Slurry Phase Organic-Inorganic Hybrid Catalyst for Residue Hydroprocessing
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Solution Overview
Problem
Catalysts used in hydroprocessing of heavy crude oils and residues deactivate rapidly due to high asphaltene and metal content, leading to reduced catalyst life and efficiency, especially in downstream processes where coke formation and metal poisoning are prevalent.
Innovation Solution
A slurry phase organic-inorganic fused hybrid catalyst is developed, comprising metals from group VI B and VIII B in a 4:1 ratio, specifically molybdenum and nickel, which is thermally stable and highly soluble in reaction media, prepared through a process involving the mixing of aqueous solutions of ammonium hepta molybdate and hexahydrate nickel nitrate, followed by preheating and reaction under supercritical conditions to form a bi-phase reaction mixture that is then separated and dried to obtain an organo-metallic catalyst.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional catalysts are used in hydroprocessing of heavy crude oils and residues, then the hydroprocessing reactions can proceed, but the catalyst deactivates rapidly due to high asphaltene and metal content
Solution Approach 1:
The invention changes the physical and chemical parameters of the catalyst by creating an organic-inorganic fused hybrid structure with specific metal ratios (Group VI B and VIII B metals in 4:1 ratio). This hybrid structure fundamentally alters the catalyst's resistance to deactivation by asphaltenes and metals, enabling it to maintain activity in harsh residue feed conditions where conventional catalysts fail rapidly.
Solution Approach 2:
The invention uses composite materials by fusing organic and inorganic components into a hybrid catalyst structure. The organic component provides resistance to asphaltene deactivation while the inorganic metal components (molybdenum and nickel in 4:1 ratio) provide hydroprocessing activity. This composite approach resolves the contradiction between maintaining catalyst activity and resisting deactivation by high metal and asphaltene content.
2Productivity
If catalysts are used to process high metal content residues, then hydrodemetallization can occur, but metal poisoning deactivates the catalyst
Solution Approach 1:
The invention changes the chemical composition parameters by incorporating specific ratios of Group VI B (molybdenum) and VIII B (nickel) metals in a 4:1 ratio. This specific compositional parameter enables the catalyst to perform hydrodemetallization while resisting metal poisoning, as the organic-inorganic hybrid structure prevents metal accumulation that typically causes deactivation.
3Productivity
If conventional catalysts are used in downstream processes, then hydroprocessing reactions can proceed, but coke formation causes rapid deactivation
Solution Approach 1:
The organic-inorganic fused hybrid catalyst combines the advantages of organic materials (resistance to coke formation and asphaltene deactivation) with inorganic metals (high hydroprocessing activity). This composite structure enables the catalyst to maintain high conversion rates while resisting coke-induced deactivation, extending catalyst life in downstream hydroprocessing operations.
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 high activity for hydrodemetallization, hydrodesulfurization, and hydrocracking, with enhanced thermal stability and solubility, allowing for effective upgrading of heavy crude oils and residues with reduced coke formation and prolonged catalyst life.
Implementation Method 1
The catalyst is sulfided in situ in the presence of H2/H2S
Implementation Method 2
a slurry phase organic-inorganic fused hybrid catalyst having high solubility in reaction media
Data Source
AI summary
Oil soluble organic-inorganic fused slurry phase hydroprocessing catalysts for heavy oils and residues are prepared at supercritical conditions. The hydrodemetallization, hydrodesulfurization, asphaltene conversion and hydrocracking activities of a residue having high percentage of metals, sulfur and asphaltene have been tested in an autoclave batch reactor. The different organic compounds are used to modify the solid fused material (catalyst). The effect of the concentration of modifier on the hydroprocessing and hydrocracking reactions has also been investigated.