Structured Catalyst with Metal Oxide Nanoparticles for Heavy Oil Cracking
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Solution Overview
Problem
Current catalysts for catalytic cracking and hydrodesulfurization of heavy oils face issues with catalytic activity decline due to aggregation and instability, particularly with iron oxide-based catalysts, which require cumbersome hydrogen gas supply to stabilize decomposed heavy oils.
Innovation Solution
A structured catalyst comprising a porous zeolite-type compound support with metal oxide nanoparticles, specifically composed of Fe, Al, Zn, Zr, Cu, Co, Ni, Ce, Nb, Ti, Mo, V, Cr, Pd, and Ru oxides, embedded within the support's channels to prevent aggregation and enhance stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If iron oxide-based catalyst is used for catalytic cracking of heavy oil, then catalytic activity is initially high, but aggregation occurs during the process leading to reduction of catalytic activity
Solution Approach 1:
The patent uses a porous support material with controlled pore size to disperse and anchor metal oxide nanoparticles, preventing their aggregation during catalytic cracking. The porous structure provides high surface area for catalyst dispersion and maintains catalyst stability throughout the process, resolving the contradiction between initial high activity and long-term durability.
Solution Approach 2:
The patent creates a composite catalyst system combining metal oxide nanoparticles (Fe, Al, Zn, Zr, Cu, Co, Ni, Ce, Nb, Ti, Mo, V, Cr, Pd, Ru) with a porous support material. This composite structure prevents aggregation of metal oxide particles while maintaining their catalytic activity, thereby extending catalyst life without sacrificing initial performance.
2Productivity
If complex oxide catalyst containing zirconia and alumina is used for catalytic decomposition, then light oil production increases, but aggregation between catalyst particles occurs due to forces and heat from fluid
Solution Approach 1:
The patent applies local quality by creating regions of high metal oxide concentration within the porous support structure, specifically anchoring nanoparticles at strategic locations where catalytic activity is most needed. This localized distribution maintains high productivity while preventing widespread aggregation throughout the catalyst bed.
Solution Approach 2:
The porous support material provides a three-dimensional network that physically separates metal oxide nanoparticles, preventing their aggregation under the influence of fluid forces and heat. The porous structure maintains catalyst stability while allowing high light oil production through efficient mass transfer.
3Stability of the object's composition
If hydrogen gas is supplied to stabilize decomposed heavy oil, then stability of decomposed oil improves, but operation complexity increases
Solution Approach 1:
The patent enables the catalyst to perform dual functions: catalytic cracking of heavy oil and stabilization of decomposed products. The metal oxide nanoparticles on the porous support provide active sites that stabilize radical species formed during cracking, eliminating the need for separate hydrogen gas supply and reducing operational complexity while maintaining product stability.
Solution Approach 2:
The catalyst system is designed to perform multiple functions simultaneously: it cracks heavy oil into lighter products and stabilizes the decomposed oil in one step. This multi-functionality eliminates the need for separate stabilization processes using hydrogen gas, thereby simplifying operation while improving the stability of decomposed heavy oil.
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 structured catalyst maintains long-term catalytic activity and stability, reducing the need for hydrogen gas supply and extending catalyst life, while efficiently cracking and desulfurizing heavy oils.
Implementation Method 1
a structured catalyst for catalytic cracking or hydrodesulfurization including: a support of a porous structure composed of a zeolite-type compound; and at least one type of metal oxide nanoparticles present in the support
Implementation Method 2
a structured catalyst for catalytic cracking or hydrodesulfurization including: a support of a porous structure composed of a zeolite-type compound; and at least one type of metal oxide nanoparticles present in the support
Data Source
AI summary
To provide a structured catalyst for catalytic cracking or hydrodesulfurization that suppresses decline in catalytic activity, achieves efficient catalytic cracking, and allows simple and stable obtaining of a substance to be modified. The structured catalyst for catalytic cracking or hydrodesulfurization (1) includes a support (10) of a porous structure composed of a zeolite-type compound and at least one type of metal oxide nanoparticles (20) present in the support (10), in which the support (10) has channels (11) that connect with each other, the metal oxide nanoparticles (20) are present at least in the channels (11) of the support (10), and the metal oxide nanoparticles (20) are composed of a material containing any one or two more of the oxides of Fe, Al, Zn, Zr, Cu, Co, Ni, Ce, Nb, Ti, Mo, V, Cr, Pd, and Ru.