Lobular Catalyst Structure for Supercritical Water Hydrocarbon Conversion
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Solution Overview
Problem
Conventional catalysts fail to maintain structural integrity and functionality in high-pressure and high-temperature processes, especially in supercritical water conditions, leading to dissolution, disintegration, and sintering, which limits their effectiveness in upgrading heavy hydrocarbons.
Innovation Solution
A lobular catalyst with a non-porous, plate-like structure and catalytically active transition metals is used, featuring a high surface area and a hollow core with semi-ellipsoid segments, designed to withstand extreme conditions and prevent coke and solids deposition, allowing for efficient hydrocarbon conversion in reactors operating at high pressures and temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional porous catalysts are used, then catalytic activity is provided, but the catalyst dissolves, disintegrates, or sinters under high temperature and pressure conditions
Solution Approach 1:
The patent applies porous materials in a controlled manner by using a non-porous lobular structure as the base form, then selectively introducing porosity through hollow cores and channels only where needed for reactant access, while maintaining overall structural integrity. This resolves the contradiction by avoiding the use of fully porous conventional catalysts that disintegrate, instead using a hybrid approach with controlled porosity.
Solution Approach 2:
The patent employs composite materials by combining the lobular structural framework with catalytically active materials deposited on its surface. This composite structure provides both the mechanical strength needed to withstand high temperature and pressure conditions and the catalytic activity required for hydrocarbon conversion, resolving the contradiction between structural integrity and productivity.
2Ease of operation
If conventional particulate catalysts are used, then catalytic reactions occur, but the catalyst generates operational problems and is difficult to remove after degradation
Solution Approach 1:
The patent applies segmentation by dividing the catalyst into distinct functional zones within the lobular structure, including hollow cores and channels that segment the internal volume. This segmentation allows for easier removal of degraded catalyst materials while maintaining operational stability during the catalytic process.
Solution Approach 2:
The patent inverts the conventional approach by using a non-porous lobular structure instead of porous particulate catalysts. This inversion eliminates the operational problems associated with fine particulate matter while maintaining catalytic activity on the lobular surface, making catalyst removal much easier after degradation.
3Productivity
If high surface area is achieved through porous structures, then catalytic activity increases, but the pores plug under high pressure and temperature conditions
Solution Approach 1:
The patent applies dimensionality change by transitioning from conventional three-dimensional porous structures to a lobular structure with hollow cores and channels that provide surface area in a different geometric configuration. This dimensional reconfiguration maintains high surface area for catalytic activity while avoiding pore plugging issues under high pressure and temperature conditions.
Solution Approach 2:
The patent changes the structural parameters from porous to non-porous lobular geometry, fundamentally altering how surface area is achieved. This parameter change allows the catalyst to maintain high surface area for catalytic reactions without the pore plugging problem that occurs in conventional porous structures under extreme conditions.
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 lobular catalyst sustains operational integrity over extended periods, enhancing hydrocarbon upgrading by 25% to 45% compared to conventional catalysts, while minimizing coke and solids deposition, and improving product selectivity by maintaining structural integrity and reaction efficiency.
Implementation Method 1
Catalysts provide active sites for cracking, isomerization, dealkylation, desulfurization, and demetallization of hydrocarbons, including heavy crudes
Data Source
AI summary
Apparatuses and methods of use are provided for a lobular catalyst for use in processes featuring water at high pressures and high temperatures, including in supercritical or near supercritical water conditions. The lobular catalyst structure features a shaped, plate-like structure extending along the reactor length with a high surface area. The lobular catalyst structure is fixed in place and mounted within a high temperature and high pressure reactor. The catalyst includes a catalytically active component, which can be a transition metal. The catalyst can be used in high pressure and high temperature processes, including in supercritical or near supercritical water processes, to improve heavy oil upgrading and hydrocarbon conversion in chemical processes.