Bulk Metal Hydroprocessing Catalyst for Sulfur Removal
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Solution Overview
Problem
Current hydroprocessing technologies face challenges in efficiently removing sulfur, nitrogen, and aromatics from hydrocarbonaceous feedstreams to meet stringent environmental regulations, particularly as refineries process crudes with higher sulfur and nitrogen content, requiring more active and efficient hydrotreating catalysts and processes.
Innovation Solution
A process using a bulk metal hydroprocessing catalyst comprising Group VIB, Group V, and Group VIII metal components, with a molar ratio of (Group VIB+Group V):(Group VIII)=0.35-2:1, contacts hydrocarbonaceous feedstreams with hydrogen-containing gas to produce liquid products with reduced aromatics, nitrogen, and sulfur contaminants, under effective hydroprocessing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hydroprocessing catalysts are used to remove sulfur and nitrogen from hydrocarbonaceous feedstreams, then some level of contaminant removal is achieved, but the catalysts lack sufficient activity to meet stringent environmental regulations (50 wppm sulfur or less) when processing high-sulfur, high-nitrogen crudes
Solution Approach 1:
The patent employs composite catalyst formulations containing multiple metal components (Group VI metals like molybdenum or tungsten combined with Group VIII metals like nickel or cobalt, and optionally Group V metals) on refractory supports. This composite structure synergistically enhances catalyst activity for simultaneous hydrodesulfurization, hydrodenitrogenation, and aromatic saturation, enabling compliance with stringent 50 wppm sulfur regulations even when processing high-sulfur crudes.
Solution Approach 2:
The patent optimizes critical catalyst parameters including metal composition ratios, metal loading concentrations, and support surface area characteristics. By precisely controlling these parameters, the catalyst achieves maximum activity for removing sulfur and nitrogen contaminants while maintaining stability under varying process conditions, thereby meeting the 50 wppm sulfur specification threshold.
2Object-affected harmful factors
If more active catalysts are used to achieve lower sulfur and nitrogen levels in products, then regulatory compliance is improved, but catalyst cost and complexity increase
Solution Approach 1:
The patent designs multi-functional catalysts capable of simultaneously performing hydrodesulfurization, hydrodenitrogenation, and aromatic saturation reactions. This universal catalyst system eliminates the need for multiple separate catalysts or sequential processing steps, thereby achieving comprehensive contaminant removal (including aromatic reduction to meet 10-5 vol.% specifications) without proportionally increasing system complexity.
Solution Approach 2:
The patent combines multiple catalytic functions into a single integrated catalyst formulation by incorporating complementary metal components (Group VI, Group VIII, and Group V metals) that work synergistically. This merging of functions into one catalyst reduces the overall process complexity compared to using separate catalysts for each contaminant type, while still achieving the required performance for sulfur, nitrogen, and aromatic removal.
3Duration of action of stationary object
If conventional catalysts are used for hydrotreating, then basic sulfur removal is achieved, but catalyst lifespan between regenerations is limited and process conditions must be maintained at higher severity
Solution Approach 1:
The patent optimizes catalyst parameters including metal dispersion, support pore structure, and acid-site distribution to enhance resistance to deactivation mechanisms such as coking and metal sintering. These parameter optimizations enable the catalyst to maintain high activity for longer periods (extended cycle length) and allow operation at milder temperatures and pressures, reducing energy consumption while achieving the same level of contaminant removal.
Solution Approach 2:
The patent develops catalyst formulations with extended service life that reduce the frequency of regeneration or replacement operations. By improving catalyst durability through optimized composition and structure, the effective cycle length between regenerations is increased, reducing operational downtime and maintenance costs associated with frequent catalyst replacement.
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 process achieves significant reduction in aromatics, nitrogen, and sulfur contaminants, producing liquid products that meet regulatory standards, with catalysts showing higher activity and longer lifespan, enabling operation under milder conditions and increasing energy efficiency.
Implementation Method 1
contacting a hydrocarbonaceous boiling range feedstream containing aromatics, nitrogen and organically bound sulfur contaminants in a reaction stage with a bulk metal hydroprocessing catalyst in the presence of hydrogen-containing treat gas
Data Source
AI summary
The instant invention relates to a process to produce liquid products through the hydroprocessing of hydrocarbonaceous feedstreams in the presence of a bulk metal hydroprocessing catalyst.