Hydroprocessing Catalyst Sulfiding and Morphology Control
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Solution Overview
Problem
Current hydroprocessing catalysts for heavy oils and residua face challenges in achieving optimal morphology, structure, and catalytic activity, with existing core-shell catalysts exhibiting lower activity and requiring improved sulfur incorporation and dispersion.
Innovation Solution
A hydroprocessing catalyst with a specific formula (M t< ) a (L u< ) b (S v< ) d (C w< ) e (H x< ) f (O y< ) g (N z< ) h, where M is a Group VIB metal, L is a non-noble metal, and the catalyst is prepared by combining Group VIB and non-noble metal compounds, sulfiding, and mixing with a hydrocarbon compound to achieve a broad X-ray powder diffraction pattern and enhanced catalytic activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If core-shell catalyst structure is used with pre-sulfided metal components, then catalyst formation is simplified, but catalytic activity decreases
Solution Approach 1:
The patent applies preliminary action by pre-sulfiding metal components before catalyst formation, which simplifies the manufacturing process. However, this pre-sulfiding creates a core-shell structure with lower catalytic activity. The patent resolves this contradiction by allowing metals to react with each other prior to sulfidation, forming a more homogeneous structure that maintains high catalytic activity while still benefiting from the simplified pre-sulfiding approach.
2Productivity
If sulfur incorporation is increased in the sulfidation step, then catalyst activity improves, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by optimizing the sulfidation process conditions, including temperature, pressure, and sulfur source concentration, to achieve maximum sulfur incorporation. This increases catalyst activity while managing manufacturing complexity through controlled parameter adjustment rather than process complexity.
3Productivity
If catalyst particle size is reduced for better dispersion, then catalytic activity improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies segmentation by creating a core-shell catalyst structure where the core provides structural stability and the shell provides active catalytic sites. This segmentation allows for better dispersion of catalyst particles while reducing the stringency of manufacturing precision requirements for individual particle size control.
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 improved catalytic activity, increased sulfur incorporation, and optimized morphology, leading to higher yield conversions and efficient upgrading of heavy oils and residua.
Implementation Method 1
The slurry catalyst is produced from group VIB metal compounds by sulfiding an aqueous mixture of the metal compound with hydrogen sulfide (H2S) gas
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, or feedstocks to lower molecular weight hydrocarbons
Implementation Method 3
The catalyst has an X-ray powder diffraction pattern with at least one broad peak at any of Bragg angles: 8 to 18°, 32 to 40°, and 55 to 65°
Implementation Method 4
The catalyst has an X-ray powder diffraction pattern with at least one broad peak at any of Bragg angles: 8 to 18°, 32 to 40°, and 55 to 65° (from 0 to 70° 2θ scale)
Data Source
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AI summary
A hydroprocessing bulk catalyst is provided. A process to prepare hydroprocessing bulk catalysts is also provided. The use of the bulk catalyst in hydroprocessing oil feedstock is also provided. The hydroprocessing catalyst has the formula (Mt)a(Lu)b(Sv)d(Cw)e(Hx)f(Oy)g(Nz)h, wherein M is at least one group VIB metal; promoter metal L is optional and if present, L is at least one Group VIII non-noble metal; 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); ta+ub+vcd+we+xf+yg+zh=0; 0 =< b; and 0 =< b / a =< 5, (a + 0.5b) <= d <= (5a + 2b), 0 <= e <= 11(a+b), 0 <= f <= 7(a+b), 0 <= g <= 5(a + b), 0 <= h <= 0.5(a + b). The catalyst has an X-ray powder diffraction pattern with at least one broad diffraction peak at any of Bragg angles: 8 to 18°, 32 to 40°, and 55 to 65° (from 0 to 70° 2-θ scale). In one embodiment, the catalyst is prepared by sulfiding at least one Group VIB metal compound and optionally at least one group VIII metal compound with a sulfiding agent forming a catalyst precursor; and mixing the catalyst precursor with a hydrocarbon compound to form the hydroprocessing catalyst composition.