Slurry-Phase Catalyst Using Disulfide Oil Ligands

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The processing of hydrocarbon streams, particularly residual oils with high metal content, is limited by the inefficiencies of existing technologies such as fixed-bed and ebullated-bed methods, and the disposal of disulfide oil by-products from mercaptan oxidation processes poses environmental challenges, necessitating a more effective conversion of these by-products into useful materials.

Innovation Solution

A slurry-phase catalyst composition comprising disulfide oil and a first metal complex, where the complex includes transition metals like molybdenum, cobalt, nickel, tungsten, or iron bonded to disulfide ligands, is used to upgrade hydrocarbon feeds, enhancing the economic viability of slurry-phase hydrocracking and reducing waste production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If fixed-bed or ebullated-bed technologies are used to process residual oils, then conversion efficiency is improved, but the technology is limited to feedstock with low metal content (below 400 ppmw)

Engineering Contradiction:

Improveconversion efficiencyVSAvoidfeedstock metal content tolerance

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The invention changes the fundamental parameters of the catalytic system by using slurry-phase technology with soluble metal complexes instead of fixed-bed heterogeneous catalysts. This allows processing of feedstock with metal content up to 4,000 ppmw, representing a ten-fold increase in tolerance compared to conventional technologies while achieving up to 95% conversion efficiency.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If slurry-phase hydrocracking is used to process high metal content residual oils, then conversion rate is improved (up to 95%), but the economic viability is reduced due to waste disposal costs

Engineering Contradiction:

Improveconversion rateVSAvoideconomic viability

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The invention converts the harmful waste by-product (disulfide oil) into a beneficial catalyst component. The disulfide oil, which would normally require costly disposal, is now used as the ligand source for the metal complex catalyst, eliminating waste disposal costs and improving economic viability while maintaining high conversion rates.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The disulfide oil by-product serves itself by becoming the ligand for the catalyst. The system uses its own waste product to maintain catalytic activity, creating a self-sustaining process that improves economics without sacrificing performance.

Inventive Principle:

Principle #25Self-service

3Object-generated harmful factors

If disulfide oil is produced as a by-product of MEROX process, then mercaptan removal is achieved, but additional waste product is generated that requires disposal

Engineering Contradiction:

Improvemercaptan removalVSAvoidwaste production

Core Design Contradiction:

Object-generated harmful factorsVSLoss of substance

Solution Approach 1:

The invention transforms the harmful waste by-product (disulfide oil) into a useful catalyst ligand. The disulfide oil that would normally require disposal is now the source of ligands for the metal complex catalyst, converting a waste stream into a valuable process component and eliminating disposal requirements.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The disulfide oil serves multiple functions: it is both the product of mercaptan oxidation and the ligand source for the catalyst. This multi-functionality eliminates the need for separate waste disposal systems and integrates the waste stream into the catalytic process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 proposed catalyst composition effectively converts disulfide oil by-products into useful materials, improving the conversion rates and economic viability of slurry-phase hydrocracking, while minimizing waste and addressing environmental concerns associated with disulfide oil disposal.

Implementation Method 1

a slurry-phase catalyst composition may comprise a disulfide oil and a first metal complex. The first metal complex may comprise at least one transition metal selected from the group consisting of molybdenum, cobalt, nickel, tungsten, iron and combinations of these

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

The transition metal may be bonded to a sulfur atom of the at least one first ligand

Methodology Applied

Scientific EffectChemical Bonding: Chemical Bonding

Data Source

PatentUS11911750B1Slurry-phase catalyst compositions and methods of making the same

Publication Date: 2024.02.27 SAUDI ARABIAN OIL CO

AI summary

A slurry-phase catalyst composition may include a disulfide oil and a first metal complex. The first metal complex may include at least one transition metal selected from the group consisting of molybdenum, cobalt, nickel, tungsten, iron, and combinations of these. The first metal complex may also include a plurality of ligands bonded to the at least one transition metal. The plurality of ligands may include at least one first ligand selected from the group consisting of dim ethyl sulfide, dimethyldisulfide, diethyl sulfide, diethyldisulfide, methyl ethyl sulfide, methylethyldisulfide, and combinations thereof, and the transition metal may be bonded to a sulfur atom of the at least one first ligand.