Encapsulated Hydroprocessing Catalyst Precursor Management
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Solution Overview
Problem
Conventional hydroprocessing catalysts require excessive use of catalyst activation and deactivation precursors, leading to inefficiencies and catalyst deactivation, as they need to be constantly supplied and managed within refinery processes.
Innovation Solution
Encapsulating catalyst activation and deactivation precursors onto the pores of hydroprocessing catalysts using a coating layer composed of polymers or paraffinic oil, reducing the need for supplemental precursors and slowing down their desorption or decomposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sulfidation treatments (ex-situ or in-situ) are used to activate metal components, then the catalyst achieves catalytic activity, but excessive supply of catalyst activation precursor is required and continuous management within refinery process is needed
Solution Approach 1:
The catalyst activation precursor (sulfur compound) and deactivation precursor (nitrogen compound) are loaded onto the catalyst support in advance during the manufacturing process, before the catalyst is deployed in the refinery. This preliminary loading eliminates the need for continuous supply and management of these precursors during catalyst operation, as they are already positioned on the catalyst structure ready for activation and deactivation cycles.
Solution Approach 2:
The catalyst structure itself serves as the storage medium for both activation and deactivation precursors. The support material is designed to hold these precursor compounds, allowing the catalyst to self-regulate its activation state without external intervention. The catalyst essentially serves itself by containing the necessary chemicals for its own activation and deactivation.
2Reliability
If catalyst activation precursor is continuously supplied to maintain catalytic activity, then the catalyst remains active, but catalyst deactivation occurs due to excess precursor supply
Solution Approach 1:
Both activation and deactivation precursors are pre-loaded onto the catalyst in controlled amounts during manufacturing. This preliminary action ensures that the catalyst has access to activation precursor when needed, while also having deactivation precursor available to prevent excessive accumulation that would lead to deactivation. The balance is established in advance rather than through continuous external supply.
Solution Approach 2:
The catalyst is designed to undergo cyclic activation and deactivation processes. After serving its function, the catalyst can be deactivated using the pre-loaded nitrogen compound, allowing for regeneration and extended lifespan. This cyclic process prevents permanent deactivation by enabling controlled recovery phases.
3Adaptability or versatility
If catalyst activation precursor and deactivation precursor are brought into refinery process continuously, then catalyst can be activated and deactivated, but process complexity and management burden increase
Solution Approach 1:
The catalyst support structure is merged with the precursor storage function. Instead of having separate supply systems for activation and deactivation precursors, the support material itself serves as the reservoir for both compounds. This integration eliminates complex external supply infrastructure and simplifies the overall system architecture.
Solution Approach 2:
The catalyst becomes self-sufficient by containing its own activation and deactivation precursors. The catalyst structure performs the dual function of catalysis and precursor storage, eliminating the need for external management systems. This self-service capability dramatically reduces process complexity while maintaining full adaptability for activation and deactivation cycles.
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 enhances catalytic activity by maintaining the effectiveness of the catalysts over time without the need for continuous precursor supply, thereby improving the efficiency and longevity of hydroprocessing catalysts.
Implementation Method 1
applying a catalyst activation precursor comprising a sulfur containing compound, a catalyst deactivation precursor comprising a nitrogen containing compound, or both onto pores of the hydroprocessing catalyst to form a loaded hydroprocessing catalyst
Data Source
AI summary
Embodiments of the present disclosure are directed to a method of producing an encapsulated hydroprocessing catalyst comprising: preparing a hydroprocessing catalyst comprising a porous support and at least one metal supported on the porous support, the porous support comprising alumina, silica, titania, or combinations thereof, and the at least one metal selected from IUPAC Groups 6, 9 and 10 metals; applying a catalyst activation precursor comprising a sulfur containing compound, a catalyst deactivation precursor comprising a nitrogen containing compound, or both onto pores of the hydroprocessing catalyst to form a loaded hydroprocessing catalyst; and coating the loaded hydroprocessing catalyst with a coating material to produce the encapsulated hydroprocessing catalyst, wherein the coating material comprises a polymer or a paraffinic oil.