Bulk CoMoNb Catalyst for Diesel Hydrotreating

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Solution Overview

Problem

Current hydrotreating catalysts are insufficient for efficiently reducing sulfur and nitrogen content in diesel boiling range hydrocarbon streams to meet stringent environmental regulations, particularly as low-sulfur, low-nitrogen crudes become scarcer.

Innovation Solution

A bulk metal hydrotreating catalyst comprising Co, Mo, and Nb, used in the presence of hydrogen, effectively desulfurizes and denitrogenates diesel boiling range feedstreams, enhancing hydrodesulfurization, hydrodenitrogenation, and hydrogenation activities compared to conventional catalysts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional supported catalysts (CoMo or NiMo on alumina) are used for hydrotreating, then hydrodesulfurization or hydrodenitrogenation can be achieved, but the catalyst complexity and cost increase due to support materials and promotion requirements

Engineering Contradiction:

Improvehydrodesulfurization and hydrodenitrogenation effectivenessVSAvoidcatalyst structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention extracts and eliminates the support material component from conventional catalyst systems. By using bulk metal oxides (CoO, MoO3, Nb2O5) without any support, the patent removes the complex support-catalyst interaction issues while maintaining catalytic activity. This extraction principle directly resolves the contradiction by simplifying catalyst structure while preserving reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention employs composite metal oxide materials combining CoO, MoO3, and Nb2O5 in specific ratios. This composite approach creates a synergistic effect where the combination of metals provides both hydrodesulfurization and hydrodenitrogenation activities simultaneously, eliminating the need for separate promoted catalysts and reducing overall complexity.

Inventive Principle:

Principle #40Composite materials

2Reliability

If multiple promoted metals are added to enhance catalytic activity, then hydrodenitrogenation and partial aromatic saturation improve, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improvehydrodenitrogenation and aromatic saturation performanceVSAvoidcatalyst preparation simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The bulk metal oxide catalyst system is designed to perform multiple functions simultaneously: hydrodesulfurization, hydrodenitrogenation, and partial aromatic saturation. By incorporating specific metal combinations (CoO-MoO3-Nb2O5), the single catalyst formulation achieves all required functions without needing separate promoted components, thereby simplifying manufacturing while maintaining comprehensive performance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If conventional catalysts are used with decreasing low-sulfur crude supply, then processing high-sulfur crudes becomes necessary, but existing catalysts become insufficient for meeting regulatory standards

Engineering Contradiction:

Improvecatalyst effectiveness with varying crude qualityVSAvoidregulatory compliance achievement

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The invention changes the fundamental parameters of catalyst composition by using bulk metal oxides with specific weight ratios (CoO: 1-50 wt%, MoO3: 1-60 wt%, Nb2O5: 1-50 wt%). This parameter optimization enables the catalyst to handle a broader range of sulfur and nitrogen contents in feedstocks while consistently achieving regulatory compliance, thereby improving adaptability without sacrificing reliability.

Inventive Principle:

Principle #35Parameter changes

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 CoMoNb catalyst significantly reduces sulfur and nitrogen contaminants in diesel products, meeting regulatory standards and outperforming commercial hydrotreating catalysts in terms of activity and efficiency.

Implementation Method 1

a bulk metal hydrotreating catalyst comprising Co, Mo, and Nb used for hydrotreating diesel boiling range feedstreams

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

enhancing hydrodesulfurization, hydrodenitrogenation, and hydrogenation activities

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 3

processes to produce fuels to meet the ever more restrictive Environmental regulations, such as hydrotreating, are well known in the art and typically requires treating the petroleum streams with hydrogen

Methodology Applied

Scientific EffectHydrogenation: Hydrogenation

Data Source

PatentUS7709412B2Bulk metal hydrotreating catalyst used in the production of low sulfur diesel fuels

Publication Date: 2010.05.04 EXXONMOBIL TECHNOLOGY & ENGINEERING CO

AI summary

The invention relates to a bulk metal hydrotreating catalyst, suitable for the production of low sulfur diesel fuels, said bulk metal hydrotreating catalyst being in the oxide state and having a composition of MoxCoyNbz, excluding the oxygen, wherein x, y, and z represent about 0.1 to about 2 moles of Mo, about 0.5 to about 2 moles of Co, and about 0.1 to about 2 moles Nb and wherein Nb is present in amounts from about 2 to about 45 wt. %, Mo is present in amounts from about 1 to about 50 wt. %, and Co is present in amounts from about 10 to about 45 wt. %.