Supported Catalyst Fines for Renewable Fuel Slurry Upgrading
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional dispersed catalysts used in slurry hydroprocessing for converting renewable feedstocks are expensive and difficult to manufacture, necessitating the development of more cost-effective alternatives.
Innovation Solution
A method involving the preparation of a slurry catalyst using rework material from supported hydroprocessing catalysts, mixed with a liquid component such as a polyol or recycled renewable feedstock, followed by sulfiding to form an active catalyst for upgrading renewable feedstocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional dispersed catalysts (nanosized transition metal sulfides) are used in slurry hydroprocessing, then the conversion of renewable feedstocks can be achieved, but the manufacturing cost increases and manufacturing difficulty increases
Solution Approach 1:
The patent uses inexpensive, readily available materials such as iron oxide, zinc oxide, and aluminum oxide as catalyst precursors instead of expensive nanosized transition metal sulfides. These materials can be obtained from common sources like rust, galvanized metal, and alumina, dramatically reducing catalyst manufacturing cost while maintaining functional effectiveness in slurry hydroprocessing
Solution Approach 2:
The patent changes the physical and chemical parameters of the catalyst system by using larger particle size materials (millimeter-scale precursors) that are easily handled and mixed, versus nanosized materials. The catalyst is activated in situ through sulfidation during the hydroprocessing process, transforming the inactive oxide precursors into active sulfide catalysts directly in the reaction medium
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 method provides a cost-effective and efficient means to convert low-value biomass feedstocks into higher-value liquid products, utilizing a catalyst that can be recycled and refreshed, reducing manufacturing costs and improving process efficiency.
Implementation Method 1
sulfiding the slurry catalyst precursor forming the slurry catalyst
Implementation Method 2
hydroprocessing the renewable feed in the slurry hydroprocessing unit to produce an upgraded renewable feed
Data Source
AI summary
A method is disclosed for preparing a slurry catalyst for use in upgrading a renewable feedstock. The method includes the steps of (a) providing a rework material obtained from a process of making a supported hydroprocessing catalyst, the hydroprocessing catalyst comprising a support and an active component supported thereon, wherein the rework material has an average particle size of from 1 to 300 μm; (b) mixing the rework material with a liquid component to form a slurry catalyst precursor, wherein the liquid component is selected from the renewable feedstock and a liquid carrier, wherein the liquid carrier is a polyol and/or a recycled renewable feedstock comprising heavy and/or unconverted fractions from a slurry hydroprocessing process; and (c) sulfiding the slurry catalyst precursor forming the slurry catalyst.