Single-Stage Catalyst for Aromatic Feedstock Conversion
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Solution Overview
Problem
Conventional hydrotreating processes struggle to efficiently convert heavy hydrocarbon feedstocks 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 utilizing a catalyst composition that combines a hydrotreating catalyst with a hydrogenation/hydrocracking catalyst, containing 5%-30% nickel and 5%-30% tungsten, to convert highly aromatic hydrocarbon feedstocks with a boiling range of 300° F. to 800° F. into products within the jet or diesel boiling range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydrotreating processes are used to convert heavy hydrocarbon feedstocks with high aromatic content, then the process requires multiple stages and catalyst beds, but this increases device complexity and reduces productivity
Solution Approach 1:
The patent combines hydrotreating and hydrogenation/hydrocracking functions into a single reactor stage by using a catalyst system that integrates both activity types. The catalyst composition includes metal components (Ni, Mo, W) that provide both hydrotreating and hydrocracking functions simultaneously, eliminating the need for separate reactor stages and reducing device complexity while maintaining high conversion efficiency
Solution Approach 2:
The catalyst system is designed to perform multiple functions within a single stage: it provides hydrotreating activity for aromatic saturation, hydrocracking activity for heavy hydrocarbon conversion, and hydrogenation capability. This multi-functional catalyst eliminates the need for sequential processing stages, directly resolving the contradiction between productivity and device complexity
2Productivity
If multiple catalyst beds are used to achieve efficient conversion, then conversion efficiency improves, but manufacturing complexity and operational complexity increase
Solution Approach 1:
The patent merges multiple catalyst functions into a single catalyst composition and single reactor stage. The catalyst includes Ni (5-30 wt%), Mo (5-30 wt%), and W (5-30 wt%) on an alumina support, providing integrated hydrotreating, hydrocracking, and hydrogenation capabilities in one unit, thereby simplifying manufacturing and operation while maintaining high conversion efficiency
Solution Approach 2:
The catalyst is designed as a composite material system combining multiple metal components (Ni, Mo, W) with an alumina support. This composite structure provides synergistic effects where each metal component contributes different catalytic functions, achieving high conversion efficiency in a single stage without requiring multiple separate catalyst beds
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 heavy hydrocarbonaceous feed under catalytic conditions with a catalyst system
Implementation Method 2
contacting the heavy hydrocarbonaceous feed with hydrogen in the presence of a catalyst composition
Implementation Method 3
converting heavy hydrocarbon feedstreams to jet and diesel products using a single reactor, dual stage catalyst system; and using a single reactor, single stage catalyst system
Data Source
AI summary
A process of upgrading a highly aromatic hydrocarbon feedstream comprising(a) contacting a highly aromatic hydrocarbon feedstream, having a normal paraffin content of greater than at least about 5 wt %, 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, a hydrogenation/hydrocracking catalyst, and a dewaxing 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.