Heavy Oil Catalyst Mixing With Cooled High-Boiling Diluent
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Solution Overview
Problem
Conventional methods face challenges in efficiently mixing catalyst precursors into heavy oil feedstocks using high boiling hydrocarbons as diluents due to premature decomposition and agglomeration issues, leading to reduced catalyst activity and increased equipment fouling in hydroprocessing systems.
Innovation Solution
The use of a high boiling hydrocarbon diluent, cooled to a controlled temperature below the catalyst precursor's decomposition point, to form a diluted precursor mixture, which is then mixed with the heavy oil feedstock, ensuring proper dispersion and formation of active dispersed metal sulfide catalyst particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If high boiling hydrocarbon diluent is used to mix catalyst precursor into heavy oil feedstock, then catalyst dispersion is improved, but catalyst precursor decomposes prematurely and agglomerates
Solution Approach 1:
The patent changes the temperature parameter of the high boiling hydrocarbon diluent from its normal operating temperature to a controlled lower temperature below the catalyst precursor decomposition point. This parameter change allows the diluent to effectively disperse the catalyst precursor without causing thermal decomposition and agglomeration, thus resolving the contradiction between maintaining precursor stability and achieving proper dispersion quality.
Solution Approach 2:
The patent applies preliminary cooling to the high boiling hydrocarbon diluent before it contacts the catalyst precursor. This preliminary action prepares the diluent in a state suitable for catalyst precursor dispersion, preventing premature decomposition while ensuring adequate mixing and dispersion quality in the subsequent process.
2Reliability
If high boiling hydrocarbon diluent is cooled to prevent catalyst decomposition, then catalyst activity is maintained, but diluent viscosity increases
Solution Approach 1:
The patent optimizes the temperature parameter of the high boiling hydrocarbon diluent to find a balance point that is low enough to prevent catalyst precursor decomposition (maintaining catalyst activity) but high enough to maintain acceptable viscosity and flowability for easy handling and mixing operations.
3Device complexity
If conventional mixing methods are used, then process simplicity is maintained, but equipment fouling increases
Solution Approach 1:
The patent modifies the temperature parameter of the diluent as a simple process change that prevents catalyst precursor decomposition and agglomeration. This parameter modification improves catalyst dispersion quality and reduces equipment fouling without significantly increasing mixing process complexity, as it primarily involves temperature control before mixing.
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 method enhances catalyst activity and reduces equipment fouling, allowing for efficient hydroprocessing of heavy oils by maintaining catalyst integrity and promoting beneficial upgrading reactions.
Implementation Method 1
The high boiling hydrocarbon diluent is cooled to a controlled temperature below the catalyst precursor's decomposition point
Implementation Method 2
The diluted precursor mixture is mixed with the heavy oil feedstock, and the mixture is heated to decompose the catalyst precursor and form dispersed metal sulfide catalyst particles
Implementation Method 3
the mixture is heated to decompose the catalyst precursor and form dispersed metal sulfide catalyst particles
Data Source
AI summary
System and method for mixing a catalyst precursor into heavy oil using a high boiling hydrocarbon diluent to form a diluted precursor mixture, which is mixed with the heavy oil feedstock to form a conditioned feedstock, which is subsequently heated to decompose the precursor and form dispersed metal sulfide catalyst particles in situ. Because the high boiling hydrocarbon diluent is typically at a temperature above the decomposition temperature of the catalyst precursor, it is first feed through a cooler to reduce its temperature to avoid premature decomposition of the catalyst precursor. The high boiling hydrocarbon diluent may include a portion of the heavy oil feedstock, a portion of the conditioned feedstock, a vacuum tower bottoms product, or other high boiling hydrocarbon material having a boiling point higher than 524° C. A portion of the diluent may optionally include a medium boiling hydrocarbon material having a boiling point less than 524° C.