Hydroconversion Catalyst Precursor Formulation for Fouling Reduction
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Solution Overview
Problem
Heavy oil feedstocks pose challenges in hydroconversion due to fouling in equipment upstream of the hydroconversion reactor, particularly in preheating devices, and the formation of coke precursors and sediments, which reduces equipment lifespan and processing efficiency.
Innovation Solution
A hybrid hydroconversion process involving a colloidal or molecular catalyst formed by mixing a catalyst precursor composition containing molybdenum with an organic chemical compound having carboxylic acid or ester functions, and a hydrocarbon oil diluent, is used to minimize fouling and enhance catalyst activity, allowing for more effective processing of heavy oil feedstocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heavy oil feedstock is processed in conventional hydroconversion reactors, then conversion of heavy fractions is achieved, but fouling occurs in equipment upstream and coke precursors form
Solution Approach 1:
The patent applies preliminary action by mixing the catalyst precursor with the heavy oil feedstock before it enters the hydroconversion reactor. This pre-mixing ensures that the catalyst is already dispersed in the feedstock, enabling immediate catalytic activity upon heating and preventing fouling in upstream equipment such as pumps and heat exchangers. The catalyst precursor formulation is prepared in advance and injected into the feedstock stream prior to the reactor inlet.
Solution Approach 2:
The patent uses an intermediary approach by introducing a catalyst precursor formulation that acts as a mediator between the heavy oil feedstock and the hydroconversion reactor. This precursor formulation, containing metal compounds dispersed in a carrier oil, serves as an intermediate catalytic system that prevents direct contact between the aggressive heavy oil and the reactor equipment, thereby reducing fouling while maintaining conversion efficiency.
2Object-affected harmful factors
If catalyst precursor is mixed with heavy oil feedstock, then equipment fouling is reduced, but catalyst activity must be enhanced to maintain conversion levels
Solution Approach 1:
The patent applies composite materials by formulating a catalyst precursor composition that combines metal compounds (such as molybdenum, nickel, or tungsten) dispersed in a carrier oil medium. This composite formulation ensures both stable dispersion in the heavy oil feedstock (reducing fouling) and sufficient catalytic activity (maintaining conversion levels). The carrier oil acts as a matrix that holds the metal compounds in a readily available form for catalysis.
Solution Approach 2:
The patent uses parameter changes by adjusting the concentration and composition of metal compounds in the catalyst precursor formulation. By optimizing the metal content (e.g., 0.1-10 g/L of molybdenum compound) and the type of carrier oil used, the formulation achieves the right balance between preventing equipment fouling and providing adequate catalytic activity for high conversion levels in the hydroconversion process.
3Device complexity
If conventional catalysts are used, then processing is simpler, but catalyst lifespan is reduced due to coke formation
Solution Approach 1:
The patent applies continuity of useful action by implementing a continuous supply of catalyst precursor to the heavy oil feedstock. This ensures that fresh catalytic sites are continuously available throughout the hydroconversion process, preventing catalyst deactivation by coke formation and extending catalyst lifespan. The continuous presence of dispersed metal compounds in the feedstock maintains steady catalytic activity without requiring frequent catalyst replacement or regeneration.
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 reduces equipment fouling, increases conversion levels, extends catalyst lifespan, and improves the processing of lower quality feedstocks, leading to increased throughput and reduced maintenance needs, thereby enhancing process safety and equipment longevity.
Implementation Method 1
mixing a heavy oil feedstock with a catalyst precursor formulation comprising a catalyst precursor composition and an organic additive, in order to form a colloidal or molecular catalyst
Implementation Method 2
heating the conditioned heavy oil feedstock and introducing the heated conditioned heavy oil feedstock into at least one hybrid ebullated bed reactor
Implementation Method 3
operating the hybrid ebullated bed reactor in the presence of hydrogen and at hydroconversion conditions to produce an upgraded material
Data Source
AI summary
The present invention relates to a hydroconversion process of a heavy oil feedstock comprising: (a) preparing a conditioned feedstock (103) by mixing said heavy oil feedstock (101) with a catalyst precursor formulation (104) so that a colloidal or molecular catalyst is formed when it reacts with sulfur, said catalyst precursor formulation (104) comprising a catalyst precursor composition (105) comprising Mo, an organic additive (102) comprising a carboxylic acid function and/or an ester function and/or an acid anhydride function, and a molar ratio organic additive (102)/Mo from formulation (104) ranging between 0.1:1 and 20:1; (b) heating said conditioned feedstock; (c) introducing the heated conditioned feedstock (106) into at least one hybrid ebullated-entrained bed reactor comprising a hydroconversion porous supported catalyst and operating said reactor in the presence of hydrogen and at hydroconversion conditions to produce an upgraded material (107), the colloidal or molecular catalyst being formed during step (b) and/or (c).