Self-Activating Hydroprocessing Catalyst for Heavy Feedstocks
Find Innovative SolutionsGenerate Solutions
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 costly to manufacture, requiring the development of a catalyst with improved stability and activity for efficient desulfurization and demetallization.
Innovation Solution
A self-activating hydroprocessing catalyst comprising a calcined particle with a co-mulled mixture of inorganic oxide powder, molybdenum trioxide, and a nickel compound, characterized by a specific pore size distribution and low nickel-to-molybdenum ratio, which exhibits increased activity with use and is economical to produce.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hydroprocessing catalysts are used to treat heavy hydrocarbon feedstocks with high sulfur and metal concentrations, then initial catalytic activity is achieved, but catalyst activity decreases over time
Solution Approach 1:
The patent applies parameter changes by precisely controlling the nickel-to-molybdenum weight ratio within 0.01:1 to 0.3:1, and adjusting molybdenum content to 3-8 wt%, which transforms the catalyst's performance characteristics to achieve self-activation and improved stability over time
Solution Approach 2:
The patent uses composite materials by combining nickel compound, molybdenum trioxide, and inorganic oxide material in specific proportions to create a synergistic catalyst system that exhibits enhanced stability and self-activation properties when treating heavy hydrocarbon feedstocks
2Productivity
If higher nickel content is used in the catalyst to improve initial activity, then catalytic performance increases, but manufacturing cost increases
Solution Approach 1:
The patent optimizes the nickel content by controlling the nickel-to-molybdenum weight ratio to be between 0.01:1 and 0.3:1, which reduces nickel usage and manufacturing cost while maintaining acceptable initial activity that improves over time through self-activation
Solution Approach 2:
The catalyst exhibits self-service through self-activation, where the catalyst improves its own activity over time when exposed to heavy hydrocarbon feedstocks, eliminating the need for high initial nickel content and reducing manufacturing costs
3Productivity
If conventional catalyst compositions are used for heavy hydrocarbon feedstocks, then basic hydroprocessing is achieved, but energy consumption increases due to higher reactor temperatures required
Solution Approach 1:
The patent changes the chemical composition parameters by using low nickel-to-molybdenum ratios (0.01:1 to 0.3:1) and specific molybdenum content (3-8 wt%), which enables effective hydroprocessing at lower reactor temperatures, reducing energy consumption while maintaining productivity
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, leading to energy savings and extended catalyst life, while being more economical to manufacture.
Implementation Method 1
the calcined particle comprises molybdenum that is present in an amount in the range of from 3 to 8 weight percent, as metal and based on the total weight of the calcined particle, and nickel that is present in an amount such that the weight ratio of nickel-to-molybdenum is from 0.01:1 to 0.3:1
Data Source
Figure 1~2
Figure 3~4
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.