Selective Hydroisomerization Catalyst for Cold Flow Improvement
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Solution Overview
Problem
Existing methods for improving the cold flow properties of hydrocarbon mixtures, such as diesel fuel, are either expensive or result in yield loss and high hydrogen consumption during hydroisomerization processes.
Innovation Solution
A catalytically active material comprising a dehydrogenating metal function, a molecular sieve with AEL topology, and a metal oxide support, where the metal function is distributed between the molecular sieve and the support, optimizing the distribution to achieve high activity and selectivity in hydroisomerization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If catalytic hydrocracking is used to improve cold flow properties, then cold flow properties are improved, but product yield decreases and hydrogen consumption increases
Solution Approach 1:
The patent applies local quality by creating distinct zones within the catalyst structure: the molecular sieve component provides shape-selective isomerization activity for improving cold flow properties, while the metal oxide support provides hydrocracking activity. By controlling the distribution and proportion of these components, the catalyst achieves localized functions that optimize both cold flow improvement and product yield retention.
Solution Approach 2:
The patent uses composite materials by combining molecular sieve (for isomerization) with metal oxide support (for hydrocracking) into a single catalyst system. This composite structure enables simultaneous execution of multiple reactions (isomerization and hydrocracking) with optimized selectivity, achieving improved cold flow properties while minimizing yield loss and hydrogen consumption compared to conventional single-function catalysts.
2Object-affected harmful factors
If catalytic hydrocracking is used to improve cold flow properties, then cold flow properties are improved, but hydrogen consumption increases
Solution Approach 1:
The catalyst structure creates local quality zones where the molecular sieve component selectively promotes isomerization reactions that improve cold flow properties without requiring excessive hydrogen consumption, while the metal oxide support handles necessary hydrocracking. This spatial differentiation of catalytic functions minimizes unnecessary hydrogen consumption while achieving the required cold flow improvement.
Solution Approach 2:
The patent optimizes parameters including the ratio of molecular sieve to metal oxide support, the distribution of active sites, and the physical structure of the catalyst to change the reaction pathway selectivity. These parameter changes enable the system to achieve cold flow improvement through isomerization preferentially over hydrocracking, thereby reducing hydrogen consumption while maintaining product yield.
3Object-affected harmful factors
If product blending with lower boiling streams is used to improve cold flow properties, then cold flow properties are improved, but production cost increases
Solution Approach 1:
The catalyst enables the feedstock to self-improve its cold flow properties through catalytic isomerization and hydrocracking reactions. Instead of requiring external blending with lower boiling streams or additives, the catalyst directly transforms the long-chain n-paraffins in the feedstock into branched isomers with improved cold flow properties, eliminating the need for expensive blending operations and reducing production costs.
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 described catalytically active material achieves improved cold flow properties with higher yield and lower hydrogen consumption compared to traditional methods, retaining at least 6% more 250-700°F distillation fraction at a -30°C total liquid product cloud point.
Implementation Method 1
The process requires presence of hydrogen and is carried out in the presence of a catalyst, which comprises a noble metal component selected from Group VIII of the Periodic System and being supported on a carrier comprising a metal oxide such as alumina, silica, titania or silica-alumina or combinations of these, as well as a molecular sieve
Implementation Method 2
a molecular sieve having a topology such as AEI, AEL, AFO, AFX, ATO, BEA, CHA, FAU, FER, MEL, MFI, MOR, MRE, MTT, MWW or TON
Implementation Method 3
The process requires presence of hydrogen
Data Source
AI summary
A catalyst is provided for hydrodeoxygenation and hydroisomerization of paraffins having higher activity. The catalyst contains a molecular sieve, such as SAPO-11, a metal component such as platinum and/or palladium or nickel tungsten sulfide or nickel molybdenum sulfide and a binder such as gamma alumina. The catalyst exhibits a high proportion of weak acid sites and a relatively equal distribution of the metal component on the molecular sieve and the binder.