Self-Activating Hydroprocessing Catalyst for Heavy Feedstocks
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Solution Overview
Problem
Current hydroprocessing catalysts face challenges in effectively treating heavy hydrocarbon feedstocks with high sulfur and metal concentrations, as they tend to lose activity over time and are not economically efficient.
Innovation Solution
A self-activating hydroprocessing catalyst is developed, comprising a calcined particle with a co-mulled mixture of inorganic oxide, molybdenum trioxide, and a nickel compound, with a specific pore structure and low metal concentrations, which exhibits increased activity with use due to nickel sorption from the feedstock.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hydroprocessing catalysts are used to treat heavy hydrocarbon feedstocks, then initial catalytic activity is achieved, but catalyst activity decreases over time
Solution Approach 1:
The catalyst is designed to self-activate by sorbing nickel from the heavy hydrocarbon feedstock during the hydroprocessing operation. This self-service mechanism transforms the initially low-activity catalyst into a highly active catalyst over time, eliminating the need for external activation steps and improving long-term reliability
Solution Approach 2:
The catalyst composition parameters are specifically optimized with controlled low levels of nickel (0.1-5.0 wt%) and molybdenum (5-20 wt%) combined with alumina support. These parameter changes enable the catalyst to undergo transformation from low initial activity to high sustained activity through nickel sorption from the feedstock
2Productivity
If high metal content catalysts are used to treat heavy hydrocarbon feedstocks, then catalytic activity is improved, but manufacturing cost increases
Solution Approach 1:
The catalyst employs optimized parameter ranges with reduced metal content compared to conventional catalysts: nickel at 0.1-5.0 wt% and molybdenum at 5-20 wt%. These parameter changes maintain adequate initial activity while significantly reducing manufacturing costs, and the catalyst compensates through self-activation
Solution Approach 2:
The catalyst obtains additional nickel content in-situ from the heavy hydrocarbon feedstock during operation. This self-service approach eliminates the need to load high levels of nickel during manufacturing, reducing raw material costs while ensuring adequate nickel content is achieved through feedstock interaction
3Productivity
If conventional catalysts are used for heavy hydrocarbon treatment, then initial desulfurization capability is achieved, but catalyst performance deteriorates with high sulfur content
Solution Approach 1:
The high sulfur content in heavy hydrocarbon feedstocks, which typically poisons conventional catalysts, is converted into a benefit for this catalyst. The sulfur compounds facilitate nickel sorption onto the catalyst surface, transforming the harmful sulfur into a mechanism that enhances catalyst activation and long-term stability
Solution Approach 2:
The catalyst utilizes the sulfur-containing environment of heavy hydrocarbon processing to drive nickel sorption from the feedstock onto the catalyst surface. This self-service mechanism ensures the catalyst develops optimal composition in-situ, improving both desulfurization performance and stability
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 demonstrates improved catalytic activity over time, achieving enhanced desulfurization and demetallization of heavy hydrocarbon feedstocks with high sulfur and metal content, while being more economical to manufacture and maintain.
Implementation Method 1
the catalyst exhibits increased activity with use due to nickel sorption from the feedstock
Implementation Method 2
achieving enhanced desulfurization and demetallization of heavy hydrocarbon feedstocks
Implementation Method 3
achieving enhanced desulfurization and demetallization of heavy hydrocarbon feedstocks with high sulfur and metal content
Data Source
AI summary
A self activating catalyst for treating heavy hydrocarbon feedstocks that comprises a calcined particle comprising a co-mulled mixture made by co-mulling inorganic oxide powder, molybdenum trioxide powder, and a nickel compound and then forming the co-mulled mixture into a particle that is calcined to thereby provide the calcined particle. The calcined particle comprises from 1 to 10 weight percent molybdenum and nickel that is present in an amount such that the weight ratio of said nickel-to-molybdenum is less than 0.4. The calcined particle has a pore size distribution that contributes to the unique properties of the catalyst. The calcined particle and catalyst also exhibits a unique Raman spectrum. The self activating catalyst is activated when contacted under suitable process conditions with a heavy residue feedstock having high nickel, vanadium and sulfur concentrations.