Metallo-silicate Catalysts for TAN Reduction in Heavy Hydrocarbons
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Solution Overview
Problem
Current methods for reducing the total acid number (TAN) in heavy hydrocarbons, such as bitumen, are inefficient and costly, often requiring complex and capital-intensive processes like distillation, which are not feasible for all production scenarios, and existing catalysts are prone to deactivation due to heavy molecules present in the feedstock.
Innovation Solution
Development of porous metallo-silicate compositions (MSCs) with specific chemical and morphological properties that act as molecular sieves, incorporating cerium, nickel, copper, and zinc within micro- and meso-porous silicate frameworks, which are effective in reducing TAN, viscosity, density, and sulfur content through steam or CO2 catalytic processes without the need for hydrogen or separation steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex distillation processes are used to reduce TAN in heavy hydrocarbons, then TAN reduction effectiveness is improved, but process complexity and capital cost increase
Solution Approach 1:
The patent extracts and removes the harmful acidic components (TAN) from heavy hydrocarbon feedstocks through catalytic treatment, separating the purification function from complex distillation processes. The catalyst selectively targets and removes acidic moieties while leaving the bulk hydrocarbon unchanged, achieving TAN reduction without requiring complex multi-stage distillation systems
Solution Approach 2:
The patent employs porous metallo-silicate catalysts with specific pore structures (micro-porous and meso-porous frameworks) that enable selective access to acidic components within the hydrocarbon feedstock. The porous structure provides high surface area for catalytic activity while maintaining selectivity, simplifying the overall process compared to conventional distillation
2Productivity
If conventional catalysts are used in heavy hydrocarbon processing, then catalytic activity is achieved, but catalyst lifetime decreases due to deactivation by heavy molecules
Solution Approach 1:
The patent applies local quality by creating catalysts with specific localized properties - bi-metallic or tri-metallic combinations (e.g., Ni-Ce, Cu-Ce, Zn-Ce) embedded within porous silicate frameworks. Different metal components provide complementary functions: one metal provides catalytic activity for acid removal while another enhances stability and resistance to deactivation by heavy molecules, achieving both high productivity and extended catalyst lifetime
Solution Approach 2:
The patent uses composite metallo-silicate materials combining multiple metals with silicate framework structures. These composite catalysts integrate the benefits of different materials - the structural stability of silicates with the catalytic properties of transition metals - creating a robust catalyst that maintains activity and resists deactivation by heavy hydrocarbon molecules over extended periods
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 MSCs demonstrate high activity and selectivity in removing acidic moieties from hydrocarbon feedstocks, achieving significant TAN reduction and improving the quality of heavy oils, reducing viscosity and sulfur content, and extending catalyst lifetime through oxygen regeneration, thus enhancing the efficiency and cost-effectiveness of hydrocarbon upgrading processes.
Implementation Method 1
porous metallo-silicate compositions (MSCs) with specific chemical and morphological properties that act as molecular sieves
Implementation Method 2
demonstrate high activity and selectivity in removing acidic moieties from hydrocarbon feedstocks
Implementation Method 3
steam or CO2 catalytic processes
Implementation Method 4
extending catalyst lifetime through oxygen regeneration
Data Source
AI summary
The invention relates to the preparation of novel bi- or tri metallic silicate micro-porous and/or meso-porous materials based on cerium, nickel, copper and/or zinc on a porous silicate framework matrix to use its molecular sieve effect to target preferentially the acidic organic molecules present in hydrocarbon feedstocks like crude oil, bitumen, VGO and the like. The chosen metals are selected based on their ability to activate steam and transfer oxygen for completing the oxidation of carboxylic compounds or decarboxylating them. These composite materials can be prepared under hydrothermal synthesis conditions in order to produce suitable porous solids where the metals are well dispersed and preferentially distributed inside the channels of the silicate framework where they can interact only with the molecules that can go inside the channels. According to the invention, the metallo-silicate materials are prepared under hydrothermal synthesis conditions Modification of the physical-chemical properties of the porous silicate materials can be accomplished by partial replacement of the silicon atoms by cerium, nickel, copper and/or zinc atoms in the material by isomorphous substitutions of these elements in a synthesis gel or by post-synthesis modifications like ion-exchange or impregnation/deposition. The materials can be used as prepared catalysts for the steam catalytic reduction of the total acid number (TAN) in acidic crude oil feedstocks and in the presence of steam and/or CO2 as oxidizing agent to complete decarboxylation and to keep the metal oxide active sites from reducing and deactivating as well as other partial upgrading reactions.