Low Density Catalysts for Hydroprocessing
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Solution Overview
Problem
Current methods for catalytic hydroprocessing of hydrocarbon feedstocks are costly due to the high volume of catalyst required and the need for frequent reactor replacements, with existing catalysts degrading quickly and requiring higher operating temperatures.
Innovation Solution
Employing high productivity and low density catalysts, such as those with Group VIII metals supported on M41S catalysts and ZSM-48 with specific SiO2:Al2O3 ratios, which reduce the amount of catalyst needed, lower operating temperatures, and allow for processing different feedstocks without equipment modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional supported Group VIII and/or Group VI metal catalysts are used for hydroprocessing, then catalytic activity is achieved, but catalyst cost increases due to substantial metal content and large catalyst volume required
Solution Approach 1:
The patent changes the physical and chemical parameters of the catalyst by using low-density porous supports (aerogels, foams, hollow spheres) with densities of 0.01-0.5 g/cm³, compared to conventional dense supports. This parameter change reduces the catalyst volume by factors of 10-100 times while maintaining the same metal loading and catalytic activity, directly resolving the contradiction between catalytic activity and catalyst quantity required.
Solution Approach 2:
The patent employs highly porous catalyst supports including aerogels (porosity 80-90%), foams, and hollow spherical structures with controlled pore sizes. These porous materials provide large surface areas for metal dispersion while occupying minimal volume, enabling the same catalytic function with dramatically reduced catalyst quantity, thus resolving the technical contradiction.
2Productivity
If conventional dense catalysts are used to load a hydroprocessing reactor, then reactor capacity is achieved, but operational cost increases due to frequent catalyst replacement and higher operating temperatures
Solution Approach 1:
The patent changes the density parameter of the catalyst from conventional values (1.0-2.0 g/cm³) to low-density values (0.01-0.5 g/cm³) using aerogels and foams. This enables the use of smaller catalyst volumes to achieve the same reactor capacity, while the high surface area and improved mass transfer in porous structures allow operation at lower temperatures, reducing energy loss.
Solution Approach 2:
The patent's low-density catalysts with enhanced porosity provide improved mass transfer and reduced diffusion limitations, maintaining high catalytic activity over extended periods. This continuity of effective action reduces the frequency of catalyst replacement and regeneration operations, lowering operational costs while maintaining reactor capacity.
3Productivity
If conventional catalysts are used for hydroprocessing, then processing of specific feedstocks is achieved, but adaptability decreases due to need for equipment modifications when changing feedstocks
Solution Approach 1:
The patent's low-density porous catalyst supports with tunable pore sizes and high surface areas provide universal applicability across different hydroprocessing reactions and feedstock types. The modular nature of these catalysts allows easy replacement and reconfiguration without equipment modifications, enabling the same reactor to process various feedstocks (naphtha, diesel, jet fuel, etc.) by simply changing the catalyst formulation while maintaining 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 decreases operational costs by minimizing catalyst usage and extending reactor lifespan, while maintaining high product quality and flexibility in processing various feedstocks.
Implementation Method 1
exposing a feedstock to a first catalyst, said first catalyst comprising at least one Group VIII metal supported on a M41S catalyst support
Implementation Method 2
contacting the feed sequentially with a large pore size, small crystal size, crystalline molecular sieve and an intermediate pore size, small crystal size crystalline molecular sieve
Data Source
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AI summary
Integrated hydroprocessing methods using high activity, low density catalysts are provided. The high activity catalysts allow for lower temperature operation, which reduces catalyst degradation, while the low density of the catalysts means a corresponding reduction in the amount of metal needed to fill a reactor volume. The methods allow for flexible processing of feedstocks with a variety of wax contents.