Hydrotreating Catalyst Boron Phosphorus Co-Extrusion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydrotreating catalysts for hydrocarbon feedstocks do not achieve optimal catalytic activity due to limitations in the incorporation and concentration of boron and phosphorus components, which are crucial for enhanced performance in processes like hydrodesulfurization and hydrodenitrogenation.
Innovation Solution
A catalyst composition is developed with a boron-containing carrier formed by co-extrusion with a boron source, combined with a phosphorus source and metal components, allowing for higher boron concentrations and improved catalytic activity through a single calcination step, resulting in a catalyst with 1-13 wt% boron and 1-10 wt% phosphorus, enhancing hydrotreating efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional impregnation methods are used to incorporate boron and phosphorus components, then the catalyst can be prepared with these components, but the catalytic activity is insufficient due to limitations in incorporation and concentration
Solution Approach 1:
The patent changes the preparation method from conventional impregnation to co-extrusion, which enables higher boron concentrations (1-13 wt%) and phosphorus concentrations (1-10 wt%) to be incorporated into the catalyst. This parameter change in the preparation technique directly resolves the contradiction by allowing greater quantity of active components while maintaining catalyst reliability
Solution Approach 2:
The patent creates a composite catalyst material containing Group VIB metal components, Group VIII metal components, phosphorus components, and boron-containing carrier components. This composite structure enables synergistic effects that improve catalytic activity while incorporating high concentrations of both boron and phosphorus, resolving the technical contradiction between quantity and reliability
2Manufacturing precision
If multiple calcination steps are used in catalyst preparation, then thorough conversion of metal components can be achieved, but the process complexity and time increase
Solution Approach 1:
The patent merges multiple calcination steps into a single calcination step by incorporating boron into the carrier through co-extrusion before calcination. This consolidation maintains thorough conversion of metal components to their oxides while reducing process complexity and preparation time, directly resolving the contradiction between manufacturing precision and device complexity
3Productivity
If conventional catalyst preparation methods are used, then the catalyst can be produced with standard composition, but the sulfur and nitrogen removal efficiency is suboptimal
Solution Approach 1:
The patent changes the catalyst composition parameters by incorporating specific ranges of boron (1-13 wt%) and phosphorus (1-10 wt%) through co-extrusion. This parameter modification significantly improves sulfur and nitrogen removal efficiency in hydrotreating processes while maintaining ease of manufacture through the streamlined co-extrusion and single calcination process
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 exhibits significantly improved catalytic activity in hydrotreating processes, achieving higher sulfur and nitrogen removal efficiencies, as demonstrated by activity tests in various hydrocarbon feedstocks, indicating enhanced performance over traditional catalyst preparation methods.
Implementation Method 1
the boron-containing carrier is formed by co-extrusion of a boron source with the carrier
Implementation Method 2
the composite is calcined to convert the metal components into their oxides
Implementation Method 3
the catalysts are generally presulfided to convert the hydrogenation metals into their sulfides
Data Source
AI summary
A catalyst having at least one Group VIB metal component, at least one Group VIII metal component, a phosphorus component, and a boron-containing carrier component. The amount of the phosphorus component is at least 1 wt %, expressed as an oxide (P2O5) and based on the total weight of the catalyst, and the amount of boron content is in the range of about 1 to about 13 wt %, expressed as an oxide (B2O3) and based on the total weight of the catalyst. In one embodiment of the invention, the boron-containing carrier component is a product of a co-extrusion of at least a carrier and a boron source. A method for producing the catalyst and its use for hydrotreating a hydrocarbon feed are also described.