Catalyst Sulphurisation via Acid-Organic Emulsion Pre-Treatment
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Solution Overview
Problem
Existing sulphurisation processes for hydrocarbon treatment catalysts in oil refineries and petrochemical units are inefficient in achieving high catalyst activity and stability, leading to undesirable catalyst attrition and reduced performance over time.
Innovation Solution
A process involving the use of an emulsion comprising an acid aqueous phase and an organic phase, followed by treatment with a sulphur-containing gaseous mixture, to enhance the sulphurisation of catalysts, thereby improving their activity and reducing attrition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional gaseous phase sulphurisation processes are used, then the catalyst can be sulphurised, but the sulphurisation degree is insufficient and catalyst activity is low
Solution Approach 1:
The patent applies preliminary action by treating the catalyst with an emulsion containing sulphur compounds and surfactants before the main gaseous phase sulphurisation process. This pre-treatment deposits sulphur-containing species on the catalyst surface and within pores, creating a foundation that enhances subsequent sulphurisation efficiency and achieves higher catalyst activity.
Solution Approach 2:
The patent uses an emulsion as an intermediary substance that facilitates sulphur transfer to the catalyst. The emulsion comprises sulphur compounds dispersed in a liquid medium with surfactants, acting as a mediator that delivers sulphur more effectively than direct gaseous contact, thereby improving sulphurisation degree and catalyst activity.
2Device complexity
If conventional sulphurisation methods are applied, then the process is simple, but catalyst attrition increases and performance degrades over time
Solution Approach 1:
The patent employs a composite treatment system combining multiple components: sulphur compounds, surfactants, and liquid carriers in an emulsion formulation. This composite approach creates a more stable and effective sulphurisation treatment that reduces catalyst attrition and maintains performance over time, while the added complexity is justified by the significant improvement in catalyst stability.
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 proposed process achieves a higher degree of catalyst sulphurisation, significantly improves catalyst activity, and reduces undesirable attrition phenomena, making it suitable for both new and regenerated hydrotreatment catalysts.
Implementation Method 1
placing the catalyst in contact with an emulsion comprising: (ia) an aqueous phase comprising at least one acid; and (ib) an organic phase
Implementation Method 2
transforming the metal oxides into mixed sulphides, which constitute the active phase of the catalyst
Data Source
AI summary
The object of the present invention is a process for sulphurising a hydrocarbon treatment catalyst, comprising:(i) at least one step of placing the catalyst in contact with an emulsion comprising:(ia) an aqueous phase comprising at least one acid; and(ib) an organic phase; then(ii) at least one step of placing the catalyst in contact with a sulphur-containing gaseous mixture containing hydrogen and a sulphur compound.The present invention also relates to a process for treating a used catalyst, implementing such a sulphurisation treatment after a regeneration step.