Coated Hydroprocessing Catalyst Precursor Management
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Solution Overview
Problem
Conventional hydroprocessing catalysts require excessive use of catalyst activation and deactivation precursors, which can lead to inefficiencies and increased costs in refining processes, as they need to be constantly supplied and managed within refinery processes.
Innovation Solution
A coated hydroprocessing catalyst is developed, featuring a porous support with metals from IUPAC Groups 6, 9, and 10, loaded with sulfur and nitrogen compounds as catalyst activation and deactivation agents, encapsulated within a polymer or paraffinic oil coating layer, reducing the need for supplemental precursors by slowing desorption and decomposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sulfidation treatments are used to activate metal components in hydroprocessing catalysts, then the catalyst achieves catalytic activity, but excessive amounts of catalyst activation precursor are required and must be continuously supplied
Solution Approach 1:
The catalyst activation precursor (sulfur compound) is loaded onto the catalyst support before use, and the coating layer is applied in advance to encapsulate it. This preliminary preparation allows the precursor to be released slowly during catalyst operation, eliminating the need for continuous external supply and reducing the total quantity required.
Solution Approach 2:
The coating layer acts as an intermediary between the catalyst activation precursor and the external environment. It controls the release rate of the precursor, providing a steady supply to the metal components while preventing excessive loss, thus reducing the overall quantity of precursor needed.
2Reliability
If catalyst activation and deactivation precursors are continuously supplied in refinery processes, then catalyst activity is maintained, but process complexity and costs increase
Solution Approach 1:
The catalyst becomes self-sufficient by containing its own activation and deactivation precursors within the coating layer. The catalyst automatically regulates its own activity state through controlled release of these precursors, eliminating the need for external process management and reducing refinery process complexity.
Solution Approach 2:
Both activation and deactivation precursors are pre-loaded onto the catalyst before deployment. This preliminary action allows the catalyst to autonomously manage its activity cycle without requiring continuous external intervention, simplifying refinery process management.
3Reliability
If catalyst precursors are frequently supplemented, then catalyst effectiveness is maintained, but process efficiency decreases and costs increase
Solution Approach 1:
The coating layer enables continuous, controlled release of catalyst precursors over extended periods, maintaining constant catalyst effectiveness without interruption. This continuous action eliminates the need for frequent supplementation and improves overall process efficiency.
Solution Approach 2:
Large quantities of catalyst precursors are pre-loaded onto the catalyst support in advance, creating a reservoir that can sustain catalyst activity over long periods. This preliminary loading reduces the frequency of supplementation operations and improves productivity.
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 solution enhances catalytic activity while minimizing the requirement for catalyst precursors, thereby improving process efficiency and reducing costs by maintaining catalyst effectiveness over a longer period without the need for frequent supplementation.
Implementation Method 1
a coating layer on a surface of the hydroprocessing catalyst, the coating layer encapsulating the catalyst activation agent, the catalyst deactivation agent, or both within the hydroprocessing catalyst
Implementation Method 2
the catalyst is contacted with a sulfur compound (catalyst activation precursor) outside the reactor and the metal is converted into the metal sulfide
Implementation Method 3
a catalyst activation agent, a catalyst deactivation agent, or both loaded onto pores of the porous support
Data Source
AI summary
Embodiments of the present disclosure are directed to a coated hydroprocessing catalyst comprising: a hydroprocessing catalyst comprising a porous support and at least one metal supported on the porous support; wherein the porous support comprising silica, alumina, titania, or combinations thereof; and the at least one metal selected from IUPAC Groups 6, 9 and 10 metals; a catalyst activation agent, a catalyst deactivation agent, or both loaded onto pores of the porous support, the catalyst activation agent comprising at least one sulfur compound and the catalyst deactivation agent comprising at least one nitrogen compound; and a coating layer on a surface of the hydroprocessing catalyst, the coating layer encapsulating the catalyst activation agent, the catalyst deactivation agent, or both within the hydroprocessing catalyst, wherein the coating layer comprises a polymer, or a paraffinic oil.