Molybdenum Carbonized Catalyst for Slurry Hydrocracking
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Solution Overview
Problem
The challenge lies in finding a cost-effective and efficient catalyst for slurry hydrocracking heavy hydrocarbons that can effectively reduce the concentration of metal required for the process while minimizing coke formation and mesophase production, as conventional catalysts like iron sulfate are expensive and insufficient, and existing methods struggle with processing heavy oil feedstocks.
Innovation Solution
The use of dealkylated aromatic liquid derived from heavy hydrocarbon materials, such as those subjected to fluid catalytic cracking or slurry hydrocracking, to create a molybdenum carbonized catalyst, which requires less metal concentration and suppresses the formation of toluene insoluble organic residue and mesophase, allowing for improved processing of heavy residual hydrocarbon feedstocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional catalysts like iron sulfate are used in slurry hydrocracking, then catalytic activity is achieved, but the cost is high and metal concentration requirements are excessive
Solution Approach 1:
The patent changes the chemical parameters of the catalyst system by using molybdenum compounds (such as molybdenum trioxide or molybdenum sulfate) instead of conventional iron sulfate, and by controlling the metal concentration at 1-10 ppm range with a sulfur-to-metal molar ratio of 2:1 to 5:1. This parameter optimization achieves effective catalytic activity at lower metal concentrations, reducing both cost and material requirements
Solution Approach 2:
The patent creates a composite catalyst system comprising molybdenum compound, sulfur compound, and heavy hydrocarbon liquid. The interaction between these components forms a synergistic system where the molybdenum-sulfur complex dispersed in the heavy hydrocarbon liquid provides enhanced catalytic activity, allowing reduced metal concentration while maintaining or improving performance
2Productivity
If severe operating conditions are applied in slurry hydrocracking, then conversion of heavy hydrocarbons is improved, but mesophase and coke formation increase
Solution Approach 1:
The patent optimizes operating parameters including temperature (400-500°C), pressure (1000-3000 psig), and LHSV (0.5-5.0 hr⁻¹) to achieve high conversion while controlling mesophase formation. The controlled metal concentration (1-10 ppm) and sulfur-to-metal ratio (2:1 to 5:1) further modulate reaction severity, enabling high productivity with reduced harmful byproducts
Solution Approach 2:
The patent introduces molybdenum-sulfur complex as an intermediary catalyst that facilitates hydrocracking reactions under milder effective conditions. This catalyst mediates the breakdown of heavy hydrocarbons into lighter products while reducing direct thermal cracking that leads to coke formation, thus improving conversion efficiency without proportionally increasing harmful byproducts
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 enables the production of a more effective metal carbonized catalyst that reduces metal requirements in slurry hydrocracking, enhances conversion and selectivity to desirable products, and minimizes coke and mesophase formation, making it suitable for a wide range of heavy residual hydrocarbon feedstocks.
Implementation Method 1
heating the catalyst precursor concentrate to an elevated temperature to form a catalyst concentrate
Implementation Method 2
heating the catalyst precursor concentrate to an elevated temperature in the presence of sulfur to form an activated catalyst concentrate
Implementation Method 3
a three-phase mixture of heavy hydrocarbon feed cracks in the presence of gaseous hydrogen over solid catalyst to produce lighter products
Data Source
AI summary
A process using a dealkylated aromatic liquid improves a heavy hydrocarbon liquid used for supporting molybdenum carbonized catalyst. Dealkylated aromatic liquid can be derived from heavy hydrocarbon materials that have been subjected to cracking, such as fluid catalytic cracking or slurry hydrocracking. The heavy hydrocarbon liquid can comprise a portion of resid SHC feed and a portion of a gas oil stream from SHC effluent.