Bulk Bimetallic Catalyst for Hydrodesulfurization
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Solution Overview
Problem
Current bimetallic bulk catalysts are less effective for hydroprocessing compared to trimetallic catalysts, particularly in removing nitrogen and sulfur from hydrocarbon feeds, which limits their ability to achieve low residual sulfur and nitrogen levels.
Innovation Solution
A bulk catalyst comprising at least 60 wt.% metal oxidic particles of Group VIII metals like nickel and molybdenum, with a metastable hexagonal phase characterized by specific X-ray diffraction patterns, is used for hydroprocessing, allowing for high hydrodesulfurization and hydrodenitrogenation activity, even in feeds containing both nitrogen and sulfur.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional supported bimetallic catalysts are used, then mechanical strength and ease of handling are improved, but catalytic activity for hydrodesulfurization and hydrodenitrogenation deteriorates
Solution Approach 1:
The invention merges the support material and catalyst active components into a single bulk catalyst particle. The catalyst comprises metal oxidic particles (Group VIII and Group VIB metals) where the metal oxides themselves form the bulk structure rather than being dispersed on a separate support, eliminating the support-catalyst interface limitations while maintaining mechanical strength
Solution Approach 2:
The invention creates a composite bulk catalyst material combining Group VIII metal oxides (NiO, CoO, FeO) and Group VIB metal oxides (MoO3, WO3) in a bulk structure. This composite material achieves both mechanical strength and high catalytic activity for hydrodesulfurization and hydrodenitrogenation by integrating multiple metal oxide phases in a unified bulk particle
2Ease of manufacture
If bulk bimetallic catalysts are used, then catalyst simplicity and ease of manufacture are improved, but hydroprocessing performance deteriorates
Solution Approach 1:
The invention changes the compositional parameters by incorporating specific ratios of Group VIII and Group VIB metal oxides, and controlling the crystalline phase structure (metastable hexagonal phase with specific XRD patterns). These parameter changes enable bulk bimetallic catalysts to achieve trimetallic-level performance in hydrodesulfurization and hydrodenitrogenation
Solution Approach 2:
The invention creates a composite bulk catalyst material combining Group VIII metal oxides and Group VIB metal oxides in a unified bulk structure with at least 60 wt% metal oxidic particles. This composite achieves high hydroprocessing performance by synergistic interaction between different metal oxide phases
3Reliability
If trimetallic bulk catalysts are used, then hydroprocessing effectiveness is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention extracts one metal component from the trimetallic system to create an optimized bimetallic catalyst. By removing the third metal and optimizing the binary combination of Group VIII and Group VIB metals, the catalyst achieves comparable or superior performance with reduced complexity and lower manufacturing cost
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 very low residual sulfur and nitrogen levels, comparable to or exceeding the performance of trimetallic catalysts, with high hydrodenitrogenation activity and low product nitrogen, making it suitable for producing low-sulfur, low-nitrogen hydrocarbon products.
Implementation Method 1
Hydroprocessing, which involves treating a hydrocarbon with hydrogen in the presence of a catalyst, is a conventional method for heteroatom (e.g., sulfur and nitrogen) removal
Implementation Method 2
a metastable hexagonal phase characterized by specific X-ray diffraction patterns
Data Source
AI summary
The invention relates to a process for upgrading hydrocarbonaceous feedstreams by hydroprocessing using bulk bimetallic catalysts. More particularly, the invention relates to a catalytic hydrotreating process for the removal of sulfur and nitrogen from a hydrocarbon feed such as a fuel or a lubricating oil feed. The catalyst is a bulk catalyst containing a Group VIII metal and a Group VIB metal.