Catalyst Cycle Length Prediction for Hydrocracking Control

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Solution Overview

Problem

Catalysts in hydrocracking processes become deactivated over time due to coke deposition, leading to unpredictable replacement schedules and inefficiencies, as existing methods lack effective monitoring and control for predicting catalyst life and optimizing operational parameters.

Innovation Solution

A system comprising sensors, data collection, analysis, and control platforms that monitor operating information, analyze reactant conversion, and adjust operational parameters to extend or accelerate catalyst life by predicting catalyst cycle length and manipulating process variables such as temperature, pressure, and feedstock composition.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If catalyst is used in hydrocracking process, then reactant conversion and process efficiency are improved, but catalyst becomes deactivated over time due to coke deposition requiring replacement

Engineering Contradiction:

Improvereactant conversionVSAvoidcatalyst life

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system performs preliminary analysis of operational data to predict catalyst cycle length before complete deactivation occurs. By monitoring trends in reactant conversion and operational parameters over time, the system predicts when catalyst will become ineffective, allowing proactive replacement scheduling that prevents process disruptions while maximizing catalyst utilization.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors operational data including reactant conversion rates, temperature, pressure, and other parameters, then uses this feedback to update catalyst life predictions. The predicted cycle length information feeds back to operators to optimize replacement timing, creating a closed-loop system that adapts to actual catalyst performance rather than relying on fixed schedules.

Inventive Principle:

Principle #23Feedback

2Reliability

If catalyst replacement is performed on fixed schedule, then equipment reliability is maintained, but premature replacement occurs leading to increased costs and reduced productivity

Engineering Contradiction:

Improveprocess reliabilityVSAvoidoperational efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system changes the approach from fixed-time replacement to condition-based replacement by analyzing multiple operational parameters including reactant conversion rates, temperature profiles, pressure drops, and feed composition variations. These parameter changes enable dynamic adjustment of replacement timing based on actual catalyst performance rather than predetermined schedules.

Inventive Principle:

Principle #35Parameter changes

3Duration of action of stationary object

If operational parameters are adjusted to extend catalyst life, then catalyst cycle length is increased, but process efficiency and reactant conversion may be affected

Engineering Contradiction:

Improvecatalyst cycle lengthVSAvoidprocess efficiency

Core Design Contradiction:

Duration of action of stationary objectVSProductivity

Solution Approach 1:

The system dynamically adjusts operational parameters based on real-time catalyst condition assessment. As catalyst ages and conversion efficiency naturally declines, the system optimizes temperature, pressure, and feed rate parameters to compensate and maintain overall process efficiency while extending catalyst life. This dynamic optimization allows the system to adapt to catalyst degradation without sacrificing productivity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Inventive Principle:

Principle #35Parameter changes

4Measurement precision

If advanced monitoring systems are implemented to predict catalyst life, then replacement timing precision is improved, but system complexity and initial costs increase

Engineering Contradiction:

Improvecatalyst life prediction accuracyVSAvoidsystem complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The system uses existing operational data and standard process control instruments to perform catalyst life prediction without requiring additional specialized sensors or complex external monitoring equipment. By leveraging data already collected during normal plant operation and applying analytical methods to this existing information, the system achieves accurate predictions while avoiding the complexity and cost of dedicated monitoring hardware.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS10913905B2Catalyst cycle length prediction using eigen analysis

Publication Date: 2021.02.09 UOP LLC

AI summary

Systems and methods are disclosed for managing the operation of a plant, such as a chemical plant or a petrochemical plant or a refinery, and more particularly for enhancing system performance of a catalyzed reaction system by, among other features, detecting catalyst deactivation and cycle length. Plants may include those that provide hydrocarbon cracking or other process units. A plant may include a reactor, a heater, a catalyst bed, a separator, and other equipment. The equipment may use catalyst to treat feed products to remove compounds and produce different products. Catalysts used in the various reactors in these processes become deactivated over time. Systems and methods are disclosed for extending catalyst life and thereby improving efficiency of the plant.