Alkali Metal Catalyst for Heavy Hydrocarbon Gasification
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Solution Overview
Problem
Current processes are inadequate for converting lower-value liquid heavy hydrocarbon materials into higher-value gaseous products, such as light olefins and alkanes, with existing methods either utilizing only lighter portions of the feedstock or producing unsaturated compounds that are detrimental in gasoline products.
Innovation Solution
A process involving dispersing liquid heavy hydrocarbon materials in a gaseous carrier, introducing a superheated gas stream with steam, carbon monoxide, and hydrogen into a reactor with an alkali metal-impregnated carbonaceous carrier, and optionally adding an oxygen-rich stream to generate heat and syngas, resulting in a gaseous product stream containing methane, ethylene, propylene, ethane, and propane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If liquid heavy hydrocarbon materials are converted to gaseous products via existing catalytic gasification processes, then methane and synthesis gas are produced, but light olefins are not generated and the product value is limited
Solution Approach 1:
The patent changes the reaction parameters by operating at elevated temperatures (1100-1400°F) and using a specific catalyst composition (alkali metal-impregnated carbonaceous carrier) to shift the product distribution from primarily methane and synthesis gas to include significant amounts of light olefins (ethylene, propylene) and alkanes, thereby increasing product value and variety
Solution Approach 2:
The patent employs a composite catalyst system consisting of alkali metals (such as potassium, sodium, or cesium) impregnated on a carbonaceous carrier, which combines the catalytic activity for hydrocarbon conversion with the ability to produce a diverse range of gaseous products including light olefins, alkanes, and synthesis gas
2Productivity
If thermal decomposition is used to convert liquid heavy hydrocarbons, then cracked liquid and gas products are obtained, but solid petroleum coke is also produced and liquid products require extensive hydrogen treatment
Solution Approach 1:
The patent converts the typically harmful coke formation and contamination associated with thermal decomposition into beneficial effects by using controlled catalytic gasification with alkali metal catalysts that promote complete conversion to gaseous products while managing coke deposition, thereby eliminating the need for extensive downstream hydrogen treatment and improving overall conversion efficiency
Solution Approach 2:
The patent introduces an alkali metal-impregnated carbonaceous carrier as an intermediary catalyst that mediates the conversion of liquid heavy hydrocarbons to gaseous products, controlling the reaction pathway to produce valuable light olefins and alkanes while minimizing harmful coke formation and eliminating the need for subsequent hydrogen treatment
3Productivity
If lighter portions of atmospheric petroleum residue are used in thermal cracking processes, then olefins are generated, but significant amounts of additional residue material are left unutilized
Solution Approach 1:
The patent applies a universal catalytic gasification process using alkali metal-impregnated carbonaceous carriers that can handle the entire spectrum of liquid heavy hydrocarbon feedstocks (including heavy vacuum residue and atmospheric petroleum residue), converting all portions of the feedstock into valuable gaseous products (light olefins, alkanes, and synthesis gas) rather than leaving significant residue unutilized
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This process effectively converts lower-value liquid heavy hydrocarbons into higher-value gaseous products, including significant amounts of light olefins and alkanes, while managing coke formation and syngas balance, thereby enhancing the value of the product mix.
Implementation Method 1
contacting the dispersed heavy hydrocarbon feed with steam, carbon monoxide and hydrogen in the presence of the bed of the alkali metal-impregnated carbonaceous carrier, at an elevated pressure and at a temperature of from about 1100° F. to about 1400° F.
Implementation Method 2
introducing a superheated gas feed stream comprising heat energy and steam
Implementation Method 3
contacting the dispersed heavy hydrocarbon feed with steam, carbon monoxide and hydrogen in the presence of the bed of the alkali metal-impregnated carbonaceous carrier
Data Source
AI summary
The present invention relates to processes and apparatuses for generating light olefins, methane and other higher-value gaseous hydrocarbons from “liquid” heavy hydrocarbon feedstocks.