metallic cations can be carried out according to the procedures described in U.S. patents 3,140,251, 3,140,252 and 3,140,253. The zeolite dewaxing catalyst includes a Group VIII metal component which can be exchanged into the zeolite, impregnated therein or physically and intimately admixed therewith. Ion exchange can be carried out according to procedures described above. Impregnation may be effected by treating the zeolite with a solution containing a Group VIII metal- or a Group VIII metal-containing ion. The amount of Group VIII metal in the catalyst composition can range from 0.1 to 3 weight percent, preferably from 0.2 to 1 weight percent, based on the total weight of the catalyst composition. The Group VIII metal component can be platinum, palladium, iridium, ruthenium, cobalt, nickel and mixtures thereof. The preferred Group VIII metal is platinum or palladium. The Group VIII metal component of the composition may be used alone or in combination with a metal from Group VI of the Periodic Table of Elements. Examples of metals of Group VI are chromium, molybdenum, tungsten and mixtures thereof. The catalyst composition comprising the zeolite ZSM-22 dewaxing catalyst component and Group VIII metal(s) includes a support material which is matrix or binder component comprising a material resistant to the temperature and other process conditions. Useful matrix materials include both synthetic and naturally occurring substances, as well as inorganic materials such as clay, silica and/or metal oxides. The latter may be either naturally occurring or in the form of gelatinous precipitates or gels including mixtures of silica and metal oxides. Naturally occurring clays which can be composited with the zeolite include those of the montmorillonite and kaolin families, which families include the sub-bentonites and the kaolins commonly known as Dixie, McNamee, Georgia and Florida clays or others in which the main mineral constituent is halloysite, kaolinite, nacrite or anauxite. Such clays can be used in the raw state as originally mined or initially subjected to calcination, acid treatment or chemical modification. In addition to the foregoing materials, the zeolite ZSM-22 employed herein may be composited with a porous matrix material, such as alumina, silica-alumina, silica-magnesia, silica-zirconia, silica-thoria, silica-beryllia, silica-titania as well as ternary compositions such as silica-alumina-thoria, silica-alumina-zirconia, silica-alumina-magnesia and silica-magnesia-zirconia. The matrix can be in the form of a cogel. The relative proportions of zeolite ZSM-22 component and Group VIII metal and support material on an anhydrous basis, may vary widely. The support material content will normally range from 20 to 50 percent by weight or more usually from 25 to 45 percent by weight of the dry composite; preferably the support comprises 30 to 40 percent by weight of the dried composite. The preferred supports of the catalyst composition are alumina, silica and silica-alumina. The Group VIII component associated with ZSM-22 may be on the zeolite component as above-noted or on the matrix component or both. EXAMPLES The charge stock in Comparative Examples 1 and 2 and Example 1 was a hydrocracked stock from Idemitsu having the following properties: In each of the examples, 1.6mm (1/16") extrude catalysts were sized to 14-25 mesh, 5 cc charged to a stainless steel reactor, and reduced with hydrogen at 482°C (900°F), atmospheric pressure, for one hour before introduction of the oil. Standard run conditions were 2859 kPa (400 psig), 1 LHSV (liquid hourly space velocity), 444 Nm³H₂/m³ feed (2500 SCF H₂/bbl), and temperature varied to obtain the desired pour point. Comparative Example 1 A catalyst was prepared by adding Pt(NH₃)₄Cl₂ to 65/35 ZSM-5/Al₂O₃ and extruding the mixture. The ZSM-5 had a SiO₂/Al₂O₃ molar ratio of 70:1 and the final catalyst after calcination in air at 940°C (1000°F) for 3 hours contained 0.50 wt % Pt. The catalytic results with this catalyst are summarized below. Comparative Example 2 A catalyst was prepared by impregnating HZSM-23 extrudate (65/35 zeolite/Al₂O₃), after calcination in air at 540°C (1000°F) for 3 hours, with H₂PtCl₆. The zeolite component was a 114/1 SiO₂/Al₂O₃ ZSM-23 prepared from HiSil and aluminum sulfate. The final catalyst was dried, calcined in air at 482°C (900°F) for an additional 3 hours, and contained 0.56 wt % Pt. Catalytic results with this catalyst are summarized below. Example 1 A ZSM-22 extrudate was prepared as follows. A solution was prepared by mixing one part (by wt) aluminum sulfate, 4.5 parts potassium hydroxide (86% by wt) and 50 parts water. This solution was added to an autoclave. Another solution was prepared by mixing 27.6 parts colloidal silica (30% by wt) and 36 parts water and then this mixture was added to the solution in the autoclave. Six parts of diethylamine hydrochloride was then added and the combined solution was agitated vigorously for approximately one-half hour. The autoclave was heated to 166°C (330°F) with constant stirring and maintained for 72 hours at this temperature. The resultant crystalline material was then filtered and washed on a Buchner funnel and then dried overnight at 121°C (250°F). The X-ray diffraction analysis indicated that this material was ZSM-22. Chemical analysis gave a silica to alumina molar ratio of 82. This zeolite was mixed with alpha-Al₂O₃3H₂O to make a mixture of 65 parts (by wt) zeolite and 35 parts alumina. Enough water was added to the mixture so that the resulting catalyst could be formed into the required extrudates. These extrudates were activated by first calcining in nitrogen at 540°C (1000°F), followed by aqueous exchanges with a 1.0 N ammonium nitrate solution and finally calcining in air at 540°C (1000°F). The extrudate was impregnated with H₂PtCl₆, dried and calcined in air at 482°C (900°F) for 3 hours. The final catalyst contained 0.57 wt % Pt. Catalyst results with this catalyst are summarized below. Comparison of the above examples shows that the Pt/ZSM-5 catalyst is the most active. However, Pt/ZSM-22 is superior to both Pt/ZSM-5 and Pt/ZSM-23 in both lube yield and VI after a two-day lineout, as shown in Figures 2 and 3. The differences, compared at -18°C (0°F) pour point from the figures, are as follows: Example 2 In this example, solvent refined light neutral stock characterized by the following properties was subjected to hydrodewaxing using the catalyst described in Example 1, at 2859 kPa (400 psig), 1 LHSV, 444 Nm³/H₂/m³ feed (2500 SCF H₂/bbl). The results of three runs under such conditions are set forth below: Comparative Example 3 For purposes of comparison, the solvent refined light neutral stock described in Example 2 was subjected to hydrodewaxing conditions described in Example 2 but the catalyst was replaced by a 1.0 wt% Ni/ZSM-5 extrudate, 70 alpha, sulfided in situ . Run results are set forth below: To compare the results of Example 2 and Comparative Example 3, properties of the resulting hydrodewaxed stocks were compared in graphs of Figures 4 and 5 of the drawings. In Figures 4 and 5 lube yield and VI, respectively, are plotted against pour point. It can be seen that, at -12°C (+10°F) pour point, both yield and VI with Pt/ZSM-22 are about 10 numbers higher compared to Ni/ZSM-5.

Claims: 1. A process for hydrodewaxing a hydrocarbon feedstock boiling above about 288°C (550°F), to produce a dewaxed lubricating oil base stock, comprising contacting the feedstock in the presence of hydrogen, with a supported catalyst composition comprising 20 to 50 percent by weight of a support material; 0.1 to 3 weight percent of at least one Group VIII metal and a porous crystalline zeolite having a silica to alumina mole ratio of at least about 20, wherein the zeolite exhibits the X-ray diffraction lines set out in Table A and wherein contact of said feedstock with said supported catalyst composition is effected at a pressure of from 1480 to 10786 kPa (200 psig to 3000 psig); a temperature of from 260°C to 482°C; a feedstock LHSV ranging from 0.2 to 20 and a hydrogen feed rate of 89 to 3560 Nm³ hydrogen/m³ feedstock (500 to 20,000 standard cubic feet of hydrogen per barrel of feedstock). 2. The process of Claim 1, wherein said metal includes platinum. 3. The process of Claim 1 or Claim 2, wherein said support material is alumina. 4. The process of any preceding Claim, which includes the subsequent step of hydrotreating the product resulting from said contacting in the presence of hydrotreating catalyst under hydrotreating conditions including a temperature of from 176°C to 371°C, a pressure of from 6996 to 20786 kPa (1000 to 3000 psig) and a LHSV of from 0.1 to 10. 5. The process of any preceding Claim, wherein the hydrocarbon feedstock is the effluent from a hydrocracking operation in which a hydrocarbon charge is hydrocracked in the presence of a hydrocracking catalyst at hydrocracking conditions including a temperature of from 260°C to 482°C and a pressure of from 6996 to 20786 kPa (1000 to 3000 psig).

Inventors: CHESTER, ARTHUR WARREN, GARWOOD, WILLIAM EVERETT, VARTULI, JAMES CLARKE
Applicants: MOBIL OIL CORPORATION
Application year: 1985
Main classification: C10G45
IPC codes: C10G45, B01J29, C10G65