Hydroprocessing Catalyst Composition for Heavy Oil Conversion
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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, 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 heavy oil conversion, 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 components (Fe, Zn, Cu, Ni, Co, Mn) in specific ratios within a porous support structure. This composite approach enables synergistic effects between different metal species, enhancing both catalytic activity and conversion yield simultaneously. The multi-metal composition allows for optimized performance in heavy oil hydroprocessing by combining the advantages of different metal centers.
Solution Approach 2:
The catalyst is formulated with a porous support matrix that provides high surface area and controlled pore size distribution. This porous structure facilitates mass transfer of heavy oil molecules to active sites while maintaining structural stability. The pore architecture enhances catalytic efficiency by allowing reactant access and product egress, thereby improving conversion yield without sacrificing catalytic activity.
2Adaptability or versatility
If heavy oils with high sulfur and nitrogen content are processed, then valuable feedstocks can be utilized, but unwanted components must be removed
Solution Approach 1:
The catalyst system converts harmful sulfur and nitrogen compounds in heavy oil into beneficial products through hydroprocessing. Sulfur is converted to H2S which can be removed, and nitrogen compounds are converted to ammonia. This transformation turns the presence of heteroatoms from a disadvantage into an opportunity for value-added chemical production, enabling efficient utilization of heavy feedstocks while eliminating harmful components.
Solution Approach 2:
The catalyst operates by changing the chemical parameters of the feedstock through controlled hydroprocessing reactions. By adjusting reaction conditions (temperature, pressure, H2 concentration) and catalyst composition, the transformation of harmful sulfur and nitrogen compounds is optimized. This parameter control enables selective removal of unwanted components while preserving desired hydrocarbon structures.
3Reliability
If improved catalyst morphology and structure are developed, then catalytic activity increases, but the manufacturing process becomes more complex
Solution Approach 1:
The catalyst support structure is pre-formed with optimized porosity and surface area before metal deposition. This preliminary preparation of the support matrix simplifies subsequent metal impregnation and reduces the complexity of achieving uniform metal distribution. The pre-structured support ensures that active metal sites are readily available and properly distributed, enhancing catalytic activity without requiring complex post-processing steps.
Solution Approach 2:
The catalyst exhibits local quality variations through controlled metal distribution within the porous support. Different regions of the catalyst contain varying concentrations of specific metal components optimized for their respective functions. This localized composition strategy enhances overall catalytic activity by placing the right metal species in the right locations, while simplifying manufacturing through directed deposition techniques rather than requiring perfectly uniform distributions.
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 converting heavy oils and residua, achieving high yield conversions and reducing unwanted components, thereby improving the refining process.
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
effect the removal of unwanted components, or compounds, or their conversion to innocuous or less undesirable compounds
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 a solvent carrier.