Bulk Metal Hydrotreating Catalyst for Low Sulfur Distillates
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Solution Overview
Problem
There is a continuous need for improved hydrotreating catalysts and processes to reduce sulfur and nitrogen content in distillate boiling range hydrocarbon streams, as existing technologies struggle to meet increasingly stringent environmental regulations, particularly with the decreasing supply of low sulfur, low nitrogen crudes.
Innovation Solution
A process using a bulk metal hydrotreating catalyst comprising a Group VIB metal component (molybdenum or tungsten), a Group V metal component (vanadium or niobium), and a Group VIII metal component (nickel or cobalt), with a specific molar ratio, to contact distillate boiling range feedstreams with hydrogen-containing gas under effective hydrotreating conditions, effectively removing nitrogen and organically bound sulfur contaminants and hydrogenating aromatics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hydrotreating catalysts are used to reduce sulfur and nitrogen content, then environmental regulations are met, but catalyst activity decreases and process conditions become more severe
Solution Approach 1:
The patent applies composite materials by combining Group VIB metals (molybdenum, tungsten) with Group V metals (vanadium, niobium, tantalum) and Group VIII metals (nickel, cobalt, iron) to create a synergistic catalyst system. This composite approach allows the catalyst to maintain high activity for sulfur and nitrogen removal while operating under milder conditions, resolving the contradiction between catalyst reliability and process severity.
Solution Approach 2:
The patent utilizes parameter changes by optimizing the molar ratio of metal components in the catalyst formulation. By adjusting the ratios of Group VIB, Group V, and Group VIII metals, the catalyst achieves enhanced performance at lower temperatures and pressures, thereby maintaining reliability while reducing process severity.
2Temperature
If more active catalysts are used to meet sulfur and nitrogen limits, then milder process conditions are achieved, but catalyst composition becomes more complex
Solution Approach 1:
The patent applies parameter changes by establishing specific molar ratio ranges for the metal components (Group VIB:Group V:Group VIII = 0.35-2:1) to optimize catalyst performance. This systematic parameter optimization achieves milder operating conditions while maintaining a manageable catalyst composition structure, avoiding excessive complexity.
Solution Approach 2:
The patent applies universality by designing a catalyst system where multiple metal groups perform complementary functions: Group VIB metals provide primary hydrotreating activity, Group V metals enhance stability and selectivity, and Group VIII metals promote nitrogen removal. This multi-functional design achieves mild conditions without requiring overly complex single-component catalysts.
3Duration of action of stationary object
If existing catalyst formulations are used, then sulfur and nitrogen removal is achieved, but catalyst lifespan between regenerations is limited
Solution Approach 1:
The patent applies composite materials by integrating multiple metal groups with complementary properties that enhance catalyst stability and longevity. The synergistic interaction between Group VIB, Group V, and Group VIII metals creates a more durable catalyst structure that maintains high activity over extended periods, thereby extending lifespan between regenerations while preserving reliability.
Solution Approach 2:
The patent applies continuity of useful action by designing a catalyst formulation that maintains stable activity over time through the synergistic metal combination. The multi-metal system provides continuous effective action for sulfur and nitrogen removal without rapid deactivation, extending the operational lifespan between regenerations while sustaining high reliability.
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 a significant reduction in sulfur, nitrogen, and aromatic content in distillate products, meeting regulatory standards and extending catalyst lifespan, while operating under milder conditions, thus enhancing energy efficiency and catalyst activity.
Implementation Method 1
contacting a distillate boiling range feedstream containing aromatics, nitrogen and organically bound sulfur contaminants in a reaction stage with a bulk metal hydrotreating catalyst in the presence of hydrogen-containing treat gas thereby producing a reaction product
Implementation Method 2
bulk metal hydrotreating catalyst comprises: i) a Group VIB metal component selected from molybdenum, tungsten, and mixtures thereof; ii) a Group V metal component selected from vanadium, niobium, tantalum, and mixtures thereof; and iii) a Group VIII metal component selected from nickel, cobalt, iron, and mixtures thereof
Implementation Method 3
effective hydrotreating conditions are effective at removing at least a portion of the nitrogen and organically bound sulfur contaminants and hydrogenating at least a portion of the aromatics
Data Source
AI summary
The instant invention relates to a process to produce low sulfur distillate products through the hydrotreating of distillate boiling range feedstreams in the presence of a bulk metal hydrotreating catalyst.