Suspended-bed hydrogenation catalyst with composite support
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Solution Overview
Problem
Existing suspended-bed hydrogenation catalysts have limited pore size distribution, leading to poor adsorption capacity for heavy oil components like asphaltenes and colloids, resulting in low light oil yield and catalyst deactivation due to coking and metal deposition.
Innovation Solution
A composite support is developed with a semi-coke pore-expanding material, molecular sieve, and spent catalytic cracking catalyst, providing a uniformly distributed multi-size pore structure, and a regeneration method involving dry distillation and activation to restore catalyst activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a catalyst with small and single pore size is used, then the preparation is simple, but the adsorption capacity to asphaltenes and colloids with high molecular weight is poor
Solution Approach 1:
The catalyst support structure is segmented into multiple pore size categories (micropores, mesopores, and macropores) with different functions. The micropores provide high surface area for catalytic reactions, while mesopores and macropores facilitate the diffusion and adsorption of large molecules like asphaltenes and colloids, resolving the contradiction between simple preparation and effective adsorption capacity.
Solution Approach 2:
The patent employs a composite support structure combining different pore-sized components (alumina, silica, molecular sieves) to create a multi-scale porous system. This composite approach enables the catalyst to simultaneously achieve ease of manufacture through conventional materials while providing enhanced adsorption capacity for high molecular weight compounds through the synergistic effect of diverse pore structures.
2Stability of the object's composition
If asphaltenes and colloids are deposited on the catalyst, then the catalyst structure is formed, but the pore passages are blocked and active centers are covered, lowering catalyst activity
Solution Approach 1:
The catalyst design implements local quality differentiation by creating specific pore size distributions in different regions of the catalyst particle. Larger pores are strategically positioned to accommodate and manage heavy asphaltene deposits, while maintaining accessible active centers in other regions, thus preserving catalyst activity while allowing structural formation.
Solution Approach 2:
The patent utilizes porous materials with specifically engineered pore size distributions to prevent pore blockage. The hierarchical pore structure allows asphaltene molecules to be adsorbed in larger pores without blocking the smaller pores containing active centers, maintaining catalyst reliability while enabling necessary structural formation through controlled deposition.
3Adaptability or versatility
If the pore size distribution is not uniform, then the catalyst can handle diverse feedstocks, but the adsorption capacity for high molecular weight components is insufficient
Solution Approach 1:
The patent extends the pore size dimension from a single scale to a multi-scale hierarchical structure encompassing micropores, mesopores, and macropores. This dimensional expansion in pore size space enables the catalyst to simultaneously accommodate diverse feedstock molecules while providing sufficient adsorption capacity for high molecular weight components through the addition of larger pore dimensions.
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 composite support enhances the adsorption and cracking of heavy oil components, increasing light oil yield and catalyst lifespan, while the regeneration method effectively recovers valuable metals and extends catalyst service life.
Implementation Method 1
the catalyst has poor adsorption capacity to asphaltenes and colloids with high molecular weight
Implementation Method 2
the finally-prepared catalyst facilitates approaching and cracking of macromolecular hydrocarbons
Implementation Method 3
a regeneration method involving dry distillation and activation to restore catalyst activity
Data Source
AI summary
A suspended-bed hydrogenation catalyst and a regeneration method are disclosed. A composite support comprises a semi-coke pore-expanding material, a molecular sieve and a spent catalytic cracking catalyst. The hydrogenation catalyst for heavy oil is obtained through mixing the semi-coke pore-expanding material, the molecular sieve and the spent catalytic cracking catalyst, followed by molding, calcining and activating, and then loading an active metal oxide to the composite support. According to the composite support, a macropore, mesopore and micropore uniformly-distributed structure is formed, so that full contact between all ingredients in the heavy oil and active ingredients in a hydrogenation process is facilitated, and the conversion ratio of the heavy oil is increased. The hydrogenation catalyst integrates adsorption, cracking and hydrogenation properties. According to a regeneration method, the loading performance of an active-metal-loaded support in a spent hydrogenation catalyst cannot be destroyed.