Dewaxing Catalyst Metal Content for Low Cloud Point Diesel
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Solution Overview
Problem
Current hydroprocessing methods for producing diesel and jet fuels require additional refinery resources and consume more hydrogen due to the need for dewaxing, which is not efficiently addressed by existing catalysts with high metal content.
Innovation Solution
A method involving a dewaxing catalyst with a reduced hydrogenation metal content, specifically 0.03 wt% to 0.35 wt% Pt or Pd, is used to process a distillate fuel feedstock with low sulfur and nitrogen content, achieving significant cloud point reductions and producing both arctic diesel and jet fuels with low freeze points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional dewaxing catalysts with high metal content are used, then cloud point reduction is achieved, but hydrogen consumption increases and refinery resources are consumed
Solution Approach 1:
The patent changes the metal content parameter of the dewaxing catalyst from traditional high levels (typically 0.5-2.0 wt%) to a reduced level of 0.03-0.35 wt% Pt or Pd. This parameter change maintains effective cloud point reduction (reducing cloud point by at least 25°F or 14°C) while significantly reducing hydrogen consumption and refining resource requirements.
2Manufacturing precision
If additional dewaxing process is performed to improve cold flow properties, then diesel fuel meets desired specification, but additional refinery resources are consumed
Solution Approach 1:
The patent modifies the catalyst metal content parameter to achieve effective dewaxing with reduced resource consumption. The reduced metal content catalyst (0.03-0.35 wt% Pt or Pd) produces diesel fuel meeting cold flow specifications (cloud point reduction of at least 25°F) while improving refinery resource efficiency and reducing additional processing requirements.
3Manufacturing precision
If high metal content dewaxing catalysts are used, then cloud point reduction is achieved, but metal usage increases
Solution Approach 1:
The patent fundamentally changes the metal content parameter from traditional high levels to a reduced level of 0.03-0.35 wt% Pt or Pd. This parameter optimization achieves the required cloud point reduction (at least 25°F or 14°C) while minimizing precious metal consumption and reducing catalyst cost.
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 reduces hydrogen consumption and achieves cloud point reductions of up to 120°C, allowing for the simultaneous production of arctic diesel and low-freeze-point jet fuels, outperforming traditional processes in efficiency and metal usage.
Implementation Method 1
exposing a distillate fuel boiling range feedstock having a sulfur content of less than about 10 wppm and a nitrogen content of less than about 5 wppm to a dewaxing catalyst comprising a molecular sieve and a Group VIII noble metal hydrogenation component under effective dewaxing conditions
Implementation Method 2
exposing a distillate fuel boiling range feedstock having a sulfur content of less than about 10 wppm and a nitrogen content of less than about 5 wppm to a dewaxing catalyst comprising a molecular sieve
Implementation Method 3
fractionating the dewaxed effluent to produce at least a diesel fuel product having a cloud point of about -4°F (-20°C) or less and a distillate product having a lower boiling range than the diesel fuel product
Data Source
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AI summary
Methods are provided for dewaxing a distillate fuel boiling range feed to improve one or more cold flow properties of the distillate fuel feed, such as cloud point, where the distillate fuel feed is fractionated to produce both a jet fuel product and an arctic diesel fuel product. The decrease of cloud point is achieved by using a feedstock having a concentration of nitrogen of less than about 50 wppm and a concentration of sulfur of less than about 15 wppm. Further, the dewaxing catalyst may have a reduced content of hydrogenation metals, such as a content of Pt or Pd of from about 0.05 wt% to about 0.35 wt%. A distillate fuel feed can be dewaxed to achieve a desired cloud point differential using a reduced metals content dewaxing catalyst under the same or similar conditions to those required for a dewaxing catalyst with higher metals content.