Micron-Sized Hydroprocessing Co-Catalyst Suspension for Heavy Oil Conversion
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Solution Overview
Problem
Conventional hydroprocessing catalysts in ebullated bed systems are inefficient for processing heavy oil feedstocks, leading to rapid deactivation due to metal contamination, sulfur and nitrogen retention, and the formation of sediment or sludge, which limits conversion and feedstock flexibility.
Innovation Solution
A hydroprocessing co-catalyst composition comprising micron-sized particles (2-100 microns) suspended in a liquid carrier, with a dispersant and diluent, that enhances catalytic activity and adsorbs contaminants, allowing for improved conversion and longer runtime by entraining with the feedstock through the hydroprocessing unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional pelletized hydroprocessing catalyst is used in an ebullated bed system, then the system can operate with a fluidized catalyst bed, but the catalyst rapidly deactivates due to metal contamination and sulfur/nitrogen retention, limiting conversion and runtime
Solution Approach 1:
The patent changes the physical parameters of the co-catalyst from conventional large pelletized form to micron-sized particles (1-100 microns). This size reduction increases surface area and allows the co-catalyst to remain suspended in the liquid carrier throughout the ebullated bed, preventing rapid deactivation by distributing contaminant exposure across many small particles rather than few large ones, thereby maintaining catalytic activity stability while enabling higher conversion
Solution Approach 2:
The patent creates a composite system combining conventional hydroprocessing catalyst pellets with micron-sized co-catalyst particles suspended in a liquid carrier. The co-catalyst particles comprise metal components (such as Mo, Ni, Co, or W) supported on alumina, silica, or other oxides, forming a composite material that enhances the conventional catalyst's ability to handle heavy feedstocks while resisting deactivation from metal contamination and sulfur/nitrogen compounds
2Productivity
If conversion is increased to process more difficult feedstocks, then productivity improves, but sediment and sludge formation increases, plugging equipment and reducing runtime
Solution Approach 1:
The patent introduces a liquid carrier acting as an intermediary medium that suspends micron-sized co-catalyst particles. This liquid carrier (comprising hydroprocessing oil or hydrocarbon feed) facilitates the dispersion and distribution of co-catalyst throughout the reaction zone, enabling enhanced conversion while the suspended particle system prevents sedimentation and equipment plugging by maintaining continuous circulation of active catalytic material
Solution Approach 2:
The patent transforms the static catalyst bed into a dynamic suspended particle system. The micron-sized co-catalyst particles remain in constant motion within the liquid carrier throughout the ebullated bed, allowing them to dynamically interact with the feedstock and continuously distribute themselves to prevent localized sediment accumulation and equipment plugging, thereby enabling higher conversion without increased sediment formation
3Device complexity
If conventional catalysts are used, then the system structure is simple, but the catalyst deactivates rapidly due to metal contamination, requiring frequent catalyst replacement
Solution Approach 1:
The patent implements a self-service catalyst system where micron-sized co-catalyst particles suspended in liquid carrier continuously circulate through the ebullated bed, automatically maintaining catalytic activity by distributing themselves throughout the reaction zone. The liquid carrier continuously suspends and redistributes the co-catalyst particles, providing self-maintenance of catalytic function without external intervention, thereby extending runtime while adding minimal structural complexity
Solution Approach 2:
The patent segments the catalytic function into two components: conventional pelletized catalyst providing structural support and micron-sized co-catalyst particles providing active catalytic sites. This segmentation allows the co-catalyst particles to circulate and self-distribute throughout the liquid carrier, preventing localized deactivation and extending overall system runtime while maintaining relatively simple device structure
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 co-catalyst composition significantly enhances catalytic activity, reduces sediment formation, and allows for the processing of more difficult feedstocks without the typical issues of sedimentation, thereby increasing conversion rates and unit runtime.
Implementation Method 1
co-catalyst particles in admixture with the liquid carrier
Implementation Method 2
co-catalyst particles... adsorbs contaminants
Data Source
AI summary
A hydroprocessing co-catalyst composition may comprise in an embodiment a first component comprising co-catalyst particles and a liquid carrier, and a second component comprising a dispersant and a dispersant diluent. The co-catalyst particles may be in the micron size range, and the dispersant may promote dispersion of the co-catalyst particles in materials such as the liquid carrier, the dispersant diluent, and combinations thereof. Methods of introducing a hydroprocessing co-catalyst composition into a hydroprocessing system are also disclosed.