Catalyst Formation Using Concentrated Metal Solutions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing catalysts for hydrotreating, hydrodesulfurization, and hydrodenitrogenation processes face limitations in achieving high loadings of hydrogenation metals on catalyst supports, requiring multiple impregnation steps and lower concentrations of Group VI and VIII metals, which restricts the efficiency and cost-effectiveness of the processes.
Innovation Solution
A process for forming catalysts using concentrated solutions with higher concentrations of Group VI metals (6.9 to 9.7 mol/L) and Group VIII metals, along with phosphorus, which allows for a single impregnation step and higher loadings of hydrogenation metals, utilizing specific molar ratios and pH adjustments to maintain solubility and viscosity, and incorporating non-acidic organic additives and organic acids to enhance metal dissolution and catalyst formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If higher concentrations of Group VI and VIII metals are used in impregnation solutions, then catalyst loading of hydrogenation metals is improved, but solution viscosity increases and metal adhesion to containers occurs
Solution Approach 1:
Non-acidic organic additives serve as intermediaries between the concentrated metal solutions and container surfaces, preventing metal adhesion through steric hindrance and electrostatic repulsion. These additives form protective layers that allow high metal concentrations to be handled without contamination
Solution Approach 2:
The patent adjusts solution parameters including pH control and the addition of organic additives to modify the chemical and physical properties of concentrated impregnation solutions. These parameter changes maintain metal solubility and prevent adhesion even at high concentrations up to 9.7 mol/L for Group VI metals
2Quantity of substance
If multiple sequential impregnation steps are employed to increase hydrogenation metal loading, then catalyst loading is improved, but process complexity and time consumption increase
Solution Approach 1:
Multiple impregnation steps are merged into a single step by using highly concentrated impregnation solutions containing both Group VI and VIII metals along with phosphorus. This combining approach achieves the same metal loading that previously required sequential steps, thereby simplifying the process
Solution Approach 2:
The concentration parameters of impregnation solutions are dramatically increased (Group VI metals up to 9.7 mol/L, Group VIII metals up to 4.85 mol/L) to enable single-step impregnation. This parameter change allows sufficient metal loading in one operation without requiring multiple cycles
3Quantity of substance
If higher concentrations of Group VI metals are used in impregnation solutions, then catalyst loading is improved, but solution stability and handling properties deteriorate
Solution Approach 1:
Non-acidic organic additives act as stabilizing intermediaries in highly concentrated metal solutions. These additives prevent metal precipitation and maintain solution homogeneity through complexation and steric stabilization, enabling handling of solutions with Group VI metal concentrations up to 9.7 mol/L
Solution Approach 2:
The impregnation solutions are formulated as composite systems containing Group VI metals, Group VIII metals, phosphorus, and non-acidic organic additives. This composite approach creates synergistic interactions that enhance solution stability while maintaining high metal concentrations
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
This approach enables the production of catalysts with higher loadings of hydrogenation metals in a single impregnation step, improving process efficiency and cost-effectiveness while maintaining solution properties that prevent metal adhesion to containers, resulting in enhanced catalyst performance in hydrotreating and hydrodesulfurization processes.
Implementation Method 1
pore volume impregnation
Data Source
AI summary
This invention provides processes for forming solution compositions, which processes comprises bringing together, in an aqueous medium, i) at least one phosphorus compound; ii) at least one Group VI metal compound; and iii) at least one Group VIII metal compound, such that a solution having a Group VI metal concentration of more than about 5.6 mol/L is formed. Also provided are compositions formed by such processes, processes for forming catalyst compositions from these compositions, and catalyst compositions formed by these processes.