Dewaxing Catalyst Metal Content Optimization
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Solution Overview
Problem
Existing diesel fuel production methods require additional refinery resources for dewaxing, which increases hydrogen consumption, and existing dewaxing catalysts with higher metal hydrogenation content are inefficient in reducing cloud point effectively.
Innovation Solution
A method using a dewaxing catalyst with a reduced metal hydrogenation component content, specifically 0.03 wt % to 0.35 wt % of Group VIII noble metals, applied to a distillate fuel boiling range feedstock to achieve significant cloud point reduction while minimizing hydrogen consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional dewaxing catalysts with higher metal hydrogenation content are used, then cloud point reduction effectiveness is improved, but hydrogen consumption increases
Solution Approach 1:
The patent changes the metal content parameter of the dewaxing catalyst from traditional higher levels (e.g., 0.5-2.0 wt%) to an optimized lower range (0.03-0.35 wt% for Group VIII noble metals). This parameter change achieves surprising effectiveness in cloud point reduction while simultaneously reducing hydrogen consumption, as the lower metal content catalyst requires less hydrogen for the hydrogenation reactions during dewaxing
Solution Approach 2:
The patent employs composite catalyst formulations combining molecular sieves (such as ZSM-23, ZSM-48, or ZSM-5) with controlled amounts of metal hydrogenation components (Group VIII noble metals like Pt, Pd, or Ir). This composite structure creates synergistic effects where the molecular sieve provides shape-selective cracking and isomerization while the metal component provides hydrogenation activity, achieving effective dewaxing with reduced overall metal content and thus reduced hydrogen consumption
2Reliability
If additional dewaxing process is added to improve cold flow properties, then fuel specification compliance is improved, but refinery resource consumption increases
Solution Approach 1:
The patent optimizes the metal content parameter of the dewaxing catalyst to a lower range (0.03-0.35 wt%), which reduces hydrogen consumption during the dewaxing process. This allows the dewaxing operation to be performed more efficiently, improving cold flow properties and ensuring fuel specification compliance while consuming fewer refinery resources, particularly hydrogen
Solution Approach 2:
The patent uses a dewaxing catalyst with partially reduced metal content compared to traditional catalysts. The metal content is reduced to 0.03-0.35 wt%, which is sufficient to achieve the required cloud point reduction (at least 10°F) and meet fuel specifications, but represents a partial reduction from traditional higher metal content catalysts, thereby reducing hydrogen consumption while maintaining effectiveness
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 method effectively reduces cloud point by at least 10° F. with reduced hydrogen consumption, achieving similar results to higher metal content catalysts under the same conditions, and consumes less hydrogen, thereby optimizing refinery operations.
Implementation Method 1
exposing a distillate fuel boiling range feedstock to a dewaxing catalyst comprising a molecular sieve and a metal hydrogenation component under effective dewaxing conditions to produce a dewaxed effluent having a cloud point that is reduced relative to a cloud point of the feedstock by at least about 10° F.
Implementation Method 2
the dewaxing catalyst having an amount of metal hydrogenation component comprising about 0.03 wt % to about 0.35 wt %, or about 0.05 wt % to about 0.35 wt % of a Group VIII noble metal
Data Source
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, with reduced consumption of hydrogen during the dewaxing process. The reduced hydrogen consumption is achieved by using a dewaxing catalyst with a reduced content of hydrogenation metals, such as a content of Pt or Pd of from about 0.03 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.