Iron Molybdenum Catalyst Slurry Hydrocracking Coke Control
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Solution Overview
Problem
The challenge in upgrading heavy oils to meet increasing demands lies in their low reactivity, high coking tendency, and difficulty in distillation, particularly due to the presence of asphaltenes and mesophase formation during hydrocracking processes, which results in inefficient conversion and excessive coke formation.
Innovation Solution
A process involving a slurry hydrocracking method using a bi-functional catalyst system comprising molybdenum and iron particles, where iron assists molybdenum in controlling mesophase formation, reducing coke production, and allowing for the conversion of heavy hydrocarbons into lighter products, with iron being less expensive and more abundant than molybdenum, and capable of processing a wide range of difficult feedstocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydrocracking processes are used to upgrade heavy oils, then conversion of heavy hydrocarbons to lighter products is achieved, but excessive coke formation occurs and conversion efficiency is low
Solution Approach 1:
The patent changes the chemical parameters of the catalyst system by using iron particles instead of traditional iron sulfate or bauxite, and optimizes the molybdenum concentration to 50-200 wppm. This parameter change enables adequate conversion of heavy hydrocarbons while minimizing coke formation, resolving the contradiction between conversion efficiency and coke generation.
Solution Approach 2:
The patent employs a composite catalyst system comprising iron particles and molybdenum compounds. This composite material combines the advantages of iron (cost-effectiveness, abundance) with molybdenum (catalytic activity for hydrocracking), achieving both high conversion efficiency and reduced coke formation through synergistic effects.
2Productivity
If iron sulfate monohydrate is used as catalyst, then conversion activity is achieved, but catalyst cost is high and availability is limited
Solution Approach 1:
The patent replaces expensive iron sulfate monohydrate with iron particles that are cheaper and more abundant. The iron particles serve as an effective catalyst support for molybdenum, providing the same conversion activity at lower cost and with better availability, thus resolving the contradiction between productivity and ease of manufacture.
Solution Approach 2:
The patent changes the physical form and chemical composition parameters of the iron-based catalyst from iron sulfate monohydrate to iron particles. This parameter change maintains catalytic activity while dramatically improving cost-effectiveness and availability for large-scale heavy oil upgrading operations.
3Ease of manufacture
If molybdenum concentration is reduced to lower catalyst cost, then catalyst cost decreases, but conversion efficiency and coke control may be compromised
Solution Approach 1:
The patent uses a composite catalyst system where iron particles provide structural support and cost-effectiveness, while molybdenum compounds at optimized concentrations (50-200 wppm) provide the necessary catalytic activity. This composite approach maintains conversion efficiency and coke control while reducing overall catalyst cost, resolving the contradiction between ease of manufacture and productivity.
Solution Approach 2:
The patent optimizes the molybdenum concentration parameter to a specific range (50-200 wppm) when used with iron particles. This parameter optimization ensures adequate conversion activity and effective coke suppression while minimizing catalyst cost, achieving the balance between ease of manufacture and productivity.
4Ease of operation
If heavy oils are processed without effective catalyst, then processing simplicity is maintained, but conversion is inadequate and coking tendency is high
Solution Approach 1:
The patent introduces iron particles as a simple yet effective catalyst component that can be easily incorporated into existing hydrocracking processes. The iron particles, combined with optimized molybdenum concentrations, provide adequate conversion and effective coking control without complicating the processing operation, thus resolving the contradiction between ease of operation and productivity.
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 enhances the conversion of heavy hydrocarbons to lighter products while minimizing coke formation, reducing catalyst costs, and maintaining or improving performance with lower molybdenum concentrations, effectively addressing the limitations of existing hydrocracking processes.
Implementation Method 1
A process involving a slurry hydrocracking method using a bi-functional catalyst system comprising molybdenum and iron particles, where iron assists molybdenum in controlling mesophase formation, reducing coke production, and allowing for the conversion of heavy hydrocarbons into lighter products
Implementation Method 2
In SHC, a three-phase mixture of heavy liquid oil feed cracks in the presence of gaseous hydrogen over solid catalyst to produce lighter products under pressure at an elevated temperature
Data Source
AI summary
A process and catalyst is disclosed for converting heavy hydrocarbon feed into lighter hydrocarbon products using multifunctional catalysts. Multifunctional catalysts enable use of less expensive metal by substituting expensive metals for less expensive metals with no loss or superior performance in slurry hydrocracking. Less available and expensive ISM can be replaced effectively.