Hydrocarbon Catalyst Regeneration via Ester Additive Pre-Sulfurization
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Solution Overview
Problem
Existing methods for regenerating spent catalysts used in hydrocarbon treatment processes, such as hydrotreatment and hydroconversion, often fail to restore their activity to a level comparable to new catalysts, and do not efficiently pre-sulfurize the catalysts, requiring additional sulfurization steps that are time-consuming and resource-intensive.
Innovation Solution
A two-stage process involving controlled combustion of coke at temperatures between 350°C to 550°C, followed by the deposition of specific additives, particularly 2-hydroxy-4-methylthiobutanoic acid, on the catalyst surface to enhance activity and achieve pre-sulfurization simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional combustion regeneration is used to remove coke from spent catalysts, then the catalyst surface is cleaned, but the catalyst activity is significantly reduced and additional sulfurization steps are required
Solution Approach 1:
The patent combines the regeneration process (coke removal) and sulfurization process into a single integrated operation. By adding sulfur-containing compounds during the combustion phase, the catalyst is both cleaned and re-sulfurized simultaneously, eliminating the need for separate sulfurization steps and reducing total regeneration time while maintaining high catalyst activity
Solution Approach 2:
The patent performs preliminary sulfurization during the regeneration process itself. By introducing sulfur-containing compounds in the first combustion stage, the catalyst surface is pre-sulfurized before final activation, which reduces the time required for subsequent sulfurization steps and accelerates the overall process
2Reliability
If multiple separate steps (regeneration then sulfurization) are used to restore catalyst activity, then thorough treatment is achieved, but the process becomes time-consuming and resource-intensive
Solution Approach 1:
The patent merges regeneration and sulfurization into one consolidated process by introducing sulfur-containing compounds during the combustion phase. This integration maintains thorough treatment of the catalyst while significantly improving regeneration efficiency by eliminating intermediate steps and reducing overall processing time
Solution Approach 2:
The first combustion stage is designed to perform multiple functions simultaneously: removing coke deposits, re-sulfurizing the catalyst surface, and preparing the catalyst for activation. This multi-functionality approach restores catalyst activity effectively while enhancing productivity by reducing the number of separate operations required
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 process effectively restores catalyst activity to a level higher than previous methods, simplifies the sulfurization process by incorporating pre-sulfurization, and uses easily preparable and inexpensive additives, ensuring a substantial portion of the additive remains on the catalyst.
Implementation Method 1
Regeneration of spent catalysts is traditionally carried out by combustion of coke, by heating the catalyst to an elevated temperature in the presence of an oxygen-containing gas
Implementation Method 2
a second step of depositing, on the surface of the catalyst, one or more additives
Data Source
AI summary
Regenerating a catalyst containing at least a metal of the group VIII and at least one metal of the VIB group deposited on a refractory oxide support, comprises: (a) at least a first step of heat treatment of the catalyst in the presence of oxygen at 350-550[deg] C; and (b) at least one second step of deposition of one or more additives having ester structure (I) on the catalyst surface,. Regenerating a catalyst containing at least a metal of the group VIII and at least one metal of the VIB group deposited on a refractory oxide support, comprises: (a) at least a first step of heat treatment of the catalyst in the presence of oxygen at 350-550[deg] C; and (b) at least one second step of deposition of one or more additives having ester structure of formula (R 1>O-C(=O)-R 2>-S-R 3>) (I) on the catalyst surface. R 1>, R 3>H or optionally saturated 1-30C hydrocarbon group; R 2>optionally saturated 1-30C divalent hydrocarbon group optionally containing one or more heteroatoms comprising O and N, and optionally substituted by one or more groups of -OH,-OR,-NH 2, -NHR or -NRR1a; and R, R1a : 1-4C, preferably 1-2C alkyl groups. Independent claims are included for: (1) the regenerated catalyst obtained by the process; and (2) use of one or more additives (I) to increase the activity of a catalyst containing at least one metal from group VIII and at least one VIB group metal deposited on a refractory oxide support.