Hydroprocessing Catalyst Metal Deposition with Modifying Agent
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Solution Overview
Problem
Current hydroprocessing catalysts exhibit unpredictable activity, selectivity, and stability, leading to challenges in achieving optimal performance for hydrocarbon conversion and impurity removal, particularly in processes like hydrotreating, hydrocracking, and hydroisomerization.
Innovation Solution
A method for producing a hydroprocessing catalyst involving a support material, such as alumina or silica-alumina, with deposited metals like nickel and tungsten, in the presence of a modifying agent like 2-hydroxy-1,2,3-propanetricarboxylic acid, which enhances catalyst activity and selectivity by preventing metal aggregation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal deposition is performed without a modifying agent, then the catalyst structure forms, but metal aggregation occurs leading to reduced activity and selectivity
Solution Approach 1:
A modifying agent comprising a carboxylic acid or hydroxycarboxylic acid is introduced as an intermediary substance during metal deposition. This modifying agent coordinates with metal ions to form stable complexes, preventing metal aggregation and ensuring uniform metal distribution on the support surface, thereby resolving the contradiction between achieving reliable catalyst activity and maintaining manufacturing precision of metal distribution.
Solution Approach 2:
The modifying agent alters the chemical parameters of the deposition process by changing the coordination chemistry between metal ions and the support surface. By introducing carboxylic acid groups that can chelate metal ions, the deposition mechanism is transformed from simple adsorption to controlled complex formation, improving both metal distribution uniformity and subsequent catalyst performance.
2Productivity
If metal loading is increased to improve activity, then hydrogenation capability increases, but metal aggregation occurs reducing selectivity and stability
Solution Approach 1:
The modifying agent acts as a spatial and chemical intermediary that maintains separation between metal particles even at high loadings. By forming stable metal-modifier complexes distributed across the support surface, it enables increased metal loading for higher hydrogenation rates while preventing the aggregation that would otherwise reduce catalyst stability and selectivity.
3Ease of manufacture
If conventional catalyst preparation methods are used, then the process is simple, but activity and selectivity are unpredictable
Solution Approach 1:
The modifying agent introduces a controlled chemical interaction step that bridges the simple physical deposition process and the desired uniform metal distribution. This additional intermediary step involves impregnating the support with a carboxylic acid solution followed by metal salt addition, which systematically ensures predictable metal dispersion and consistent catalyst performance while maintaining relative 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 method results in improved catalyst activity and selectivity, extending catalyst life and reducing unwanted by-products, such as coke formation, while maintaining or improving hydrogenation performance across various hydroprocessing conditions.
Implementation Method 1
deposition of at least one of the metals is achieved in the presence of a modifying agent
Data Source
Figure 1
AI summary
The present invention is directed to a hydroprocessing catalyst containing at least one catalyst support, one or more metals, optionally on or more molecular sieves, optionally one or more promoters, wherein deposition of at least one of the metals is achieved in the presence of a modifying agent.