Hydrocracking Catalyst Layering Optimization via DBE Analysis
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Solution Overview
Problem
Current hydrocracking processes rely on trial and error methods for optimizing catalyst layering, requiring extensive testing to achieve desired product yields and quality, especially when processing heavier feedstocks, which results in reduced efficiency and profitability.
Innovation Solution
The method involves ranking and classifying catalysts using model compounds to determine molecular composition and reactivity, specifically utilizing the double bond equivalence (DBE) of the feedstock to select and layer catalysts optimally for hydrocracking, ensuring each catalyst performs a distinct function in the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If trial and error methods are used for optimizing catalyst layering, then desired product yields and quality can be achieved, but extensive testing is required resulting in reduced efficiency and profitability
Solution Approach 1:
The patent applies preliminary action by using model compounds (naphthalene, dibenzothiophene, carbazole) to pre-evaluate and rank catalysts based on their activity for hydrogenation, hydrodesulfurization, and hydrocracking. This preliminary characterization allows the selection of optimal catalyst combinations and layering configurations before actual feedstock processing, eliminating the need for extensive trial-and-error testing on real feedstocks while ensuring desired product yields and quality.
2Productivity
If model compounds are used to rank and classify catalysts, then catalyst selection and layering can be optimized efficiently, but the complexity of evaluating multiple catalyst properties increases
Solution Approach 1:
The patent applies segmentation by dividing the catalyst evaluation process into three distinct functional assessments using specific model compounds: naphthalene for hydrogenation activity, dibenzothiophene for hydrodesulfurization activity, and carbazole for hydrocracking activity. This segmentation allows each catalyst's performance to be characterized independently for each function, simplifying the overall evaluation complexity while enabling comprehensive optimization of catalyst layering based on the three key catalytic functions.
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 allows for the development of an efficient hydrocracking method that maximizes product yield and quality by selecting the appropriate catalysts based on feedstock properties, reducing the need for extensive testing and improving process performance.
Implementation Method 1
Hydrocracking is an established, reliable and flexible method for transforming materials such as low-value heavy oil fractions into higher value products
Implementation Method 2
hydrocracking processes typically improve the quality of the hydrocarbon feedstock used by increasing the hydrogen to carbon ratio of the products
Implementation Method 3
cracked products, along with partially cracked and unconverted hydrocarbons, are passed to a distillation column for fractionating into products
Data Source
AI summary
The invention relates to a method for optimizing layered catalytic processes. This is accomplished by testing various catalysts with a compound found in a feedstock to be tested, to determine the facility of the catalyst in hydrogenating, hydrosulfurizing, or hydrodenitrogenating the molecule, and hence the feedstock. In a preferred embodiment, the Double Bond Equivalence of the feedstock and molecule are determined, and catalysts are pre-selected based upon their known ability to work with materials of this DBE value.