Co-precipitated Catalyst for HDS and HDN
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Solution Overview
Problem
Conventional hydroprocessing catalysts are ineffective in removing both simple and complex sulfur compounds and nitrogen contaminants from refinery feedstocks, leading to reduced catalytic activity and stability, especially when exposed to impure refinery streams.
Innovation Solution
A new catalyst composition is developed through a co-precipitation process involving non-noble Group VIII and Group VIb metals, along with refractory oxides, which are heated and aged to create a unique XRD-amorphous structure, enhancing hydrodesulphurization (HDS) and hydrodenitrogenation (HDN) activities while maintaining mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional impregnation techniques are used to deposit metals on shaped carrier, then catalyst structure is simple and easy to manufacture, but metals dispersion is limited due to diffusional and space limitations
Solution Approach 1:
The patent applies preliminary action by forming the catalyst composition before shaping occurs. The metal compounds and carrier material are mixed and formed into a monolithic structure prior to the shaping step, allowing metals to be dispersed throughout the carrier material before the final catalyst shape is created. This eliminates the diffusional limitations of post-shaping impregnation methods.
Solution Approach 2:
The patent changes the physical state parameters of the carrier material and metal compounds during preparation. The carrier material is maintained in a plasticized or softened state during mixing and forming, enabling intimate contact and uniform dispersion of metal compounds throughout the carrier before shaping and final curing.
2Reliability
If bulk catalysts are used without binder, then catalytic activity is maximized, but mechanical strength is insufficient for commercial use
Solution Approach 1:
The patent merges the bulk catalyst particles with a binder material to create a composite monolithic structure. The bulk catalyst composition (containing metal compounds on refractory oxide) is mixed with binder material and formed into a monolithic shape, combining the high catalytic activity of bulk catalysts with the mechanical strength of the binder-supported structure.
Solution Approach 2:
The patent creates a composite catalyst material by combining bulk catalyst particles with binder material in a monolithic structure. The composite comprises metal compounds, refractory oxide material, and binder material, where the binder provides mechanical strength while the bulk catalyst components provide high catalytic activity for HDS and HDN reactions.
3Reliability
If conventional hydroprocessing catalysts are used, then catalyst structure is simple, but effectiveness in removing both sulfur compounds and nitrogen contaminants is reduced
Solution Approach 1:
The patent creates a universal catalyst composition that performs both hydrodesulphurization and hydrodenitrogenation functions simultaneously. The monolithic structure contains metal compounds (such as Ni, Co, Mo, W) on refractory oxide material that provide dual functionality for removing both sulfur and nitrogen contaminants from refinery feedstocks in a single catalyst bed.
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 new catalyst composition exhibits significantly higher HDS and HDN activities compared to conventional and bulk catalysts, effectively handling feedstocks with both sulfur and nitrogen contaminants, and demonstrates improved mechanical strength and catalytic performance.
Implementation Method 1
heating a composition of the general formula (II) at a temperature in the range of from 100 to 600° C.
Implementation Method 2
optionally after ageing at a temperature in the range of from 20 to 95° C. for a minimum of 10 minutes
Implementation Method 3
by co-precipitation, the incorporation of a dispersed metals content into a conventional carrier material is attempted
Data Source
AI summary
A bulk metal oxide catalyst composition of the general formula(X)b(M)c(Z)d(O)e (I)whereinX represents at least one non-noble Group VIII metal;M represents at least one non-noble Group VIb metal;Z represents one or more elements selected from aluminium, silicon, magnesium, titanium, zirconium, boron, and zinc;one of b and c is the integer 1; andd and e and the other of b and c each are a number greater than 0 such that the molar ratio of b:c is in the range of from 0.5:1 to 5:1, the molar ratio of d:c is in the range of from 0.2:1 to 50:1, and the molar ratio of e:c is in the range of from 3.7:1 to 108:1; is prepared by controlled (co)precipitation of component metal compounds, refractory oxide material, and alkali compound in protic liquid. Resulting compositions find use in hydrotreatment processes involving particularly hydrodesulphurisation and hydrodenitrification.