Colloidal Catalyst Hydroprocessing Heavy Oil
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Solution Overview
Problem
Conventional hydroprocessing systems face challenges in efficiently upgrading heavy oil feedstocks rich in asphaltenes due to catalyst fouling, low conversion levels, and equipment instability, particularly in processing vacuum tower bottoms and other low-grade feedstocks.
Innovation Solution
The use of colloidal or molecular hydroprocessing catalysts dispersed throughout the feedstock, which catalyze reactions with asphaltene radicals to prevent coke and sediment formation, allowing for higher conversion levels and reduced fouling, combined with a hot separation process to maintain efficient processing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional supported catalysts are used for hydroprocessing heavy oil, then hydrocracking and hydrotreatment can occur, but catalyst fouling by coke precursors and sediment increases, reducing catalyst life and reliability
Solution Approach 1:
The invention changes the physical state and size parameters of the catalyst from conventional macro-supported catalysts to colloidal or molecular-sized catalysts. This parameter change allows the catalyst to remain dispersed in the feedstock without fouling, maintaining both high conversion levels and extended catalyst life by preventing coke and sediment deposition on catalyst surfaces
Solution Approach 2:
The invention extracts the catalyst from the traditional supported catalyst format and presents it as free-standing colloidal or molecular catalysts that are inherently resistant to fouling. By removing the support structure that is susceptible to coke deposition, the catalyst maintains reliability while preserving hydroprocessing activity
2Productivity
If conventional catalysts process heavy oil with high asphaltene content, then some conversion can be achieved, but equipment fouling increases and processing stability decreases
Solution Approach 1:
The invention converts the harmful effect of asphaltenes, which normally cause fouling and instability, into a beneficial process. The colloidal or molecular catalysts specifically interact with asphaltene radicals during hydrocracking, stabilizing them through hydrogenation reactions and preventing the formation of harmful coke and sediment, thereby converting a problematic feedstock component into a manageable intermediate
3Productivity
If higher conversion levels are pursued to upgrade heavy oil, then more valuable products are produced, but coke and sediment formation increases, worsening equipment fouling
Solution Approach 1:
The invention introduces a feedback mechanism where the colloidal or molecular catalysts continuously monitor and respond to the formation of harmful species. As asphaltenes undergo hydrocracking at high conversion levels, the catalysts immediately hydrogenate the resulting radicals, preventing coke and sediment formation. This feedback loop allows high conversion to proceed without the usual increase in harmful byproducts
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 enables increased conversion levels, reduced equipment fouling, and more efficient processing of heavy oil feedstocks, including those with high asphaltene content, by effectively upgrading asphaltenes and maintaining reactor stability, thereby extending catalyst life and reducing maintenance needs.
Implementation Method 1
The invention relates to hydroprocessing systems that employ a colloidal or molecular hydroprocessing catalyst that promotes hydrocracking and hydrotreatment of heavy oil feedstocks
Implementation Method 2
colloidal or molecular hydroprocessing catalysts dispersed throughout the feedstock, which catalyze reactions with asphaltene radicals to prevent coke and sediment formation
Data Source
AI summary
Methods and systems for hydroprocessing heavy oil feedstocks to form an upgraded material involve the use of a colloidal or molecular catalyst dispersed within a heavy oil feedstock, a hydrocracking reactor, and a hot separator. The colloidal or molecular catalyst promotes hydrocracking and other hydroprocessing reactions within the hydrocracking reactor. The catalyst is preferentially associated with asphaltenes within the heavy oil feedstock, which promotes upgrading reactions involving the asphaltenes rather than formation of coke precursors and sediment. The colloidal or molecular catalyst overcomes problems associated with porous supported catalysts in upgrading heavy oil feedstocks, particularly the inability of such catalysts to effectively process asphaltene molecules. The result is one or more of reduced equipment fouling, increased conversion level, and more efficient use of the supported catalyst if used in combination with the colloidal or molecular catalyst.