Hydrodesulfurization Catalyst for Low-Sulfur Gas Oil
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Solution Overview
Problem
Current methods for producing low-sulfur gas oil fractions using light cycle oil face challenges in maintaining catalyst activity and achieving stringent sulfur and color index requirements, especially with increased reaction temperatures leading to catalyst deactivation and product quality deterioration.
Innovation Solution
A process involving the hydrodesulfurization of a feedstock oil blend of straight-run gas oil and light cycle oil, using a desulfurization catalyst with specific metal supports and conditions, to achieve a sulfur content below 10 ppm and a color index of L1.5, while maintaining catalyst activity and improving cetane index.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the reaction temperature of hydrodesulfurization is increased to improve sulfur content reduction, then the sulfur content can be reduced to meet the 10 ppm limit, but the catalyst activity deactivates markedly and catalyst life is significantly shortened
Solution Approach 1:
The patent changes the chemical composition parameters of the catalyst by incorporating specific metal combinations (Ni-W, Ni-Mo, Co-W, Co-Mo) and controlling their ratios, rather than simply increasing reaction temperature. This allows achieving the required sulfur content reduction at lower temperatures, thereby extending catalyst life while meeting the 10 ppm sulfur limit.
Solution Approach 2:
The patent uses composite catalyst materials combining multiple metals (Ni and W, or Ni and Mo, or Co and W, or Co and Mo) on alumina support. These composite structures provide synergistic effects that enhance desulfurization activity at lower temperatures, avoiding the need to increase reaction temperature and thus preserving catalyst life.
2Manufacturing precision
If the reaction temperature is increased to improve sulfur content reduction, then the sulfur content can be reduced to meet the 10 ppm limit, but the color index of the obtained gas oil deteriorates
Solution Approach 1:
The patent changes the catalyst composition parameters to enable sulfur removal at lower reaction temperatures. By using specific metal combinations (Ni-W, Ni-Mo, Co-W, Co-Mo) with controlled ratios, the process achieves 10 ppm sulfur content without requiring temperature increases that would deteriorate color index, thus maintaining product quality.
3Adaptability or versatility
If light cycle oil is used in feedstock oil to improve economic viability, then the sulfur content is within the 2000 ppm limit, but a higher level of hydrodesulfurization is required to meet the 10 ppm limit
Solution Approach 1:
The patent develops composite catalysts with multiple metal components (Ni-W, Ni-Mo, Co-W, Co-Mo systems) that provide enhanced desulfurization activity specifically effective for the sulfur compounds present in light cycle oil. This allows achieving the 10 ppm sulfur limit from feedstocks containing light cycle oil (up to 30% by volume) without requiring excessive processing intensity.
Solution Approach 2:
The patent optimizes catalyst composition parameters (metal types, metal ratios, support properties) to maximize desulfurization efficiency for light cycle oil blends. By adjusting these parameters, the process achieves the required 10 ppm sulfur content from feedstocks with higher initial sulfur content (up to 30% light cycle oil), maintaining feedstock flexibility while meeting product specifications.
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 process effectively reduces sulfur content and maintains catalyst activity, enabling the production of low-sulfur gas oil fractions that meet stringent regulations without significant catalyst deactivation, thus improving economic viability and product quality.
Implementation Method 1
hydrodesulfurizing a feedstock oil to a sulfur content of not more than 10 ppm by mass
Implementation Method 2
a desulfurization catalyst containing at least one active metal selected from the group consisting of metals from group 6 of the periodic table and metals from groups 8 to 10 of the periodic table supported on an inorganic support containing an aluminum oxide
Data Source
AI summary
A process for producing a gas oil fraction by hydrodesulfurizing a feedstock oil prepared by blending a straight-run gas oil and a light cycle oil, wherein the process is capable of maintaining the activity of the desulfurization catalyst over a long period, and is capable of producing a low-sulfur gas oil fraction having a low sulfur content and excellent color index. The process for producing a low-sulfur gas oil fraction includes hydrodesulfurizing a feedstock oil to a sulfur content of not more than 10 ppm by mass, wherein the feedstock oil is prepared by blending a straight-run gas oil with a light cycle oil having a 10 volume % distillation temperature of less than 220° C. and a 90 volume % distillation temperature of less than 325° C., such that the blend proportion of the light cycle oil is not more than 30% by volume. Further, a low-sulfur gas oil is obtained by blending the low-sulfur gas oil fraction with a kerosene fraction.