Single-Stage Catalyst for Aromatic Hydrocarbon Upgrading
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Solution Overview
Problem
Conventional hydrotreating processes struggle to effectively convert heavy hydrocarbon feedstreams with high aromatic content into jet and diesel products in a single reactor system, often requiring multiple stages and catalyst beds, which complicates the process and reduces efficiency.
Innovation Solution
A single stage reactor system using a catalyst composition with a hydrotreating catalyst and a hydrogenation/hydrocracking catalyst, where the active metals comprise 5%-30% nickel and 5%-30% tungsten, is employed to contact highly aromatic hydrocarbon feedstreams, facilitating the conversion of feedstocks with a boiling range of 300° F. to 800° F. to products within the jet or diesel boiling ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydrotreating processes use multiple stages and catalyst beds, then the conversion of heavy hydrocarbon feedstreams to jet and diesel products is achieved, but the process complexity increases and efficiency decreases
Solution Approach 1:
The patent combines multiple catalyst functions into a single dual-function catalyst composition containing both hydrotreating components (Group VIB metals like Mo or W) and hydrogenation components (Group VIII metals like Ni or Pt). This single catalyst performs both hydrodesulfurization and aromatic hydrogenation simultaneously in one reactor stage, eliminating the need for multiple separate catalyst beds and process stages, thereby reducing process complexity while maintaining high conversion efficiency
Solution Approach 2:
The catalyst composition is designed with multi-functionality to perform multiple reactions concurrently: it provides hydrodesulfurization activity through Group VIB metals, aromatic hydrogenation through Group VIII metals, and hydrocracking through the acidic support. This universal catalyst handles diverse conversion requirements in a single reactor, simplifying the overall process architecture while achieving comprehensive feedstock upgrading
2Device complexity
If a single stage reactor system is used, then the process is simplified, but the effective conversion of high aromatic content feedstocks to jet and diesel products is insufficient
Solution Approach 1:
The patent employs a composite catalyst material combining multiple metal components (Group VIB and Group VIII metals) on an acidic refractory oxide support. This composite structure integrates diverse functional properties: hydrodesulfurization activity from Mo/W, hydrogenation activity from Ni/Pt, and hydrocracking activity from the acidic support. The synergistic interaction of these components within a single catalyst enables effective conversion of high aromatic feedstocks in one reactor stage, achieving both process simplicity and high conversion effectiveness
Solution Approach 2:
The catalyst design utilizes parameter changes in metal composition ratios and support acidity to optimize performance for single-stage operation. By adjusting the proportions of Group VIB and Group VIII metals and tuning the acidity of the refractory oxide support, the catalyst achieves balanced activity for hydrodesulfurization, hydrogenation, and hydrocracking reactions, enabling effective single-pass conversion of challenging high aromatic feedstocks to jet and diesel products
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
This approach enables the efficient upgrading of heavy hydrocarbon feedstocks to high-energy density jet and diesel fuels with low aromatic content, achieving product streams with greater than 70% aromatic saturation and energy densities above 120,000 Btu/gal, while simplifying the process by eliminating the need for multiple reactor stages.
Implementation Method 1
contacting a highly aromatic hydrocarbon feedstream with hydrogen in the presence of a catalyst composition
Implementation Method 2
active metals in the hydrogenation/hydrocracking catalyst comprises from about 5%-30% by weight of nickel and from about 5%-30% by weight tungsten
Data Source
AI summary
A process of upgrading a highly aromatic hydrocarbon feedstream comprising(a) contacting a highly aromatic hydrocarbon feedstream, wherein, a major portion of the feedstream has a boiling range of from about 300° F. to about 800° F., under catalytic conditions with a catalyst system, containing a hydrotreating catalyst and a hydrogenation/hydrocracking catalyst in a single stage reactor system, wherein the active metals in the hydrogenation/hydrocracking catalyst comprises from about 5%-30% by weight of nickel and from about 5%-30% by weight tungsten; and(b) wherein at least a portion of the highly aromatic hydrocarbon feedstream is converted to a product stream having a boiling range within jet or diesel boiling ranges.