Supported Catalyst for Slurry Hydrocracking
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Solution Overview
Problem
Conventional catalyst systems for slurry phase hydrocracking of refinery residue are costly, prone to deactivation, and do not achieve high conversions at low residence times and catalyst concentrations, making them less viable for industrial applications.
Innovation Solution
A supported catalyst is prepared by exfoliating metal sulphides or oxides with support materials like activated carbon, multiwall carbon nanotubes, and porous silica, followed by calcination, to create a catalyst suitable for slurry phase hydrocracking, which involves sonicating a mixture of metal sulphides with a fluid medium and support materials, then heating and calcining under inert conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional catalyst systems are used for slurry phase hydrocracking, then catalytic activity is achieved, but the catalyst cost is high and deactivation occurs under severe reaction conditions
Solution Approach 1:
The patent uses composite materials by combining metal sulphides (MoS2, WS2, or WSe2) with support materials (activated carbon, multiwall carbon nanotubes, or porous silica) to create a supported catalyst system. This composite structure provides both catalytic activity and stability under severe hydrocracking conditions while reducing deactivation, thereby achieving reliable performance without requiring expensive conventional catalyst systems.
2Productivity
If conventional hydrocracking methods are used, then residue conversion is achieved, but high temperature and high pressure are required
Solution Approach 1:
The patent changes the operational parameters by enabling hydrocracking to proceed at lower temperatures (200-500°C) and pressures compared to conventional methods. This is achieved through the use of the supported catalyst system with metal sulphides, which maintains high catalytic activity under milder conditions, thereby improving productivity without requiring extreme temperature and pressure conditions.
3Productivity
If high catalyst concentration is used to achieve high conversion, then conversion rate increases, but catalyst cost and deactivation increase
Solution Approach 1:
The supported catalyst composite structure allows efficient utilization of the active metal sulphide phases on the support material surface, achieving high conversion rates even at low catalyst concentrations (0.1-5 wt%). The support material prevents aggregation and deactivation of the metal sulphide particles, extending catalyst lifespan while maintaining high productivity at reduced catalyst loading.
4Loss of time
If short residence time is used for industrial applications, then process efficiency improves, but conversion rate decreases with conventional catalysts
Solution Approach 1:
The patent changes the kinetic parameters of the hydrocracking reaction by using the supported catalyst system, which provides high activity and enables achieving high conversion rates (up to 74% or higher) even at very short residence times. This allows industrial processes to operate with reduced residence time while maintaining or improving conversion efficiency, thereby reducing the loss of time without sacrificing productivity.
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 achieves high yield and conversion of refinery residue into lighter hydrocarbons, with conversion rates of up to 74% within a short residence time, reducing residue production and extending catalyst lifespan.
Implementation Method 1
sonicating the first mixture to obtain an exfoliated product
Implementation Method 2
drying and calcining the heated slurry under inert atmosphere to obtain the supported catalyst
Implementation Method 3
drying and calcining the heated slurry under inert atmosphere to obtain the supported catalyst
Data Source
AI summary
The present disclosure relates to a catalyst for slurry phase hydrocracking of refinery residue 5 and a process for its preparation. The present disclosure provides a very simple method for exfoliation of metal sulphide, and a process of that provides effective slurry phase hydrocracking of refinery residue with a high yield.