Hydroprocessing Catalyst Bimodal Pore Structure Vanadium Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current hydroprocessing catalysts face challenges in effectively treating heavy hydrocarbon feedstocks with high vanadium concentrations, requiring improved catalytic activity and stability while being economical to manufacture.
Innovation Solution
A hydroprocessing catalyst comprising a calcined particle made by co-mulling inorganic oxide powder, molybdenum trioxide powder, and Group VIII metal particles, with a specific pore structure and composition that includes a molybdenum content of 2-12 wt%, nickel content of 0.2-6 wt%, and cobalt content of 0.2-6 wt%, and a surface area greater than 250 m2/g, optimized for heavy hydrocarbon feedstocks with high sulfur and metal content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hydroprocessing catalysts are used to treat heavy hydrocarbon feedstocks with high vanadium concentrations, then basic hydroprocessing activity is maintained, but catalytic activity and stability deteriorate due to vanadium deposition
Solution Approach 1:
The patent changes the pore size distribution parameters of the catalyst, specifically creating a bimodal distribution with mesopores (70-250 Å) and macropores (>5000 Å). This parameter change allows the catalyst to maintain stability while improving vanadium removal activity, as the macropores facilitate the removal of large vanadium-containing molecules while mesopores provide the necessary surface area for catalytic activity.
Solution Approach 2:
The patent creates a composite catalyst structure combining inorganic oxide material with specific pore-forming agents that create the bimodal pore distribution. This composite approach integrates multiple functional elements: the inorganic oxide provides structural stability, while the controlled pore structure provides both catalytic activity and resistance to vanadium deposition.
2Productivity
If reactor temperature is increased to improve hydroprocessing activity, then treatment effectiveness increases, but energy consumption increases
Solution Approach 1:
The patent changes the catalyst's pore size distribution and surface area parameters to create a more efficient catalytic system. The bimodal pore structure with specific surface area (>250 m²/g) enhances the catalyst's ability to process heavy hydrocarbons at lower temperatures, thereby improving hydroprocessing activity without increasing energy consumption.
3Productivity
If catalyst pore structure is optimized for high surface area, then catalytic activity improves, but resistance to vanadium deposition deteriorates
Solution Approach 1:
The patent optimizes the pore size distribution parameters by creating a bimodal structure with specific ranges: mesopores (70-250 Å) for catalytic activity and macropores (>5000 Å) for vanadium deposition resistance. This parameter optimization allows the catalyst to simultaneously achieve high catalytic activity through increased surface area and resistance to vanadium deposition through appropriate pore sizing.
Solution Approach 2:
The patent applies different pore size qualities to different functional requirements: smaller mesopores (70-250 Å) provide the high surface area needed for catalytic activity, while larger macropores (>5000 Å) provide the space needed to prevent vanadium deposition. This local differentiation of pore qualities allows the catalyst to satisfy conflicting requirements simultaneously.
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 catalyst exhibits enhanced vanadium removal activity and product stability, with improved resistance to vanadium deposition, effectively treating heavy hydrocarbon feedstocks with high sulfur and metal content, and extending catalyst life while reducing reactor temperatures for energy savings.
Implementation Method 1
the catalyst exhibits enhanced vanadium removal activity
Implementation Method 2
hydroprocessing catalyst and a hydrotreating process for the treatment of a heavy feedstock
Implementation Method 3
The calcined particle has a pore structure such that at least 23% of its total pore volume is contained in pores having pore diameters greater than 5,000 Å and less than 70% of its total pore volume is contained in pores having pore diameters in the range of from 70 Å to 250 Å
Implementation Method 4
a hydroprocessing catalyst comprising a calcined particle made by co-mulling inorganic oxide powder, molybdenum trioxide powder, and Group VIII metal particles
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A catalyst for treating heavy hydrocarbon feedstocks. The catalyst comprises a calcined particle comprising a co-mulled mixture made by co-mulling inorganic oxide powder, molybdenum trioxide powder, and a nickel compound or cobalt compound, or both compounds, and then forming the co-mulled mixture into a particle that is calcined to provide the calcined particle. The calcination is conducted at a temperature such that at least 20% of the pore volume of the calcined particle is in pores of greater than 5,000 and less than 70% of the pore volume of the calcined particle is in the pores having a pore size in the range of from 70 to 250.