Hydrofining Catalyst Pore Structure Optimization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydrofining catalysts have insufficient activity and small pore sizes, which limits their effectiveness in treating low-quality distillate oils, particularly in desulfurization, denitrification, and dearomatization, and existing grading systems cannot meet stricter oil quality requirements.
Innovation Solution
A hydrofining catalyst system with a specific pore structure, comprising an inorganic refractory component, a second hydrodesulfurization catalytically active component supported on the refractory component, and an organic component including carboxylic acid and alcohol, with pore sizes optimized for improved reactant diffusion and catalyst activity, and a method for preparing this catalyst system that reduces production costs and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional impregnation or kneading methods are used to prepare hydrofining catalysts, then the catalyst can be produced with standard pore structures, but the catalyst activity is insufficient and pore sizes are too small to effectively treat low-quality distillate oils
Solution Approach 1:
The patent applies preliminary action by pre-treating pseudo-boehmite powder through calcination at 400-700°C for 2-5 hours before impregnation. This pre-calcination creates a carrier with optimized pore structure (average pore size 100-300 nm) that enables better reactant diffusion and improves catalyst activity for treating low-quality distillate oils
Solution Approach 2:
The patent changes the pore size parameter of the catalyst carrier from conventional small pores to large pores with average size of 100-300 nm by controlling the calcination temperature (400-700°C) and time (2-5 hours) of pseudo-boehmite. This parameter change enables effective diffusion of large reactant molecules from low-quality feedstocks
2Volume of stationary object
If pore-expanding agents are added to increase pore size, then the pore structure is improved for better reactant diffusion, but the production cost increases and mixing uniformity is poor
Solution Approach 1:
The patent extracts and eliminates the need for pore-expanding agents by using a different approach: pre-calcining pseudo-boehmite to naturally form large pores (100-300 nm). This removes the harmful factor of adding external agents while achieving the desired pore structure through thermal treatment alone
Solution Approach 2:
The patent applies self-service by allowing pseudo-boehmite to self-organize into large pore structures through controlled calcination at 400-700°C. The material itself performs the pore-expansion function through thermal treatment without requiring external pore-expanding agents, achieving both cost reduction and uniform mixing
3Productivity
If multi-step impregnation or coprecipitation methods are used to improve catalyst performance, then the catalytic activity may be enhanced, but the preparation process becomes complicated and is not widely used in industry
Solution Approach 1:
The patent merges the carrier preparation and catalyst preparation into a single integrated process. Pseudo-boehmite is pre-calcined to create the carrier structure, then active metal precursors are impregnated in one step. This combines what would traditionally be separate multi-step processes into a simplified two-step method that maintains high catalyst activity while reducing operational complexity
4Ease of manufacture
If conventional catalysts with small pore sizes are used, then the catalyst structure is simple to manufacture, but the catalyst cannot effectively treat low-quality distillate oils with large reactant molecules
Solution Approach 1:
The patent applies preliminary action by pre-calcining pseudo-boehmite at 400-700°C for 2-5 hours before impregnation to create a carrier with optimized large pore structure (100-300 nm). This pre-treatment enables the simple manufacturing process to produce catalysts with pore sizes suitable for treating low-quality distillate oils
Solution Approach 2:
The patent changes the pore size parameter from conventional small pores to large pores (100-300 nm) by controlling the calcination temperature (400-700°C) and time (2-5 hours) of the pseudo-boehmite carrier. This parameter change enables effective diffusion of large reactant molecules while maintaining ease of manufacture
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 system achieves enhanced desulfurization, denitrification, and dearomatization performance, effectively treating low-quality distillate oils with improved catalyst activity and reduced production costs and environmental impact.
Implementation Method 1
catalysts should have a proper pore structure to adapt to the diffusion of reactants
Implementation Method 2
hydrofining catalysts comprise a sulfide of a VIB Group metal (Mo and/or W) as a main active component, and a sulfide of a VIII Group metal (Co and/or Ni) as an auxiliary active component
Data Source
AI summary
Disclosed is a hydrofining catalyst comprising: an inorganic refractory component comprising a first hydrodesulfurization catalytically active component in a mixture with at least one oxide selected from the group consisting of alumina, silica, magnesia, calcium oxide, zirconia and titania; a second hydrodesulfurization catalytically active component; and an organic component comprising a carboxylic acid and optionally an alcohol. The hydrofining catalyst of the present application shows improved performance in the hydrofining of distillate oils. Also disclosed are a hydrofining catalyst system comprising the hydrofining catalyst, a method for preparing the catalyst and catalyst system, and a process for the hydrofining of distillate oils using the catalyst or catalyst system.