Group VIII-VIB Catalyst Synthesis for Deep Hydrodesulfurization
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Solution Overview
Problem
Current catalytic processes for hydrodesulfurization and hydrodenitrogenation in petroleum refining are inefficient in removing sulfur and nitrogen pollutants from heavier fuel fractions, leading to increased emissions and higher costs due to the use of dense metals like tungsten, which increases catalyst density and production costs.
Innovation Solution
A catalytic composition comprising at least one Group VIII non-noble metal and one Group VIB metal, with an organic carbon precursor added during synthesis to enhance sulfiding and catalytic activity, is prepared through a process involving the complete dissolution of precursor salts in a polar solvent, followed by crystallization and thermal treatment in an inert atmosphere, and subsequent sulfiding to create active sulfide phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalysts supported on alumina are used, then the catalyst structure is stable and well-defined, but the catalytic activity for hydrodesulfurization and hydrodenitrogenation is insufficient
Solution Approach 1:
The invention uses composite materials by combining Group VIII non-noble metals (Ni, Co, Fe, Ru) with Group VIB metals (Mo, W, Cr) to create bifunctional catalysts that simultaneously promote hydrodesulfurization and hydrodenitrogenation reactions, achieving superior catalytic activity compared to single-metal or supported catalysts
Solution Approach 2:
The invention changes the chemical composition parameters by using specific metal combinations and ratios (Group VIII:Group VIB ratio from 1:9 to 9:1) and controlling oxidation states during synthesis to optimize catalytic performance for removing sulfur and nitrogen from petroleum fractions
2Quantity of substance
If dense metals like tungsten are used to increase catalyst density, then the catalyst bulk density increases, but production costs increase
Solution Approach 1:
The invention changes the metal composition parameters by replacing expensive dense metals like tungsten with less expensive Group VIB metals (Mo, Cr) while maintaining appropriate catalyst density through optimized metal ratios and particle morphology control
Solution Approach 2:
The invention uses cost-effective Group VIII non-noble metals (Ni, Co, Fe, Ru) combined with Group VIB metals to create affordable catalysts that achieve the required catalytic activity without relying on expensive precious metals or dense tungsten-based materials
3Productivity
If conventional hydroconversion processes are used, then the process is well-established, but the efficiency in removing sulfur and nitrogen from heavier fuel fractions is low
Solution Approach 1:
The invention employs composite catalyst materials combining Group VIII and Group VIB metals that work synergistically to simultaneously perform hydrodesulfurization and hydrodenitrogenation, achieving high pollutant removal efficiency in a single catalytic system
Solution Approach 2:
The catalyst system is designed with multi-functionality, where the combined metal composition enables simultaneous promotion of multiple reactions (hydrodesulfurization, hydrodenitrogenation, and hydrocracking) to efficiently process heavier fuel fractions with high sulfur and nitrogen content
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 resulting catalyst exhibits high activity and selectivity in hydrodesulfurization and hydrodenitrogenation reactions, achieving deep desulfuration and reducing sulfur content in fuels to ultra-low levels, while maintaining a compact bulk density similar to conventional catalysts, thus addressing the inefficiencies and cost issues of existing processes.
Implementation Method 1
the complete dissolution of precursor salts in a polar solvent
Implementation Method 2
followed by crystallization
Implementation Method 3
subsequent sulfiding to create active sulfide phases
Implementation Method 4
high activity and selectivity in hydrodesulfurization and hydrodenitrogenation reactions
Implementation Method 5
high activity and selectivity in hydrodesulfurization and hydrodenitrogenation reactions
Data Source
AI summary
The invention relates to a method of preparing a catalytic composition comprising at least one non-noble metal from group VIII and at least one metal from group VIB of the periodic table. The invention also relates to the catalytic composition thus produced, which has a high specific activity in reactions involving the hydroprocessing of light and intermediate fractions, preferably in reactions involving the hydrotreatment of hydrocarbon streams, including hydrodesulphurisation (HDS), hydrodenitrogenation (HDN) and hydro-dearomatisation (HDA).