Heavy Crude Upgrading via Ni-Mo Catalytic Hydrocracking
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Solution Overview
Problem
Current technologies face limitations in efficiently improving the physical and chemical properties of heavy and extra-heavy crude oils, such as high viscosity and sulfur content, which hinders their extraction and refining, particularly due to risks associated with combustion methods and limited applicability of existing processes.
Innovation Solution
A two-stage homogeneous catalytic process using a liquid phase ionic Ni—Mo catalyst is injected into the crude oil, controlling temperature, pressure, and time to transform heavy crude oils into lighter ones by reducing viscosity, increasing API gravity, and altering the SARA composition, thereby reducing sulfur and nitrogen content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If combustion methods (steam injection, air injection, THAI) are used to improve heavy crude extraction, then recovery factor increases, but safety risks (explosion, fire) and operational complexity increase
Solution Approach 1:
The patent replaces thermal combustion methods with a chemical catalytic system. A nickel-molybdenum catalyst system is used to facilitate hydrocracking reactions that break down heavy crude components at lower temperatures, eliminating the need for high-temperature combustion and associated safety risks while maintaining improved recovery rates
Solution Approach 2:
The invention changes the fundamental operating parameters from high-temperature combustion (thermal energy) to moderate-temperature catalytic reactions (chemical energy). The catalyst enables the process to proceed at temperatures below 400°C compared to combustion methods requiring temperatures above 700°C, thereby reducing safety hazards
2Ease of operation
If steam injection or SAGD is used to reduce viscosity, then fluidity improves, but energy consumption and operational complexity increase
Solution Approach 1:
The patent replaces thermal energy input (steam injection) with chemical catalysis. The nickel-molybdenum catalyst system facilitates bond breaking and reforming reactions that reduce viscosity through chemical transformation rather than thermal heating, significantly lowering energy requirements
Solution Approach 2:
The invention changes the mechanism of viscosity reduction from thermal softening to chemical transformation. The catalyst enables hydrocracking reactions that break large hydrocarbon molecules into smaller, less viscous molecules, achieving fluidity improvement at lower energy input
3Productivity
If heavy crude is extracted and refined conventionally, then production is maintained, but sulfur and metals content remain high, reducing commercial value
Solution Approach 1:
The patent replaces conventional physical separation and mechanical refining with chemical catalysis. The nickel-molybdenum catalyst system promotes hydrocracking and hydrodesulfurization reactions that chemically remove sulfur and metals from the crude, transforming them into removable byproducts while maintaining production rates
Solution Approach 2:
The invention introduces a catalyst system as an intermediary substance that facilitates the removal of harmful components. The nickel-molybdenum catalyst acts as a mediator that enables sulfur and metals to be transformed and separated from the crude oil through chemical reactions, rather than requiring complex physical separation processes
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 process effectively increases the yield of lighter, higher-value distillates with improved selectivity towards gasoline, diesel, and fuel oils, while minimizing coke formation and enhancing commercial value, with a high liquid yield exceeding 95% and sulfur removal.
Implementation Method 1
A process has been found for improving the properties of heavy and extra-heavy crude oils 'in-situ' by means of a catalytic reaction with a liquid phase ionic composition of a Ni—Mo catalyst
Implementation Method 2
which intends to promote hydrocracking and hydrogenation type reactions
Implementation Method 3
which intends to promote hydrocracking and hydrogenation type reactions
Implementation Method 4
likewise, these procedures reduce the content of sulfur and nitrogen associated to those crudes
Implementation Method 5
by means of a catalytic reaction with a liquid phase ionic composition of a Ni—Mo catalyst
Data Source
AI summary
The physical and chemical properties of heavy and extra-heavy crudes are improved by a procedure that uses a homogeneous type catalyst and involves the stages: 1. separation and removal of the water fraction that is contained in the hydrocarbons, 2. catalyst injection and activation of the reaction system, 3. elimination of gaseous hydrocarbons and recovery of the partial pressure of hydrogen at different times, 4. reaction and 5. recovery of distillated products.