Base Metal Isomerization Catalyst for Low-Hydrogen Biofeed Processing
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Solution Overview
Problem
Existing refinery systems face challenges in efficiently processing bio-derived feedstocks due to high oxygen content and long alkyl groups, leading to increased hydrogen consumption and reactor volume requirements, which are not adequately addressed by current dewaxing and deoxygenation methods.
Innovation Solution
The use of a base metal isomerization catalyst with a zeolitic framework structure and a dispersion agent, combined with a bulk multimetallic catalyst, to reduce hydrogen consumption and minimize light ends formation during isomerization and deoxygenation of bio-derived feedstocks, allowing for integration in a single reactor without intermediate separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional dewaxing and deoxygenation methods are used to process bio-derived feedstocks, then cold flow properties can be improved, but hydrogen consumption increases and reactor volume requirements increase
Solution Approach 1:
The patent combines dewaxing and deoxygenation functions into a single catalyst system containing Group 6 metals (Mo, W) and Group 8-10 metals (Ni, Co, Fe) on a zeolite support. This merged catalyst performs both isomerization/dewaxing and deoxygenation simultaneously, reducing the need for separate processing units and minimizing overall hydrogen consumption while maintaining improved cold flow properties.
Solution Approach 2:
The invention uses a composite catalyst material comprising multiple metal components (Group 6 and Group 8-10 metals) supported on a zeolite framework. This composite structure provides synergistic effects where the zeolite contributes to isomerization activity and the metal components provide deoxygenation activity, achieving both dewaxing and deoxygenation in one unit with reduced hydrogen requirements.
2Stability of the object's composition
If conventional dewaxing and deoxygenation methods are used to process bio-derived feedstocks, then cold flow properties can be improved, but reactor volume requirements increase
Solution Approach 1:
The patent combines dewaxing and deoxygenation functions into a single catalyst system containing Group 6 metals (Mo, W) and Group 8-10 metals (Ni, Co, Fe) on a zeolite support. This merged catalyst performs both isomerization/dewaxing and deoxygenation simultaneously, reducing the need for separate processing units and minimizing overall hydrogen consumption while maintaining improved cold flow properties.
3Ease of manufacture
If base metal catalysts are used for isomerization, then catalyst cost is reduced, but catalyst activity and selectivity must be maintained
Solution Approach 1:
The invention uses a composite catalyst material comprising multiple metal components (Group 6 and Group 8-10 metals) supported on a zeolite framework. This composite structure provides synergistic effects where the zeolite contributes to isomerization activity and the metal components provide deoxygenation activity, achieving both dewaxing and deoxygenation in one unit with reduced hydrogen requirements.
Solution Approach 2:
The patent optimizes the ratio of Group 6 to Group 8-10 metals and adjusts the metal loading on the zeolite support to achieve optimal catalytic performance. By carefully controlling these parameters, the catalyst maintains high activity and selectivity for isomerization and deoxygenation reactions while using cost-effective base metals instead of noble metals.
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 enhances catalyst activity and selectivity, reduces hydrogen consumption, and minimizes reactor volume, improving the efficiency and cost-effectiveness of processing bio-derived feedstocks while maintaining cold flow properties of the resulting distillate fuels.
Implementation Method 1
exposing a feed that includes a bio-derived feedstock to an isomerization catalyst that includes a zeolitic framework structure, at least one Group 6 metal, and at least one Group 8-10 metal under isomerization conditions to form an isomerized effluent
Implementation Method 2
a catalyst that includes a zeolitic framework structure
Data Source
AI summary
An isomerization catalyst is provided, along with corresponding systems and methods, which provides improved isomerization for bio-derived feeds in reaction environments where by-products from deoxygenation are present. The catalyst provides unexpectedly increased activity and/or selectivity in situations where, for example, a deoxygenation effluent is cascaded to the isomerization catalyst. Additionally, the isomerization catalyst can assist with reducing or minimizing hydrogen consumption during isomerization. The increased activity, stability, and/or reduced hydrogen consumption is achieved in part based on using a dispersion agent when adding base metals to the catalyst. In addition to the base metals, the catalyst includes a zeolitic framework structure suitable for isomerization.