Hydroprocessing Catalyst Coated with Paraffinic Wax

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Hydroprocessing catalysts are hygroscopic, leading to water adsorption, weight gain, and decreased catalytic activity when exposed to air, which affects their storability and performance.

Innovation Solution

Catalyst particles are coated with a paraffinic wax or polymer material to prevent water adsorption, ensuring nonabsorptive properties and maintaining catalytic activity, with the coating material being decomposed at activating reactor conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If hydroprocessing catalysts are exposed to air, then they adsorb water and gain weight, but their catalytic activity decreases

Engineering Contradiction:

Improvewater adsorptionVSAvoidcatalytic activity

Core Design Contradiction:

Quantity of substanceVSReliability

Solution Approach 1:

A hydrophobic coating material is applied as an intermediary layer between the catalyst particles and the environment. This coating acts as a mediator that prevents water molecules from reaching and adsorbing onto the catalyst surface, thereby maintaining catalytic activity while allowing the catalyst to be stored in air.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent creates a protective hydrophobic environment around the catalyst particles that mimics an inert atmosphere. The hydrophobic coating repels water and prevents moisture ingress, effectively creating a protective barrier that preserves catalyst performance during storage and handling.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Reliability

If catalyst particles are coated with paraffinic wax or polymer material, then water adsorption is prevented, but the coating material must be decomposed at activating reactor conditions

Engineering Contradiction:

ImprovestorabilityVSAvoidcoating decomposition process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent utilizes parameter changes in temperature to achieve different functional states of the coating material. At storage conditions, the coating remains intact to provide hydrophobic protection. At reactor activation temperatures, the coating decomposes or melts, allowing the catalyst to become active without interfering with the hydroprocessing function.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The coating material is designed as a temporary protective layer that serves its purpose during storage and handling, then decomposes or is removed during reactor activation. This disposable-like approach allows the coating to be discarded after fulfilling its protective function, leaving the catalyst ready for operation.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 nonabsorptive catalyst particles effectively prevent water adsorption, retaining catalytic activity and improving storability by ensuring the catalysts remain active and functional.

Implementation Method 1

Catalyst particles are coated with a paraffinic wax or polymer material to prevent water adsorption, ensuring nonabsorptive properties

Methodology Applied

Scientific EffectHydrophobicity: Hydrophobe

Implementation Method 2

the coating material being decomposed at activating reactor conditions

Methodology Applied

Scientific EffectThermal decomposition: Pyrolysis

Data Source

PatentUS20230191388A1Hydroprocessing method including nonadsorptive catalyst particles

Publication Date: 2023.06.22 SAUDI ARABIAN OIL CO

AI summary

Nonabsorptive presulfided catalyst particles are provided which are coated with a suitable coating material such as paraffinic oil/wax, or a suitable polymer material, to prevent water adsorption on the catalyst particles.