Macroporous Hydroprocessing Catalyst for Heavy Oil Conversion
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Solution Overview
Problem
Existing hydroprocessing catalysts for heavy hydrocarbons face challenges in achieving high conversion of pitch components to lighter hydrocarbons while minimizing sediment yield, particularly in processes involving high molecular weight polyacrylamide.
Innovation Solution
A high macroporosity ebullating bed catalyst is developed, comprising alumina, molybdenum, nickel, and high molecular weight polyacrylamide, with a bimodal pore structure and controlled calcination, to enhance catalytic properties and reduce sediment formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydroprocessing catalysts are used, then basic hydrodesulfurization activity is provided, but conversion of pitch components to lighter hydrocarbons is insufficient and sediment yield is high
Solution Approach 1:
The patent applies porous materials by developing a catalyst with a specific pore size distribution featuring macropores (diameter > 1000 Å) that constitute at least 1% of total pore volume. These macropores enable deep penetration into pitch components, facilitating their conversion to lighter hydrocarbons while reducing sediment yield through enhanced mass transport and accessibility to catalytic sites.
Solution Approach 2:
The patent applies composite materials by combining alumina support with specific pore structure characteristics (bimodal or trimodal pore distribution including micropores, mesopores, and macropores) and loading it with molybdenum and nickel components. This composite structure synergistically enhances both the catalytic activity for pitch conversion and the ability to minimize sediment formation.
2Productivity
If higher process temperatures are used to increase conversion of heavy hydrocarbon fractions, then productivity improves, but catalyst stability deteriorates
Solution Approach 1:
The patent applies parameter changes by optimizing the pore size distribution parameters, specifically ensuring macropores (>1000 Å) constitute at least 1% of total pore volume. This structural parameter change allows the catalyst to maintain stability at elevated temperatures while achieving high conversion of heavy hydrocarbons, resolving the trade-off between productivity and reliability.
3Manufacturing precision
If catalysts with narrow pore diameter ranges are used, then manufacturing precision is improved, but accessibility to heavy hydrocarbon molecules is limited
Solution Approach 1:
The patent applies segmentation by dividing the pore structure into distinct size segments: micropores (<100 Å), mesopores (100-1000 Å), and macropores (>1000 Å), with each segment serving specific functions. This segmented pore architecture enables precise manufacturing control of each segment while collectively providing enhanced accessibility to heavy hydrocarbon molecules through the macropore pathway.
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 effectively converts heavy hydrocarbons to lighter products with low sediment yield, demonstrating improved catalytic performance and efficiency in hydrodesulfurization and hydrodemetalization processes.
Implementation Method 1
These processes use various types of heterogeneous hydroprocessing catalysts to promote the reactions by contacting the catalyst with feedstock under conditions of elevated temperature and pressure in the presence of hydrogen
Implementation Method 2
convert heavy ends to lighter distillate fractions. These processes use various types of heterogeneous hydroprocessing catalysts to promote the reactions
Implementation Method 3
to remove components such as sulfur, nitrogen, metals, and micro-carbon residue by desulfurization, denitrogenation, demetallization
Implementation Method 4
to remove components such as sulfur, nitrogen, metals, and micro-carbon residue by desulfurization, denitrogenation, demetallization
Data Source
AI summary
The specification discloses a highly macroporous catalyst for hydroprocessing and hydroconversion of heavy hydrocarbon feedstocks. The high macroporosity catalyst incudes an inorganic oxide, molybdenum, and nickel components. It has a pore structure such that at least 18% of its total pore volume is in pores of a diameter greater than 5,000 angstroms and at least 25% of its total pore volume is in pores of a diameter greater than 1,000 angstroms. Preferably, the pore structure is bimodal. The catalyst is made by co-mulling the catalytic components with a high molecular weight polyacrylamide followed by forming the co-mulled mixture into a particle or an extrudate. The particle or extrudate is dried and calcined under controlled calcination temperature conditions to yield a calcined particle or extrudate of the high macroporosity catalyst composition.