Hydroconversion Catalyst Sulfidation and Pre-Carbonization for Coke Control
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Solution Overview
Problem
Existing methods for introducing cracked feedstocks to hydroconversion catalysts result in premature coke and gum formation, leading to catalyst deactivation and processing delays.
Innovation Solution
A method involving blending an inactive hydroconversion catalyst with a solid hydrocarbon material having a melting point above 50°C, followed by heating to melt and penetrate the catalyst pores, and then sulfiding and carbonizing the hydrocarbon to form a carbonaceous layer, creating a pre-sulfurized and pre-carbonized catalyst.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If cracked feedstock is introduced directly to freshly activated catalyst, then catalyst activity is high, but excessive coke and gum formation occurs causing deactivation
Solution Approach 1:
The patent applies preliminary action by coating the catalyst pores with a hydrocarbon material before introducing cracked feedstock. This pre-coating step creates a controlled carbonaceous layer that prevents excessive coke formation during subsequent operation, allowing the catalyst to maintain high activity without premature deactivation.
Solution Approach 2:
The patent implements preliminary anti-action by pre-carbonizing the catalyst pores with a controlled hydrocarbon coating before exposure to cracked feedstock. This pre-formed carbon layer acts as a protective barrier that counteracts the harmful coke and gum formation that would otherwise occur when cracked feedstock contacts the highly active catalyst surface.
2Object-generated harmful factors
If multiple treatment steps are performed before introducing cracked feedstock, then coke formation is reduced, but processing time increases
Solution Approach 1:
The patent merges multiple treatment steps into a single integrated process. The hydrocarbon coating step simultaneously achieves pore filling, controlled carbonization, and catalyst activation in one operation, eliminating the need for separate sequential treatments and reducing overall processing time while still preventing excessive coke formation.
Solution Approach 2:
The patent performs the pore coating and carbonization as a preliminary step that consolidates multiple functions. By applying the hydrocarbon coating and carbonizing it in advance before feedstock introduction, the process reduces the number of subsequent steps needed, thereby reducing total processing time while maintaining effective coke prevention.
3Productivity
If hydrocarbon material is used to coat catalyst pores, then catalyst activity is maintained, but hydrocarbon consumption increases
Solution Approach 1:
The patent applies local quality by concentrating the hydrocarbon coating specifically within the catalyst pores rather than uniformly throughout the entire catalyst mass. This localized application ensures that hydrocarbon material is used only where needed to maintain catalyst activity and prevent deactivation, minimizing overall hydrocarbon consumption while achieving the desired effect.
Solution Approach 2:
The patent utilizes the porous structure of the catalyst to efficiently contain and utilize the hydrocarbon coating material. The pores act as reservoirs that hold the hydrocarbon coating in direct contact with the catalytic active sites, maximizing the effectiveness of the hydrocarbon per unit consumed and reducing waste compared to bulk application methods.
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 inhibits excessive coke formation, maintains catalyst activity, and allows for efficient use of hydrocarbon materials, reducing processing time and complications.
Implementation Method 1
heating a mixture of the hydrocarbon solid and catalyst and/or heating the catalyst prior to contact with the hydrocarbon solid. Thus, forming a 'coating' or carbonaceous layer on the interior surface of the pores
Implementation Method 2
contacting the inactive hydroconversion catalyst/solid hydrocarbon containing material mixture with a gaseous stream comprising hydrogen (H2) and a sulfur-containing compound at a temperature sufficient to sulfide and activate the catalyst and carbonize at least a portion of the hydrocarbon containing material on the sulfided catalyst
Implementation Method 3
contacting the inactive hydroconversion catalyst/solid hydrocarbon containing material mixture with a gaseous stream comprising hydrogen (H2) and a sulfur-containing compound at a temperature sufficient to sulfide and activate the catalyst
Implementation Method 4
carbonize at least a portion of the hydrocarbon containing material on the sulfided catalyst to obtain a carbonized sulfided hydroconversion catalyst
Data Source
AI summary
Methods of treating hydroconversion catalysts used for cracking of hydrocarbons are described. A method can include mixing an inactive hydroconversion catalyst with a solid hydrocarbon containing material having a melting point of 50° C. or greater. The inactive hydroconversion catalyst/solid hydrocarbon containing material mixture can be contacted with a gaseous stream that includes hydrogen (H2) and a sulfur-containing compound under conditions sufficient to sulfide the catalyst and carbonize at least a portion of the hydrocarbon containing material on the sulfided catalyst to obtain a treated sulfided hydroconversion catalyst.