High Metal Loading Hydrolysis Catalyst for Low-Temperature Sulfur Conversion
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Solution Overview
Problem
Existing catalyst compositions for the catalytic reduction of sulfur compounds in gas streams, such as those from Claus units, are ineffective at achieving high conversion rates at low temperatures, requiring high reactor temperatures and energy-intensive processing.
Innovation Solution
A catalyst composition comprising a calcined, co-mulled mixture of pseudoboehmite, cobalt, and molybdenum, forming gamma-alumina with high metal loadings, which provides a bimodal pore structure and enhanced catalytic properties for low-temperature hydrolysis of sulfur compounds and carbon monoxide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalyst compositions are used for catalytic reduction of sulfur compounds, then high conversion rates can be achieved, but high reactor temperatures and energy-intensive processing are required
Solution Approach 1:
The patent changes the chemical composition parameters of the catalyst by incorporating specific metal oxides (molybdenum oxide, cobalt oxide, nickel oxide) in optimized ratios, along with alkali metal phosphates, to achieve high catalytic activity at lower temperatures. This compositional parameter change enables the catalyst to maintain high conversion rates while reducing the operating temperature from conventional high temperatures to 100-350°C, thereby reducing energy consumption
Solution Approach 2:
The patent creates a composite catalyst material combining multiple metal oxides (molybdenum, cobalt, nickel) with alumina support and alkali metal phosphate promoters. This composite structure synergistically enhances catalytic performance, allowing the catalyst to achieve high sulfur compound conversion at lower temperatures compared to conventional single-component catalysts, thus resolving the contradiction between productivity and energy consumption
2Productivity
If high reactor temperatures are used to achieve high conversion of sulfur compounds, then conversion efficiency improves, but energy consumption increases
Solution Approach 1:
The patent modifies the thermal parameter (operating temperature) by developing a catalyst that achieves peak activity at 100-350°C, significantly lower than conventional catalysts requiring higher temperatures. The specific composition with metal oxides and alkali metal phosphates creates active sites that facilitate sulfur compound conversion at these reduced temperatures, maintaining high conversion efficiency while reducing the stationary energy input required for heating
Solution Approach 2:
The patent utilizes the porous structure of alumina support with controlled surface area and pore distribution to increase the catalyst's surface area-to-volume ratio. This porous architecture provides more active sites for catalytic reactions, enhancing conversion efficiency at lower temperatures and reducing the energy required for the stationary reactor operation
3Productivity
If conventional catalysts are used, then sulfur compound removal is achieved, but flow rates must be reduced to maintain conversion efficiency
Solution Approach 1:
The patent changes the catalytic activity parameters through optimized metal oxide composition and ratios, creating a catalyst with enhanced intrinsic activity. This allows the catalyst to maintain high sulfur compound removal efficiency even at increased gas flow rates, as the improved active site density and reactivity compensate for the reduced residence time
Solution Approach 2:
The composite catalyst structure with multiple metal oxides and promoters creates synergistic effects that enhance mass transfer and reaction kinetics. This composite material design allows the catalyst to handle higher gas flow rates while maintaining conversion efficiency, as the improved catalytic activity compensates for the reduced contact time between reactants and catalyst surface
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 enables high conversion of sulfur compounds and carbon monoxide at reduced reactor temperatures, allowing for lower energy consumption and increased flow rates, effectively reducing sulfur compound concentrations in gas streams.
Implementation Method 1
A catalyst composition comprising a calcined, co-mulled mixture of pseudoboehmite, cobalt, and molybdenum, forming gamma-alumina with high metal loadings, which provides a bimodal pore structure and enhanced catalytic properties for low-temperature hydrolysis of sulfur compounds and carbon monoxide
Implementation Method 2
A catalyst composition comprising a calcined, co-mulled mixture of pseudoboehmite, cobalt, and molybdenum, forming gamma-alumina
Data Source
AI summary
Disclosed is a composition useful in the hydrolysis of sulfur compounds that are contained in a gas stream. The composition comprises a calcined co-mulled mixture of psuedoboehmite, a cobalt compound, and a molybdenum compound such that the composition comprises gamma-alumina, at least 7.5 wt. % molybdenum, and at least 2.75 wt. % cobalt. The composition is made by forming into an agglomerate a co-mulled mixture pseudoboehmite, a cobalt component, and a molybdenum component followed by drying and calcining the agglomerate to provide a catalyst composition comprising gamma-alumina, at least 7.5 wt. % molybdenum, and at least 2.75 wt. % cobalt.