Self-Activating Hydroprocessing Catalyst for Heavy Resid
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Solution Overview
Problem
Current hydroprocessing catalysts face challenges in efficiently treating heavy hydrocarbon feedstocks with high sulfur and metal concentrations, requiring improved catalytic activity and stability while being economically viable.
Innovation Solution
A self-activating hydroprocessing catalyst is developed by co-mulling inorganic oxide powder, molybdenum trioxide powder, and a nickel compound, calcining the mixture, and treating it with a sulfoxide compound in the presence of hydrogen, resulting in a catalyst with enhanced activity and stability, suitable for treating heavy hydrocarbon feedstocks with significant nickel, vanadium, and sulfur content.
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 the catalyst can perform basic hydroprocessing functions, but the catalytic activity is insufficient and the catalyst degrades quickly
Solution Approach 1:
The patent applies parameter changes by treating the calcined catalyst particle with a sulfoxide compound in the presence of molecular hydrogen, which transforms the catalyst's chemical state and activates its self-activating properties. This treatment modifies the catalyst's parameters to achieve both high catalytic activity and stability when treating heavy hydrocarbon feedstocks
Solution Approach 2:
The patent uses composite materials by combining inorganic oxide powder, molybdenum trioxide powder, and nickel compound in specific weight ratios (nickel 0.1-5 wt%, molybdenum 1-10 wt%). This composite structure creates a catalyst that simultaneously provides the necessary activity for desulfurization and stability for extended operation
2Productivity
If reactor temperature is increased to improve hydroprocessing activity, then the catalytic activity increases, but energy consumption increases and catalyst life decreases
Solution Approach 1:
The patent changes the catalyst's chemical parameters through sulfoxide treatment, which activates self-activating properties. This allows the catalyst to achieve high hydroprocessing activity at lower reactor temperatures, thereby reducing energy consumption while maintaining effective desulfurization and demetallization performance
3Productivity
If the catalyst is designed for high catalytic activity, then the hydroprocessing efficiency improves, but the manufacturing cost increases
Solution Approach 1:
The patent optimizes the weight ratios of components (nickel 0.1-5 wt%, molybdenum 1-10 wt%) to achieve high catalytic activity at economical concentrations. The sulfoxide treatment step further enhances activity without requiring additional expensive materials, maintaining cost-effectiveness while maximizing 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 exhibits increased catalytic activity over time, effectively reducing sulfur and metal content in heavy hydrocarbon feedstocks, leading to energy savings and extended catalyst life, while maintaining economic manufacturing costs.
Implementation Method 1
treating the calcined particle with a sulfoxide compound in the presence of molecular hydrogen to provide the self-activating hydroprocessing catalyst
Implementation Method 2
treating the calcined particle with a sulfoxide compound in the presence of molecular hydrogen
Data Source
AI summary
A self-activating catalyst for treating heavy hydrocarbon feedstocks that comprises a calcined particle treated with a sulfoxide compound in the presence of hydrogen. The calcined particle comprises 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 enhanced self-activating catalyst is used in the hydroprocessing of heavy residue feedstocks that have high nickel, vanadium and sulfur concentrations.