Aromatic Saturation Catalyst for Hydrocracking
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Solution Overview
Problem
Current hydrocracking processes face challenges in efficiently producing both naphtha and distillate fuels with improved properties and yields, as they often require severe reaction conditions and struggle to balance aromatic saturation and hydrocracking steps, leading to suboptimal product distributions and increased energy consumption.
Innovation Solution
The method involves exposing a feedstock with high aromatics content to an aromatic saturation catalyst containing a Group VIII noble metal, followed by hydrocracking with a catalyst comprising Group VIB and Group VIII non-noble metals, optimizing conditions to reduce severity and enhance conversion while increasing the yield and quality of naphtha and distillate fuels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If severe reaction conditions are used to achieve high conversion in hydrocracking, then conversion rate improves, but energy consumption increases and product quality deteriorates due to increased thermal cracking
Solution Approach 1:
The patent changes the chemical parameters by introducing an aromatic saturation catalyst upstream of the hydrocracking catalyst. This pre-saturation of aromatics modifies the feed composition, allowing hydrocracking to proceed under less severe conditions while maintaining high conversion rates and reducing energy consumption.
Solution Approach 2:
The patent applies preliminary aromatic saturation before hydrocracking. By saturating aromatics in advance, the feed is prepared in a way that reduces the severity required for subsequent hydrocracking, thereby lowering energy consumption and minimizing thermal cracking side reactions.
2Productivity
If severe reaction conditions are applied to increase conversion, then productivity improves, but product quality worsens due to increased thermal cracking
Solution Approach 1:
The patent applies preliminary aromatic saturation before hydrocracking. By saturating aromatics in advance, the feed is prepared in a way that reduces the severity required for subsequent hydrocracking, thereby lowering energy consumption and minimizing thermal cracking side reactions.
Solution Approach 2:
The patent changes the chemical parameters by introducing an aromatic saturation catalyst upstream of the hydrocracking catalyst. This pre-saturation of aromatics modifies the feed composition, allowing hydrocracking to proceed under less severe conditions while maintaining high conversion rates and reducing energy consumption.
3Device complexity
If a single catalyst is used for both aromatic saturation and hydrocracking, then device complexity is reduced, but catalytic performance deteriorates due to inability to optimize each function separately
Solution Approach 1:
The patent segments the catalytic function into two separate catalysts: an aromatic saturation catalyst and a hydrocracking catalyst. This segmentation allows each catalyst to be optimized for its specific function, with the saturation catalyst containing noble metals for aromatic hydrogenation and the hydrocracking catalyst containing base metals for cracking reactions.
Solution Approach 2:
The aromatic saturation catalyst acts as an intermediary between the feed and the hydrocracking catalyst. It pre-processes the feed by saturating aromatics, creating an optimized feedstock for the subsequent hydrocracking step, thereby enhancing overall process performance.
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 approach allows for the production of fuels with improved octane ratings, reduced aromatics content, and increased yields of branched C4 alkanes, leading to more valuable products and reduced thermal cracking, thus enhancing the overall efficiency and product quality of the hydrocracking process.
Implementation Method 1
exposing a feedstock having a T50 boiling point of at least about 430° F. (221° C.), a first aromatics content of at least about 5 wt %, and a sulfur content of about 500 wppm or less to an aromatic saturation catalyst comprising a Group VIII noble metal under effective aromatic saturation conditions to produce an aromatic saturation effluent, the aromatic saturation effluent having a second aromatics content of less than about 10 wt %
Implementation Method 2
exposing at least a portion of the aromatic saturation effluent to a hydrocracking catalyst under effective hydrocracking conditions to produce a hydrocracked effluent, the effective hydrocracking conditions being effective for converting at least about 5 wt % of the at least a portion of the aromatic saturation effluent
Data Source
AI summary
Systems and methods are provided for producing an improved product slate during hydrocracking of a feedstock for production of naphtha and distillate fuels. The methods can include use of stacked beds and/or sequential reactors so that a feedstock is exposed to a suitable catalyst under aromatic saturation conditions prior to exposing the feedstock to the hydrocracking catalyst. The catalyst for performing the aromatic saturation process can be a catalyst including a Group VIII noble metal, such as Pt, Pd, or a combination thereof, while the hydrocracking catalyst can include Group VIB and Group VIII non-noble metals.