Catalyst Composition for Heavy Hydrocarbon Conversion
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Solution Overview
Problem
Current catalyst compositions for hydroprocessing of heavy hydrocarbon feedstocks face challenges in achieving high conversion of pitch and micro carbon residue (MCR) while minimizing sediment formation and maintaining catalytic activity, with existing technologies often requiring complex impregnation processes and higher molybdenum content.
Innovation Solution
A calcined co-mulled agglomerate catalyst composition with a molybdenum content of 7.5-11 wt% and a nickel-to-molybdenum weight ratio of 0.27-0.8, combined with a high surface area and specific pore size distribution, is used for hydroconversion, which is more economical and effective in converting pitch and MCR with minimal sediment formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If higher molybdenum content is used in the catalyst, then catalytic activity for pitch conversion is improved, but catalyst cost and complexity increase
Solution Approach 1:
The patent changes the chemical composition parameters by reducing molybdenum content from traditional high levels (14.5-24 wt%) to lower levels (7.5-11 wt%), while simultaneously adjusting nickel content and the NiO/MoO3 weight ratio (0.27-0.8) to achieve optimal catalytic performance with reduced material quantity
Solution Approach 2:
The patent creates a composite catalyst system combining nickel and molybdenum oxides on an alumina support with a specific weight ratio relationship, where the synergistic interaction between the two metals compensates for the reduced molybdenum content while maintaining high pitch conversion activity
2Productivity
If complex impregnation processes are used to achieve high conversion, then catalytic performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the catalyst preparation steps by combining nickel and molybdenum compounds in a single co-mulling operation followed by one calcination step, eliminating the need for separate impregnation steps and reducing manufacturing complexity while achieving the desired catalyst composition and performance
3Productivity
If high conversion of pitch and MCR is achieved, then process efficiency is improved, but sediment formation increases
Solution Approach 1:
The patent optimizes the chemical composition parameters (lower molybdenum, adjusted nickel content, specific NiO/MoO3 ratio) and physical parameters (high surface area of 240-400 m2/g, controlled pore size distribution) to achieve a balance where high pitch and MCR conversion occurs while minimizing unwanted side reactions that lead to sediment formation
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
The catalyst composition exhibits high activity in converting pitch and MCR with reduced sediment formation, offering improved catalytic performance and process efficiency compared to traditional methods, despite lower molybdenum content and higher nickel content relative to molybdenum.
Implementation Method 1
a high surface area composition for use in the catalytic hydroconversion of a heavy hydrocarbon feedstock
Data Source
AI summary
A catalyst composition that is especially useful in the hydroconversion of pitch, micro carbon residue and sulfur contents of a heavy hydrocarbon feedstock without the excessive formation of sediment. The catalyst composition is a reasonably high surface area composition containing alumina and a low molybdenum content with a high ratio of nickel-to-molybdenum. The catalyst composition further has a unique pore distribution that in combination with the special metals loading provide for good conversion of pitch and micro carbon residue without an excessive yield of sediment.