Integrated Hydrocracking Dewaxing Catalyst for Lubricant Fuel Co-production
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Solution Overview
Problem
Conventional methods for producing low pour point or low cloud point diesel fuel and lubricant oil basestocks are hindered by the differing sensitivities of catalysts used in hydrocracking and dewaxing stages, requiring separate reactors and facilities, and are sensitive to sulfur and nitrogen contaminants, which limits the selection of suitable feeds and increases costs.
Innovation Solution
A method involving a dewaxing catalyst with a unidimensional 10-member ring pore molecular sieve, Group VI and Group VIII metals, and a low surface area binder, used in conjunction with a hydrotreating catalyst, allows for a single reaction stage processing of feedstocks with high sulfur content, reducing the need for separate catalyst beds and improving yield and cold flow properties of diesel fuel and lubricant basestocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional catalytic dewaxing is used to produce low pour point diesel fuel and lubricant oil basestocks, then cold flow properties are improved, but the process requires separate reactors and facilities due to differing catalyst sensitivities
Solution Approach 1:
The patent combines the hydrocracking catalyst and dewaxing catalyst into a single integrated catalyst bed, eliminating the need for separate reactors. The hydrocracking catalyst contains both cracking function (to break down heavy molecules) and dewaxing function (to remove wax components), allowing simultaneous performance of both functions in one unit while maintaining product specifications for cold flow properties.
Solution Approach 2:
The hydrocracking catalyst is designed with multi-functionality, incorporating both hydrocracking activity and catalytic dewaxing capability. This universal catalyst can handle both the conversion of vacuum gas oil to lighter fractions and the modification of heavier molecules to improve cold flow properties, replacing the need for specialized separate catalysts.
2Reliability
If conventional hydroprocessing is used to reduce sulfur content to protect dewaxing catalysts, then catalyst sensitivity is addressed, but the process sequence becomes fixed and costly
Solution Approach 1:
The patent merges the hydroprocessing function and dewaxing function into a single catalyst system. The hydrocracking catalyst performs both sulfur removal and wax modification simultaneously, eliminating the need for a fixed sequence where dewaxing must follow extensive hydroprocessing. This allows flexible processing of feeds with varying sulfur contents without requiring predetermined process sequences.
Solution Approach 2:
The patent changes the operational parameters of the integrated catalyst system, allowing it to process feeds with sulfur contents up to 2000 ppm or more directly. The catalyst formulation and reaction conditions are optimized to maintain both hydroprocessing activity and dewaxing selectivity under these higher sulfur conditions, providing operational flexibility.
3Productivity
If separate catalytic dewaxing is implemented, then diesel yield and lubricating oil yield are improved, but facility costs increase
Solution Approach 1:
The patent combines the dewaxing function with the hydrocracking catalyst bed, eliminating the need for a separate catalytic dewaxing reactor and associated facilities. The integrated catalyst maintains high diesel yield and lubricating oil yield by performing wax modification in-situ during the hydrocracking process, reducing capital investment while preserving productivity.
4Manufacturing precision
If hydrocracking is performed before dewaxing with intermediate separation, then product quality is maintained, but process complexity and cost increase
Solution Approach 1:
The patent merges the hydrocracking and dewaxing steps into a single continuous process within one catalyst bed, eliminating intermediate separation requirements. The integrated catalyst system maintains product quality by simultaneously performing molecular cracking and wax chain modification, producing diesel fuel and lubricant basestocks with specified cold flow properties in one pass.
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 enables the production of diesel fuel and lubricant basestocks with improved cold flow properties and reduced aromatics content, suitable for winter diesel and Group II or higher basestocks, while minimizing the production of lower boiling products and reducing the severity of subsequent hydrotreating stages, thus enhancing overall process efficiency and product quality.
Implementation Method 1
contacting a feedstock having a T95 boiling point of 1100° F. (593° C.) or less and comprising at least 100 wppm of sulfur with a dewaxing catalyst under effective conversion conditions to produce a converted effluent
Implementation Method 2
contacting at least a portion of the converted effluent with a supported hydrotreating catalyst under effective hydrotreating conditions to produce a product effluent
Implementation Method 3
fractionating the converted, hydrotreated effluent to form at least a distillate fuel product fraction and a lubricant base oil product fraction
Data Source
AI summary
Methods are provided for processing a gas oil boiling range feedstock, such as a vacuum gas oil, in a single reaction stage and/or without performing intermediate separations. The methods are suitable for forming lubricants and distillate fuels while reducing or minimizing the production of lower boiling products such as naphtha and light ends. The methods can provide desirable yields of distillate fuels and lubricant base oils without requiring separate catalyst beds or stages for dewaxing and hydrocracking. The methods are based in part on use of a dewaxing catalyst that is tolerant of sour processing environments while still providing desirable levels of activity for both feed conversion and feed isomerization.