Crystalline Ammonia Transition Metal Molybdate Catalyst for Deep Desulfurization
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Solution Overview
Problem
Current hydroprocessing catalysts face challenges in achieving deep desulfurization and denitrification to ultra-low sulfur levels in petroleum products, with limitations in catalyst stability and activity, particularly when using supported materials.
Innovation Solution
A unique crystalline ammonia transition metal molybdate material, designated UPM-10, is developed with a specific x-ray powder diffraction pattern, formulated as (NH4)2.(NH3)x(H2O)2-xMMOyOz, where 'M' is a metal selected from Mg, Mn, Fe, Co, Ni, Cu, Zn, or mixtures, and synthesized through a solvothermal process with controlled pH and temperature, which can be sulfided to enhance its hydroprocessing capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional supported catalysts are used for hydroprocessing, then catalyst stability is maintained, but sulfur and nitrogen removal efficiency is insufficient to achieve ultra-low levels
Solution Approach 1:
The patent changes the physical and chemical parameters of the catalyst by creating a crystalline material with specific crystal structure (space group P63/mmc), controlled particle size (3-50 nm), and precise stoichiometric ratios (Ni:Mo = 1:3 to 1:5, with W substitution). These parameter changes enable ultra-low sulfur and nitrogen removal while maintaining catalyst stability through the ordered crystalline structure.
Solution Approach 2:
The patent employs composite materials by combining multiple metals (Ni, Mo, W) in a crystalline structure with ammonia and water molecules intercalated in layers. This composite crystalline ammonia transition metal molybdate material integrates the benefits of different metals and compounds to achieve both high activity for deep desulfurization/denitrification and structural stability.
2Quantity of substance
If supported catalyst materials are used, then catalyst structure is stabilized, but active phase loading is limited
Solution Approach 1:
The patent extracts the support material from the conventional catalyst system, creating an unsupported crystalline catalyst. By removing the support, the entire catalyst volume consists of active phase, maximizing active phase loading. The crystalline structure itself provides the necessary stability without requiring a separate support material.
Solution Approach 2:
The crystalline ammonia transition metal molybdate material serves multiple functions simultaneously: it provides high catalytic activity for hydroprocessing, maintains structural stability, and offers high active phase loading all in one unsupported material. This multi-functional material eliminates the need for separate support and active phase components.
3Object-affected harmful factors
If deep desulfurization to ultra-low sulfur levels is pursued, then environmental compliance is improved, but catalyst activity and stability deteriorate
Solution Approach 1:
The patent achieves ultra-low sulfur removal by precisely controlling crystal structure parameters including layer spacing (determined by ammonia and water content), metal oxidation states, and particle size. These parameter changes enable the catalyst to maintain stability while achieving sulfur concentrations at the ppm level in fuel products.
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 crystalline ammonia transition metal molybdate material exhibits superior hydroprocessing activities, including deep desulfurization and denitrification, outperforming conventional catalysts by providing a stable and active phase for hydroprocessing, effectively reducing sulfur and nitrogen compounds to ultra-low levels in petroleum products.
Implementation Method 1
A unique crystalline ammonia transition metal molybdate material has been produced and optionally sulfided, to yield an active hydroprocessing catalyst
Implementation Method 2
The removal of sulfur (hyperdesulfurization—HDS) and nitrogen (hyperdenitrification—HDN) containing compounds from fuel feed stocks is targeted during the hyperd treating steps of refining
Implementation Method 3
synthesized through a solvothermal process with controlled pH and temperature
Data Source
AI summary
A hydroprocessing catalyst has been developed. The catalyst is a unique crystalline ammonia transition metal molybdate material. The hydroprocessing using the crystalline ammonia transition metal molybdate material may include hydrodenitrification, hydrodesulfurization, hydrodemetallation, hydrodesilication, hydrodearomatization, hydroisomerization, hydrotreating, hydrofining, and hydrocracking.