Multimetallic Catalyst for Heavy Oil Upgradation
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Solution Overview
Problem
The high cost and rapid deactivation of organometallic catalysts used in heavy oil hydrocracking processes necessitate the development of cost-effective, efficient catalyst formulations that can effectively upgrade heavy oil into light crude oil.
Innovation Solution
A catalyst comprising multimetallic carboxylate salts and organic acids, with specific weight ratios and preparation processes, is used to enhance the efficiency and economy of heavy oil upgradation, utilizing transition metals like Fe, Co, Ni, and Mo to improve catalyst performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If molybdenum-based catalysts are used for hydrocracking, then catalytic activity is maintained, but cost increases significantly
Solution Approach 1:
The patent combines multiple metals (Fe, Co, Ni, Mo, W) into a multimetallic catalyst system where cheaper metals (Fe, Co, Ni) work synergistically with Mo or W to achieve comparable catalytic activity at lower cost. The multimetallic formulation integrates different metal functions to maintain effectiveness while reducing dependency on expensive molybdenum alone.
Solution Approach 2:
The patent optimizes the weight ratios of different metals in the catalyst formulation, specifically controlling the ratio of multimetallic salt to organic acid (1:0.01-1:0.5) and the proportions of individual metals. This parameter optimization allows the use of cheaper metals in specific ratios that maximize catalytic performance while minimizing cost.
2Productivity
If organometallic catalysts are used for hydrocracking, then heavy oil conversion is achieved, but catalyst deactivation occurs rapidly
Solution Approach 1:
The patent creates a composite catalyst system combining multiple metals (Fe, Co, Ni, Mo, W) with organic acids and additives. This composite formulation enhances catalyst stability and resistance to deactivation during the hydrocracking process while maintaining high conversion activity. The synergistic interaction between different metals and organic components prevents rapid deactivation.
Solution Approach 2:
The patent employs cheaper transition metals (Fe, Co, Ni) that can be used in multimetallic formulations to reduce catalyst cost. These metals, when combined in specific ratios with organic acids and stabilizers, provide sufficient catalytic activity and extended stability, effectively replacing expensive long-lived catalysts with more economical alternatives.
3Ease of manufacture
If multimetallic catalysts are developed to reduce cost, then catalyst effectiveness must be maintained, but formulation complexity increases
Solution Approach 1:
The patent develops a universal multimetallic catalyst formulation that can effectively process different types of heavy oil feedstocks. The catalyst system contains multiple metals (Fe, Co, Ni, Mo, W) that perform different functions synergistically, allowing a single formulation to address various feedstock compositions and cracking requirements, thereby simplifying the need for multiple specialized catalysts.
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 proposed catalyst formulation achieves significant conversion of heavy oil into lighter hydrocarbons, with improved yields and reduced catalyst usage, demonstrating enhanced efficiency and cost-effectiveness in the hydrocracking process.
Implementation Method 1
The method for converting heavy oil feedstock into light crude oil involves the hydrocracking process predominantly employing organometallic catalysts. Hydrocracking is a two-step process, involving the cracking of the heavy oil hydrogenating to form lighter hydrocarbons.
Implementation Method 2
The organometallic catalysts used in the hydrocracking process mostly comprise transition metal complexes. The proposed catalyst formulation achieves significant conversion of heavy oil into lighter hydrocarbons, with improved yields and reduced catalyst usage.
Implementation Method 3
Hydrocracking is a two-step process, involving the cracking of the heavy oil hydrogenating to form lighter hydrocarbons.
Data Source
AI summary
A catalyst is provided having: (a) at least one multimetallic salt; and (b) at least one organic acid, wherein the at least one multimetallic salt to the at least one organic acid weight ratio is in the range of 1:0.01-1:0.5. A process is also provided for the preparation of the catalyst and for the preparation of the multimetallic salt.