Hydroconversion Catalyst Recycling via Precipitation and Sulfiding
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Solution Overview
Problem
There is a need for improved catalysts and processes that recycle waste materials generated during the production of hydroprocessing catalysts, particularly for high yield conversions of lower grade hydrocarbon feedstocks into higher value products, while also addressing environmental concerns and optimizing catalytic activity.
Innovation Solution
A method involving the formation of a precipitate with promoter metal and Group VIB metal precursors, followed by removal of excess liquid and incorporation of rework materials, shaping, and sulfiding to create a bulk multi-metallic catalyst precursor, which can contain up to 95% rework materials, optimizing the molar ratios and ligating agents for enhanced catalytic activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If waste materials are disposed of conventionally, then environmental impact is minimized through proper waste management, but economic loss occurs due to disposal costs and loss of valuable base metals
Solution Approach 1:
The patent recovers valuable base metals from waste catalyst materials through a multi-step process involving dissolution, filtration, and precipitation. The recovered metals are then reused to manufacture new catalysts, eliminating disposal costs and preventing environmental contamination while maintaining product quality
Solution Approach 2:
The patent transforms harmful waste materials into valuable resources by converting spent catalysts containing base metals into feedstock for new catalyst production. The waste stream becomes a source of recovered metals that can be reused, turning an environmental problem into an economic opportunity
2Ease of manufacture
If base metals are reused in catalyst production, then economic costs are reduced, but catalyst performance may deteriorate due to contamination or degradation from previous use
Solution Approach 1:
The patent extracts base metals from the complex waste catalyst matrix through selective dissolution and filtration processes. This separation purifies the recovered metals from contaminants and degradation products, ensuring that only high-quality metal components are reused in new catalyst formulations
Solution Approach 2:
The patent controls critical parameters including pH levels during precipitation, temperature during drying, and composition ratios in the final catalyst formulation. These parameter optimizations ensure that recovered metals maintain their catalytic properties and that the final product meets performance specifications
3Loss of substance
If complex recycling processes are implemented, then waste material recovery is maximized, but process complexity and time consumption increase
Solution Approach 1:
The patent combines multiple unit operations into an integrated continuous process where dissolution, filtration, and precipitation occur in sequence without intermediate handling steps. This merging of operations maintains high recovery efficiency while reducing overall process complexity and equipment requirements
Solution Approach 2:
The patent performs preliminary characterization of waste materials to determine metal content and composition before processing. This preliminary analysis allows for optimization of dissolution conditions and precipitation parameters, ensuring maximum recovery efficiency from the start and reducing the need for iterative adjustments
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 method enables the creation of catalysts with improved catalytic activity for hydroconversion processes, such as hydrodesulfurization and hydrodenitrification, while effectively recycling waste materials, thus enhancing the economic and environmental sustainability of hydroprocessing operations.
Implementation Method 1
sulfiding the shaped catalyst precursor forming the bulk multi-metallic catalyst
Implementation Method 2
forming a precipitate comprising at least a promoter metal precursor, at least a Group VIB metal precursor
Data Source
AI summary
A catalyst and a process for making a catalyst from a precursor composition containing rework materials are disclosed. The catalyst is made by sulfiding a catalyst precursor containing 5 - 95 wt. % rework material. The catalyst precursor employing rework materials can be a hydroxide or oxide material. Rework can be materials generated in the forming or shaping of the catalyst precursor, or formed upon the breakage or handling of the shaped catalyst precursor. Rework can also be in the form of catalyst precursor feed material to the shaping process, e.g., extrusion process, or catalyst precursor material generated as reject or scrap in the shaping process. In some embodiment, rework may be of the consistency of shapeable dough. In another embodiment, rework is in the form of small pieces or particles, e.g., fines, powder.