Ammonia-free Mixed Metal Oxide Catalyst for Hydroprocessing
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Solution Overview
Problem
Current hydroprocessing catalysts face challenges in meeting stringent fuel sulfur and nitrogen limitations without increasing reactor severity or reducing production rates, and there is a need for catalysts with higher intrinsic activity per mass to manage increasing crude oil sulfur and nitrogen content.
Innovation Solution
A novel mixed transition metal oxide material with the formula [R1R2R3R4-N]x(NH4)y(MIa)m(MIIb)n(MIIIc)o(MIVd)pOq(OH)r is developed, characterized by an essentially amorphous X-ray diffraction pattern with specific crystalline peaks, which can be sulfided to yield an active hydroprocessing catalyst, using a co-precipitation method with alkyl quaternary ammonium hydroxide compounds and optional binder incorporation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If reactor temperature is increased to meet fuel sulfur and nitrogen limitations, then conversion activity is improved, but catalyst lifetime is shortened
Solution Approach 1:
The patent changes the chemical composition parameters of the catalyst by incorporating specific ratios of Group VIII metals (Ni, Co), Group VIB metals (Mo, W), and Group VB metals (Nb, Ta) to optimize intrinsic activity. This allows the catalyst to achieve high conversion activity at lower operating temperatures, thereby extending catalyst lifetime while meeting fuel specifications.
Solution Approach 2:
The patent uses composite multi-metallic materials combining multiple metal oxides (NiO, CoO, MoO3, WO3, Nb2O5, Ta2O5) in specific ratios. This composite structure creates synergistic effects that enhance catalytic activity and stability, allowing the catalyst to maintain high performance over extended periods without requiring severe operating conditions.
2Power
If space velocity is decreased to meet fuel sulfur and nitrogen limitations, then conversion activity is improved, but production rate is reduced
Solution Approach 1:
The patent optimizes the metal composition parameters, specifically the ratios of Group VIII to Group VIB to Group VB metals, to maximize intrinsic catalytic activity. This enables the catalyst to achieve high conversion at higher space velocities, thereby maintaining production rates while meeting fuel sulfur and nitrogen specifications.
3Power
If metal content is increased to improve intrinsic activity per mass, then catalytic activity is improved, but catalyst cost is increased
Solution Approach 1:
The patent optimizes the metal content parameters by establishing specific ratio ranges: Group VIII metals (0.1-20 wt%), Group VIB metals (1-40 wt%), and Group VB metals (0.1-10 wt%). This optimized composition achieves high intrinsic activity per mass while controlling the quantity of expensive metals required, thereby reducing overall catalyst cost.
Solution Approach 2:
The patent applies local quality by distributing different metal components in specific ratios within the catalyst structure. Each metal contributes specific catalytic functions, and their optimized local concentrations maximize overall catalytic efficiency per unit mass, reducing the total metal loading required.
4Quantity of substance
If conventional supported catalysts are used, then catalyst cost is reduced, but intrinsic activity per mass is insufficient
Solution Approach 1:
The patent employs composite unsupported multi-metallic materials that combine the benefits of high intrinsic activity with cost-effectiveness. The specific composite composition of Group VIII, VIB, and VB metal oxides in optimized ratios delivers superior intrinsic activity per mass compared to conventional supported catalysts, while avoiding the cost penalty of expensive support materials.
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 novel catalyst achieves high intrinsic activity per mass, reducing metal loading requirements and maintaining production rates while meeting stringent fuel specifications, thus addressing the limitations of existing catalysts.
Implementation Method 1
A method of making a mixed transition metal oxide material by co-precipitation by adding sources of the transition metals with one or more quaternary ammonium hydroxide compounds
Data Source
AI summary
A highly active mixed transition metal oxide material has been developed. The material may be sulfided to generate metal sulfides which are used as a catalyst in a conversion process such as hydroprocessing. The hydroprocessing may include hydrodenitrification, hydrodesulfurization, hydrodemetallation, hydrodesilication, hydrodearomatization, hydroisomerization, hydrotreating, hydrofining, and hydrocracking.