Iron-Based Catalyst Disintegration for Hydrocracking Activity
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Solution Overview
Problem
The existing methods for hydrocracking petroleum heavy oil using iron-based catalysts face reduced catalytic activity due to particle aggregation, leading to increased process costs despite efforts to reuse catalysts.
Innovation Solution
The method involves disintegrating the aggregated iron-based catalyst to achieve a finely grained structure with an effective surface area similar to new catalysts, using a pulverizing machine to reduce particle size and enhance catalytic activity, and resupplying the disintegrated catalyst to maintain high activity levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the iron-based catalyst is reused after hydrocracking, then the supply amount of new catalyst can be reduced, but the catalytic activity decreases due to particle aggregation
Solution Approach 1:
The patent applies parameter changes by modifying the physical state of the catalyst particles through disintegration. The aggregated catalyst particles are mechanically disintegrated to reduce their size and increase their surface area, thereby restoring catalytic activity. This transforms the catalyst from a low-activity aggregated state to a high-activity dispersed state, resolving the contradiction between reusing catalyst (reducing supply) and maintaining activity.
2Ease of manufacture
If the iron-based catalyst particles aggregate, then the catalyst can be easily recovered, but the effective surface area decreases and catalytic activity is reduced
Solution Approach 1:
The patent applies dynamics by making the catalyst particle size dynamic rather than static. The catalyst particles are disintegrated during the process to change their size and distribution. This dynamic adjustment allows the system to maintain high catalytic activity by creating fine dispersed particles with large surface area, while still enabling easy recovery through filtration or settling after the disintegration step.
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
This approach effectively reduces process costs by maintaining high catalytic activity of the iron-based catalyst, allowing for efficient hydrocracking of petroleum heavy oil while minimizing the need for new catalyst supplies.
Implementation Method 1
a disintegrating step of disintegrating the iron-based catalyst of the recovered residual oil component to acquire a disintegrated iron-based catalyst
Implementation Method 2
a hydrocracking step of hydrocracking the petroleum heavy oil in the hydrocracking reactor
Implementation Method 3
supplying a raw material slurry containing the petroleum heavy oil and an iron-based catalyst as well as a hydrogen gas to a hydrocracking reactor
Data Source
AI summary
The present invention provides a method for hydrocracking of petroleum heavy oil containing a heavy metal component, comprising a supplying step of supplying a raw material slurry containing the petroleum heavy oil and an iron-based catalyst as well as a hydrogen gas to a hydrocracking reactor; a hydrocracking step of hydrocracking the petroleum heavy oil in the hydrocracking reactor; a recovering step of recovering a residual oil component containing the iron-based catalyst from a product after the hydrocracking step; a disintegrating step of disintegrating the iron-based catalyst of the recovered residual oil component to acquire a disintegrated iron-based catalyst; and a resupplying step of resupplying a processed residual oil component containing the disintegrated iron-based catalyst to the hydrocracking reactor. At the disintegrating step, the iron-based catalyst may be pulverized by a pulverizing machine. The iron-based catalyst may be limonite.