Hydroprocessing Catalyst with Doped Support and Organic Additive
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Solution Overview
Problem
Current hydroprocessing catalysts face challenges in achieving high activity and stability when treating petroleum-derived hydrocarbon feedstocks with high sulfur and nitrogen concentrations, necessitating the development of more effective catalyst compositions for hydrotreating processes.
Innovation Solution
A hydroprocessing catalyst composition featuring a doped support particle with a metal overlayer of hydrogenation metals and an organic additive blend of acetate and unsaturated fatty amine compounds, which enhances hydrodesulfurization (HDS) and hydrodenitrogenation (HDN) activities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hydroprocessing catalysts are used, then basic hydrodesulfurization and hydrodenitrogenation functions are provided, but catalytic activity and stability are insufficient for high sulfur and nitrogen feedstocks
Solution Approach 1:
The catalyst employs a composite structure combining a doped support (alumina with nickel or boron) overlaid with hydrogenation metals (Group VIII or Group 6+Group VIII) and impregnated with organic additives (polar compound and hydrocarbon oil). This multi-component composite material system synergistically enhances both catalytic activity and stability for treating high sulfur and nitrogen feedstocks.
Solution Approach 2:
The support is doped with specific elements (nickel 0.01-5 wt% or boron 0.01-5 wt%) at controlled concentrations to modify local catalytic properties. The overlay and additive impregnation create zones with different functional characteristics, optimizing the balance between activity and stability in different regions of the catalyst particle.
2Ease of manufacture
If the catalyst composition is simplified, then manufacturing cost and complexity are reduced, but catalytic performance for high sulfur and nitrogen removal is compromised
Solution Approach 1:
The support is pre-doped with nickel or boron elements before metal overlay and additive impregnation. This preliminary doping step modifies the support properties in advance, enabling the subsequent layers to achieve optimal catalytic performance without requiring complex multi-step synthesis procedures.
Solution Approach 2:
The catalyst employs controlled doping concentrations (0.01-5 wt% nickel or boron) and specific additive compositions (polar compound 1-50 wt% and hydrocarbon oil 50-99 wt%) to optimize catalytic performance. These parameter adjustments enhance sulfur and nitrogen removal efficiency while maintaining manufacturability through standard impregnation techniques.
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 composition exhibits improved HDS and HDN catalytic characteristics, achieving enhanced catalytic performance and producing ultra-low sulfur distillate products with reduced nitrogen content, suitable for treating a wide range of hydrocarbon feedstocks.
Implementation Method 1
Hydroprocessing catalysts are used in processes to remove organic sulfur and nitrogen compounds from hydrocarbon feedstocks that are typically derived from the distillation of crude petroleum. In these processes the organic sulfur and nitrogen compounds are catalytically converted in the presence of hydrogen respectively to hydrogen sulfide and ammonia
Implementation Method 2
Hydroprocessing catalysts are used in processes to remove organic sulfur and nitrogen compounds from hydrocarbon feedstocks
Data Source
AI summary
A highly active hydroprocessing catalyst that comprises a doped support impregnated with at lease one hydrogenation metal component and filled with an organic additive blend. The catalyst is made by providing a doped support particle followed by impregnating the doped support particle with a metal impregnation solution to provide a metal-impregnated doped support particle. The metal-impregnated doped support particle is dried but not calcined and impregnated with an organic additive blend component.