Hydrotreating Catalyst with Graded Metal Concentration for Deep Hydrodesulfurization
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Solution Overview
Problem
Conventional hydrotreating catalysts are ineffective for deep hydrodesulfurization of heavy distillate oils, particularly diesel oil, due to their inability to efficiently remove sulfur-containing compounds with complex chemical structures and significant steric hindrance, such as 4,6-dimethyl dibenzothiophene and 2,4,6-trimethyl dibenzothiophene.
Innovation Solution
A hydrotreating catalyst with a specific concentration distribution of active metal components, including Ni, Co, and Mo, supported on a porous refractory carrier, where the concentration of these metals varies systematically across the catalyst particle to enhance hydrodesulfurization activity, facilitating both hydrodearomatization and hydrodesulfurization reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hydrodesulfurization technology is used, then the process is simple and well-established, but it cannot effectively remove sulfur-containing compounds with complex structures and significant steric hindrance
Solution Approach 1:
The catalyst employs a core-shell structure where the shell layer contains active metal components (Ni, Co, Mo) with specific concentration distributions optimized for hydrodearomatization and hydrodesulfurization reactions. This local quality differentiation enables the catalyst to handle complex sulfur compounds like 4,6-dimethyl dibenzothiophene that conventional catalysts cannot effectively remove.
2Reliability
If the catalyst uses uniform metal distribution, then the manufacturing process is simple, but the hydrodesulfurization activity for heavy distillate oils is insufficient
Solution Approach 1:
The catalyst employs a core-shell structure where the shell layer contains active metal components (Ni, Co, Mo) with specific concentration distributions optimized for hydrodearomatization and hydrodesulfurization reactions. This local quality differentiation enables the catalyst to handle complex sulfur compounds like 4,6-dimethyl dibenzothiophene that conventional catalysts cannot effectively remove.
Solution Approach 2:
The catalyst particle is segmented into a core region and a shell layer with distinct functional characteristics. The shell layer contains the active metal components in specific concentrations to facilitate hydrodearomatization, while the core provides structural support and additional catalytic activity. This segmentation allows each region to perform its specialized function optimally.
3Productivity
If elevated temperatures and pressures are used to remove sulfur compounds, then the reaction intensity increases, but the removal efficiency of sterically hindered compounds remains insufficient
Solution Approach 1:
The catalyst utilizes controlled metal concentration gradients within the particle structure, creating specific chemical environments that enhance the ability to remove sterically hindered sulfur compounds. The shell layer contains higher concentrations of active metals to facilitate hydrodearomatization reactions, while the overall composition is optimized to work effectively at moderate temperatures and pressures.
4Quantity of substance
If the catalyst is designed for light-end products, then the metal content can be lower, but it cannot effectively process heavy distillate oils
Solution Approach 1:
The catalyst employs a core-shell structure where the shell layer contains active metal components (Ni, Co, Mo) with specific concentration distributions optimized for hydrodearomatization and hydrodesulfurization reactions. This local quality differentiation enables the catalyst to handle complex sulfur compounds like 4,6-dimethyl dibenzothiophene that conventional catalysts cannot effectively remove.
Solution Approach 2:
The catalyst is designed with multi-functional capabilities to handle both hydrodearomatization and hydrodesulfurization reactions simultaneously. The presence of multiple active metal components (Ni for hydrodearomatization, Co and Mo for hydrodesulfurization) in the shell layer enables the catalyst to process heavy distillate oils with complex sulfur compounds, achieving versatility across different feedstock types.
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 catalyst significantly improves the deep hydrodesulfurization activity of heavy distillate oils by enabling effective removal of difficult-to-desulfurize compounds through a relay hydrogenation reaction sequence, with the active metal components being strategically distributed to optimize reaction efficiency.
Implementation Method 1
A hydrotreating catalyst with a specific concentration distribution of active metal components, including Ni, Co, and Mo, supported on a porous refractory carrier, where the concentration of these metals varies systematically across the catalyst particle to enhance hydrodesulfurization activity, facilitating both hydrodearomatization and hydrodesulfurization reactions
Implementation Method 2
an active metal component A, an active metal component B, an active metal component C and optionally an auxiliary component supported on the porous refractory carrier
Data Source
Figure 1(a)~2
Figure 3~4
Figure 5
AI summary
This invention relates to a hydrotreating catalyst suitable for heavy distillate oil hydrodesulfurization, production and use thereof. The present hydrotreating catalyst exhibits significantly improved heavy distillate oil (deep) hydrodesulfurization activity.