Polygonal Catalyst Pellets for Surface Area and Structural Integrity

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Solution Overview

Problem

Existing catalyst pellet geometries face a trade-off between high surface area to volume ratio and structural integrity, leading to degradation and the need for increased inventory.

Innovation Solution

Catalyst pellets are designed as substantially regular polygonal prisms with apertures oriented towards corners, providing a larger surface area to volume ratio while maintaining structural integrity through geometric optimization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If catalyst pellets are designed with high surface area to volume ratio, then reaction activity is improved, but structural integrity deteriorates leading to degradation

Engineering Contradiction:

Improvereaction activityVSAvoidstructural integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The catalyst pellet is segmented into multiple polygonal prismatic bodies arranged in a circular pattern, with each body having apertures oriented towards its corners. This segmentation increases the total surface area while distributing the structural load, preventing degradation of individual segments and maintaining overall structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention transitions from conventional two-dimensional surface area optimization to three-dimensional structural optimization by creating polygonal prismatic bodies with apertures oriented towards corners. This dimensional approach allows simultaneous increase of surface area and maintenance of structural strength through geometric configuration.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If conventional catalyst pellet shapes are used, then structural integrity is maintained, but surface area to volume ratio is insufficient reducing reaction activity

Engineering Contradiction:

Improvestructural integrityVSAvoidreaction activity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The catalyst pellet is divided into multiple polygonal prismatic bodies arranged in a circular pattern, each contributing to the overall surface area. This segmentation allows the pellet to maintain structural integrity through the distributed arrangement while increasing total active surface area for reactions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each polygonal prismatic body is designed with specific local characteristics, including apertures oriented towards corners, to optimize both surface area and structural strength in different regions of the pellet, ensuring uniform performance throughout the catalyst structure.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20250288981A1Catalyst pellets that include polygonal prismatic bodies, packed bed reactors including the same, and methods for hydroprocessing utilizing the same

Publication Date: 2025.09.18 SAUDI ARABIAN OIL CO

AI summary

Embodiments herein are directed to a catalyst pellet including a substantially regular polygonal prismatic body including a first polygonal surface, a second polygonal surface opposite the first polygonal surface, and n faces each extending in a length dimension from the first polygonal surface to the second polygonal surface, where n is equal to an integer from 5 to 20. The catalyst pellet includes n apertures extending from the first polygonal surface to the second polygonal surface. Each aperture has a substantially cylindrical shape and is positioned such that it is oriented towards a corner of the first polygonal surface and the second polygonal surface. Further embodiments are directed to a packed bed reactor including a reactor vessel and a packed catalyst bed including at least one catalyst pellet described herein. Further embodiments are directed to a method for hydroprocessing a hydrocarbon feed including passing the hydrocarbon feed into a reactor vessel, such that the hydrocarbon feed contacts a packed catalyst bed including at least one catalyst pellet described herein to form a product composition and passing the product composition out of the reactor vessel.