Hydrocracking Catalyst Synthesis Using Supercritical CO2
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Solution Overview
Problem
Existing hydrocracking catalyst synthesis methods generate harmful waste and do not effectively utilize zeolite pellets as support materials, particularly when using solvents like ammonia or acidic substances, which pose health risks and environmental concerns.
Innovation Solution
A synthesis method using supercritical carbon dioxide as a solvent to adsorb Ni and/or W metal precursors onto zeolite pellets within a high-pressure container, where carbon dioxide transforms into a supercritical phase for enhanced dissolution and adsorption, followed by calcination, eliminating the need for hazardous waste disposal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If ammonia or acidic solvents are used for metal dissolution and impregnation, then metal adsorption onto support material is achieved, but harmful waste and ammonia steam are generated during calcination
Solution Approach 1:
The patent changes the physical state and chemical properties of the solvent by using supercritical carbon dioxide instead of conventional liquid solvents. By adjusting pressure and temperature parameters to achieve the supercritical state, CO2 provides effective metal dissolution and impregnation while avoiding harmful waste generation during calcination, as CO2 simply decomposes to harmless CO and O2
Solution Approach 2:
The patent utilizes the phase transition of carbon dioxide to supercritical state for the impregnation process, then allows it to return to gaseous state during calcination. This phase transition enables the solvent to penetrate the support material effectively while eliminating the generation of harmful waste products that occur with conventional solvents
2Ease of manufacture
If conventional solvents are used for metal dissolution, then impregnation process is completed, but waste disposal problems arise
Solution Approach 1:
The patent converts the potential harm of solvent residue into a benefit by using supercritical CO2, which decomposes completely during calcination into harmless CO and O2 gases. This eliminates waste disposal problems while maintaining effective impregnation, turning what would be a environmental burden into a clean process
3Reliability
If zeolite pellets are used as support material, then cracking performance is enhanced, but effective utilization requires optimized metal precursor adsorption
Solution Approach 1:
The patent optimizes metal precursor adsorption onto zeolite pellets by using supercritical CO2 as the solvent, which provides enhanced penetration and uniform distribution of metal precursors throughout the porous zeolite structure. The supercritical state allows for better mass transfer and more precise control of metal loading, improving the overall manufacturing precision of the catalyst
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
This method enhances the cracking performance of hydrocracking catalysts while avoiding the generation of harmful waste, leveraging the favorable thermo-physical properties of supercritical carbon dioxide for improved mass transfer and deposition kinetics.
Implementation Method 1
carbon dioxide transforms into a supercritical phase for enhanced dissolution and adsorption
Implementation Method 2
adsorb Ni and/or W metal precursors onto zeolite pellets
Implementation Method 3
the support material is subjected to a calcination process so as to allow oxidation of the adsorbed metals
Implementation Method 4
subjected to calcination so as to allow oxidation of the adsorbed metals
Data Source
Figure 1
Figure 2~3(c)
AI summary
The synthesis system (S) according to the present invention comprises a high-pressure container (1) into which the support material (17) and metal precursor (18) are placed and having a body (13) resistant to high pressure; a carbondioxide source (2) for supplying carbondioxide gas into the high-pressure container (1); a pump (3) for delivering carbondioxide into the high-pressure container (1); a temperature regulation unit (6) regulating the temperature of the high-pressure container (1); at least one heating furnace wherein the support material (17) is heated and subjected to calcination after the metal precursor (18) is dissolved in carbondioxide in the supercritical phase and adsorbed into the support material (17). The synthesis method using the synthesis system (S) comprises the steps of introducing (a) the metal precursor (18) and support material (17) into the high-pressure container (1); supplying carbondioxide into the high-pressure container (1); allowing the metal precursor (18) to be dissolved in carbondioxide and adsorbed (b) by the support material (17); heating the support material (17) inside the said furnace and subjecting it to a calcination (c) process so as to allow the metal precursor (18) adsorbed by the support material (17) to oxidize.