Bulk Catalyst Composition Segmentation for Hydroprocessing
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Solution Overview
Problem
The production of trimetallic bulk catalysts comprising two or more Group VIB metals and one or more Group VIII metals is complex and inflexible, leading to reduced production capacity and increased waste when switching between different catalyst compositions, with prior art processes requiring frequent downtime and difficulties in recycling precious metals.
Innovation Solution
A bulk catalyst composition comprising separately prepared metal oxidic particles with different Group VIB and Group VIII metal compositions, specifically molybdenum and tungsten, are shaped and blended to form a homogeneous or layered mixture with varying ratios, allowing for flexible and efficient production of high-activity catalysts without the need for frequent process changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single production process is used for trimetallic bulk catalysts, then manufacturing simplicity is maintained, but production capacity is reduced and downtime increases when switching between different catalyst compositions
Solution Approach 1:
The production process is segmented into separate production lines for different catalyst compositions (e.g., NiMo and NiW catalysts are produced separately). This allows each line to be optimized for its specific composition while enabling flexible switching between compositions without disrupting the entire production process, thereby increasing overall production capacity.
Solution Approach 2:
The invention creates a universal production system that can handle multiple catalyst compositions through standardized mixing and shaping equipment. The common infrastructure (mixers, extruders, pelletizers) serves multiple functions by accepting different metal oxide combinations, reducing the need for dedicated equipment for each catalyst type and improving productivity.
2Adaptability or versatility
If frequent process changes are made to produce different catalyst compositions, then product versatility is improved, but production downtime increases and waste increases
Solution Approach 1:
By segmenting the production process into separate dedicated lines for different catalyst compositions, the system can switch between compositions by activating different lines rather than reconfiguring a single line. This reduces downtime and eliminates the need to clean and reconfigure equipment between production runs of different catalyst types.
Solution Approach 2:
The invention prepares metal oxide powders and their mixtures in advance in standardized containers that are fed directly into the shaping equipment. This preliminary preparation eliminates the need for on-site mixing and configuration changes, allowing rapid switching between catalyst compositions without downtime.
3Reliability
If traditional trimetallic bulk catalyst production is used, then high catalytic activity is achieved, but metal recovery and recycling become difficult
Solution Approach 1:
The catalyst particles are segmented into distinct groups based on their metal composition (e.g., NiMo particles separate from NiW particles). This segmentation is achieved through different production lines that create particles with different physical or chemical properties, enabling easy separation and recovery of individual metal components for recycling.
Solution Approach 2:
Different regions or batches of catalyst particles are given different local qualities in terms of metal composition. By controlling the local composition during the shaping process, the invention creates distinguishable particle characteristics that facilitate the recovery and recycling of specific metals from the catalyst mixture.
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 results in a catalyst with comparable or superior activity to traditional trimetallic catalysts, enabling optimized production runs, reduced downtime, and easier recovery of Group VIB metals, while maintaining high catalytic performance in hydroprocessing applications.
Implementation Method 1
combining and reacting at least one group VIII metal compound in solution with at least two group VIB metal compounds in solution in a reaction mixture to obtain a precipitate
Implementation Method 2
one or more metal compounds remains at least partly in the solid state during the entire process
Data Source
AI summary
The invention relates to a bulk catalyst composition comprising metal oxidic particles comprising one or more Group VIII metals and two or more Group VIB metals, which bulk catalyst composition comprises first metal oxidic particles comprising one or more first Group VIII metals and one or more first Group VIB metals separately prepared second metal oxidic particles comprising one or more second Group VIII metals and one or more second Group VIB metals, wherein the composition of Group VIB and Group VIII metals in the first and second metal oxidic particles are different, wherein the first and second oxidic bulk particles are separately shaped to separate first and second shaped bulk catalyst particles, which are combined, preferably into a homogenous blend to form the bulk catalyst composition. The invention further relates to a process for the preparation of the bulk catalyst composition and to hydroprocessing a hydrocarbon feed using the bulk catalyst composition.