Nanopore Volume Hydrotreating Catalyst for Higher Base Oil Yield
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Solution Overview
Problem
Existing hydroisomerization catalytic dewaxing processes face challenges in producing base oils that meet product specifications while maintaining good yield, as they often result in increased chain cracking and aromatics content, which affects the quality and yield of base oils.
Innovation Solution
A hydrotreating catalyst system comprising a base extrudate of high nanopore volume (HNPV) amorphous silica alumina (ASA) and HNPV or non-HNPV alumina, combined with modifiers from Groups 6 to 10 and Group 14 of the Periodic Table, is used to convert wax-containing hydrocarbon feedstocks into high-grade products with reduced aromatics content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydroisomerization catalytic dewaxing processes are used, then base oil production is achieved, but chain cracking increases leading to reduced base oil yield and increased aromatics content
Solution Approach 1:
The patent changes the physical-chemical parameters of the catalyst support by using high nanopore volume amorphous silica alumina with specific pore size distribution (0.3-2.0 cc/g total pore volume, with 0.1-0.5 cc/g in the 11-20 nm range). This parameter change modifies the catalyst's interaction with hydrocarbon molecules, reducing chain cracking reactions while maintaining hydroisomerization activity, thereby improving base oil yield and reducing harmful aromatics content
Solution Approach 2:
The patent employs a composite catalyst system combining amorphous silica alumina with alumina (in ratios of 95:5 to 50:50 by weight). This composite material structure creates synergistic effects where the silica alumina component provides high nanopore volume for reduced cracking, while the alumina component maintains catalytic activity, successfully resolving the contradiction between productivity and harmful byproducts
2Productivity
If hydroisomerization reactions are intensified to improve base oil yield, then productivity increases, but the degree of branching increases leading to greater chain cracking
Solution Approach 1:
The patent applies local quality by creating specific pore environments within the catalyst structure. The high nanopore volume amorphous silica alumina provides localized regions with optimal pore sizes (11-20 nm range) that facilitate hydroisomerization while physically constraining reactions that lead to excessive branching and cracking. This local structural quality control allows intensive hydroisomerization without compromising molecular structure stability
3Manufacturing precision
If downstream hydrotreating is used to reduce aromatics content, then product quality improves, but process complexity and cost increase
Solution Approach 1:
The patent extracts the aromatics reduction function from the downstream hydrotreating process by incorporating it directly into the hydroisomerization catalyst. The high nanopore volume amorphous silica alumina catalyst selectively promotes hydroisomerization while minimizing chain cracking and aromatics formation, effectively removing the need for separate downstream hydrotreating units and reducing overall process complexity while maintaining high product quality
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 system effectively reduces aromatics content and improves product yield, producing base oils with enhanced quality characteristics.
Implementation Method 1
a base extrudate comprising a high nanopore volume amorphous silica alumina and an alumina
Implementation Method 2
the feed contacts the hydroisomerization catalyst under hydroisomerization dewaxing conditions to provide an isomerized stream
Implementation Method 3
contacting a hydrotreating and/or hydrofinishing catalyst with the stream to reduce or remove any aromatics and olefins
Data Source
AI summary
Hydrotreating catalyst and process for making a base oil product using a catalyst having a base comprising a high nanopore volume amorphous silica alumina (ASA) and an alumina. The amorphous silica alumina has a pore volume in the 11-20 nm pore diameter range of 0.2 to 0.9 cc/g and the alumina has a pore volume in the 11-20 nm pore diameter range of 0.01 to 1.0 cc/g, with the base formed from the ASA and the alumina having a total pore volume in the 2-50 nm pore diameter range of 0.12 to 1.80 cc/g. The catalyst comprises at least one modifier element from Groups 6 to 10 and Group 14 of the Periodic Table. The catalyst and process provide improved aromatics saturation.