Hydroprocessing Catalyst Composition for Heavy Oil Upgrading
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Solution Overview
Problem
The petroleum industry faces challenges in upgrading heavy oils and residua due to their high sulfur and nitrogen content, requiring improved catalysts with optimal morphology and structure for high yield conversions, as well as efficient processes for their conversion.
Innovation Solution
A novel bulk catalyst composition based on sulfides of 'd' block metals is developed, specifically formulated as (Rp)i(Mt)a(Lu)b(Sv)d(Cw)e(Hx)f(Oy)g(Nz)h, prepared by combining different metal precursors with a sulfiding agent and a hydrocarbon compound, optimizing the catalyst's structure and activity for heavy oil conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalysts are used for upgrading heavy oils, then the process can proceed, but the catalytic activity and conversion yield are insufficient
Solution Approach 1:
The patent employs composite catalyst materials comprising multiple metal sulfides (FeS, ZnS, NiS, CoS, MnS, CuS) combined with organic additives and hydrocarbon matrices. This composite approach creates synergistic effects where different metal sulfides contribute distinct catalytic functions for hydrocarbon conversion, sulfur removal, and nitrogen removal, thereby achieving both high conversion yield and reliable catalytic activity simultaneously
Solution Approach 2:
The patent systematically varies critical parameters including metal sulfide composition ratios, organic additive types and concentrations, hydrocarbon matrix properties, and processing conditions (temperature, pressure, residence time). By optimizing these parameters, the catalyst achieves peak performance in both conversion yield and catalytic activity, resolving the contradiction between productivity and reliability
2Productivity
If heavy oils with high sulfur and nitrogen content are processed, then usable products can be obtained, but the catalyst requires complex composition and structure optimization
Solution Approach 1:
The catalyst system is designed with multi-functionality to handle multiple contaminants simultaneously. Metal sulfides provide catalytic activity for hydrocarbon conversion, while organic additives and hydrocarbon matrices work together to remove sulfur, nitrogen, and other impurities in one integrated process. This universal approach enables efficient upgrading of heavy oils with high sulfur and nitrogen content without requiring separate treatment processes or multiple specialized catalysts
Solution Approach 2:
The catalyst system utilizes the heavy oil feedstock itself as both the substrate for conversion and as a source of sulfur for catalyst formation. The process is self-sustaining, where the feedstock provides both the hydrocarbons to be converted and the sulfur needed to form active catalyst sites, reducing the need for external sulfur sources and simplifying the overall process complexity
3Reliability
If improved catalyst morphology and structure are implemented, then catalytic activity increases, but the manufacturing process becomes more complex
Solution Approach 1:
The patent combines multiple catalyst components (metal sulfides, organic additives, hydrocarbon matrices) into a single integrated catalyst formulation that can be prepared through straightforward mixing and processing steps. This merging approach eliminates the need for separate preparation of individual catalyst components and their subsequent assembly, thereby maintaining high catalytic activity while simplifying the manufacturing process
Solution Approach 2:
The catalyst components are pre-mixed and pre-formed into a unified formulation before application to the heavy oil feedstock. This preliminary preparation ensures optimal distribution and interaction of catalyst components, achieving high catalytic activity while avoiding complex in-situ formation processes. The pre-formed catalyst can be directly applied to the feedstock, streamlining the overall manufacturing and application process
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 composition demonstrates enhanced catalytic activity and efficiency in upgrading heavy oils, achieving significant reductions in sulfur, nitrogen, and molecular weight, with improved product properties such as API gravity and micro carbon residue.
Implementation Method 1
combining at least two different metal precursors of 'd' block element metals with a sulfiding agent forming at least a sulfided catalyst precursor
Implementation Method 2
treating with hydrogen of various hydrocarbon fractions, or whole heavy feeds, or feedstocks, in the presence of hydrotreating catalysts to effect conversion of at least a portion of the feeds
Implementation Method 3
providing a catalyst precursor with at least two metal precursors of different 'd' block element metals in a solvent carrier
Data Source
AI summary
A hydroprocessing bulk catalyst is provided. A process to prepare hydroprocessing bulk catalysts is also provided. The hydroprocessing catalyst has the formula (Rp)i(Mt)a(Lu)b(Sv)d(Cw)e(Hx)f(Oy)g(Nz)h, wherein M is at least at least a “d” block element metal; L is also at least a “d” block element metal, but different from M; t, u, v, w, x, y, z representing the total charge for each of the components (M, L, S, C, H, O and N, respectively); R is optional and in one embodiment, R is a lanthanoid element metal; 0<=i<=1; pi+ta+ub+vd+we+xf+yg+zh=0; 0<b; 0<b/a=<5; 0.5(a+b)<=d<=5(a+b); 0<e<=11(a+b); 0<f<=7(a+b); 0<g<=5(a+b); 0<h<=2(a+b). The catalyst has an X-ray powder diffraction pattern with at least three diffractions peak located at 2-θ angles of greater than 25°. In one embodiment, the catalyst is prepared by forming at least a sulfided catalyst precursors from at least two “d” block element metals; and mixing the catalyst precursor with a hydrocarbon compound to form the hydroprocessing catalyst composition. In another embodiment, the catalyst is prepared by the thermal decomposition of an oil dispersible sulfur containing organic metal precursor upon contact with a hydrocarbon oil, generating a slurry catalyst. In yet another embodiment, the catalyst is prepared from an in-situ or ex-situ sulfidation of “d block element metal precursors in solvent carrier.