Low Surface Area Catalyst for Heavy Hydrocarbon MCR Conversion
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Solution Overview
Problem
Current catalyst compositions for hydroprocessing of heavy hydrocarbon feedstocks are inadequate in converting micro carbon residue (MCR), leading to fouling of downstream equipment and reduced process efficiency.
Innovation Solution
A calcined particulate catalyst composition made from a co-mulled mixture of molybdenum, nickel, pseudo-boehmite powder, and mineral acid, with specific surface area and pore distribution characteristics, is used to enhance MCR conversion in hydroconversion processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional catalyst compositions are used for hydroprocessing, then the catalyst structure is simple and easy to manufacture, but the MCR conversion activity is insufficient leading to fouling of downstream equipment
Solution Approach 1:
The patent employs a composite catalyst composition comprising multiple metal components (Group VIII metals such as nickel, and Group VIB metals such as molybdenum) supported on alumina with specific surface area and pore structure characteristics. This composite structure synergistically enhances MCR conversion activity while managing the complexity through defined compositional ranges and preparation methods
Solution Approach 2:
The patent utilizes alumina support materials with specifically controlled pore structures (surface area of 240-310 m²/g and defined pore size distribution) to enhance the catalytic activity for MCR conversion. The porous structure provides increased surface area for active sites while facilitating mass transfer, directly addressing the insufficient conversion activity of conventional catalysts
2Productivity
If catalyst surface area is increased to enhance activity, then MCR conversion improves, but catalyst stability and selectivity may be compromised
Solution Approach 1:
The patent optimizes the alumina support surface area to a specific range (240-310 m²/g) rather than maximizing it, and controls the pore size distribution with defined proportions of micropores, mesopores, and macropores. This parameter optimization achieves high MCR conversion activity while maintaining catalyst stability and preventing excessive surface area-related side reactions
3Object-affected harmful factors
If hydroprocessing is performed to convert MCR, then downstream equipment fouling is reduced, but process complexity and operating conditions become more demanding
Solution Approach 1:
The patent employs a pre-optimized catalyst composition with specific metal loadings (Group VIII: 2.5-6 wt%, Group VIB: 14.5-24 wt%) and support characteristics that are prepared in advance through controlled impregnation and calcination procedures. This preliminary optimization of catalyst structure enables effective MCR conversion under defined hydroprocessing conditions, reducing downstream fouling while managing process complexity through standardized preparation protocols
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 catalyst composition achieves significant improvements in MCR conversion, providing higher activity and stability compared to prior art catalysts, thereby reducing fouling and enhancing process efficiency.
Implementation Method 1
Process for the catalytic conversion of micro carbon residue content of heavy hydrocarbon feedstocks and a low surface area catalyst composition for use therein
Data Source
AI summary
An improved process for the hydroconversion of micro carbon residue content of heavy hydrocarbon feedstocks by the use of a catalyst composition that is especially useful in the conversion of micro carbon residue of such feedstocks. The catalyst composition is a low surface area composition that further has a specifically define pore structure the combination of which provides for its enhance micro carbon residue conversion property.