Ferrosilicon Hydrocracking Catalyst With Uniform Metal Dispersion
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Solution Overview
Problem
Existing catalysts for residue suspended bed hydrocracking face issues such as low conversion rates, complex preparation processes, high costs, and high coke yields, with traditional methods failing to achieve uniform distribution of active components and stability.
Innovation Solution
A metal-doped ferrosilicon catalyst is prepared using a co-precipitation method with VIIB or VIIIB group transition metals, ferric salts, and silicon sources, involving parallel-flow precipitation, aging, washing, drying, and calcination to form a stable Fe—O—Si bond, enhancing catalytic activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a supported catalyst is developed by supporting an active metal on a carrier material such as alumina, silica, and coke based on an impregnation method, then the thermal stability of the carrier is utilized, but the preparation process becomes relatively complex and active components are unlikely to be dispersed uniformly
Solution Approach 1:
The patent combines the carrier material (coke) with active metal components (Fe, Ni, Mo, Co, W) and silicon oxide into a single co-precipitation process, eliminating the need for separate impregnation steps. This merging of multiple components into one preparation method simplifies the process while ensuring uniform distribution of all active components throughout the catalyst structure.
Solution Approach 2:
The patent performs co-precipitation of all active components and carrier material simultaneously during the formation process, rather than adding components sequentially after carrier preparation. This preliminary action of combining all components in one step ensures uniform dispersion and reduces subsequent processing complexity.
2Ease of manufacture
If natural minerals are used as catalyst carriers in the early stage, then the catalyst is simpler to prepare, but it is affected by impurities and origins, and has low repeatability
Solution Approach 1:
The patent changes the chemical composition parameters by incorporating silicon oxide (20-40 wt%) into the catalyst system, which modifies the physical and chemical properties of the catalyst. This parameter change improves the repeatability and consistency of the catalyst while maintaining preparation simplicity, as the modified carrier material can be produced through controlled co-precipitation rather than relying on natural mineral variability.
3Productivity
If VIB and VIII family transition metals are supported on Y-type molecular sieve with a supporting amount of 15 wt %, then the hydrogenation reaction can proceed, but the preparation process becomes complex and the consistency of morphology and crystallinity cannot be ensured
Solution Approach 1:
The patent merges multiple metal components (Fe, Ni, Mo, Co, W) and the carrier material (coke) into a single co-precipitation process, eliminating the need for separate preparation steps for the carrier and metal support. This integration simplifies the preparation process while maintaining the hydrogenation reaction capability through the synergistic interaction of all components.
Solution Approach 2:
The patent creates a composite catalyst material containing coke, silicon oxide, and multiple transition metals (Fe, Ni, Mo, Co, W) with specific weight ratios. This composite structure provides both the hydrogenation activity from the metals and the structural stability from the coke and silicon oxide matrix, achieving high productivity with a simplified preparation process.
4Manufacturing precision
If multiple active components are added in two times to achieve uniform dispersion, then the active components can be distributed, but the time cost and economic cost become high
Solution Approach 1:
The patent performs the preliminary action of co-precipitating all active components and carrier material simultaneously during the formation process, rather than adding components sequentially in multiple steps. This preliminary combination in one step ensures uniform dispersion of all active components while significantly reducing preparation time and 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
The catalyst achieves high yields of gasoline and diesel oil, low coke production, and improved conversion rates, demonstrating a simple, cost-effective, and industrially viable solution for residue hydrocracking.
Implementation Method 1
the technology for hydrogenation in a suspended bed
Implementation Method 2
a catalyst greatly affects the reaction rate, the conversion rate, the yield of light oil and the consumption of hydrogen
Implementation Method 3
A metal-doped ferrosilicon catalyst is prepared using a co-precipitation method with VIIB or VIIIB group transition metals, ferric salts, and silicon sources
Implementation Method 4
involving parallel-flow precipitation, aging, washing, drying, and calcination to form a stable Fe—O—Si bond
Data Source
AI summary
A catalyst for residue suspended bed hydrocracking and a preparation method and application thereof are disclosed. The catalyst is obtained by mixing a VIIB or VIIIB group transition metal salt solution with a ferric salt solution, conducting parallel-flow precipitation with an alkaline solution, adding a silicon source, and then conducting aging, washing, drying, and calcination. The catalyst has a stable structure and excellent hydrogenation activity. When used in a residue suspended bed hydrocracking reaction, the yield of liquid is up to 91 wt %, the yield of gasoline and diesel oil is up to 60 wt %, and both the yield of gas and the yield of coke are low. The catalyst has a good application prospect in residue suspended bed hydroconversion process.