Hydroprocessing Catalyst Precursor Composition with In Situ Unsaturated Carbon Atoms
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Solution Overview
Problem
Current hydroprocessing catalysts face challenges in efficiently desulfurization and denitrogenation, particularly when processing crude oils with high sulfur and nitrogen content, and existing units have limited pressure capability, leading to poisoning of metal or acid sites downstream.
Innovation Solution
A catalyst precursor composition comprising metals from Group 6 and 8-10 of the Periodic Table, treated with organic compounds containing carboxylic acid and amine groups, is heated to form in situ unsaturated carbon atoms, enhancing the efficiency of promoter metals and reducing the number of sulfide stacks, resulting in improved hydroprocessing activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydroprocessing catalysts are used, then basic hydroprocessing function is provided, but desulfurization and denitrogenation efficiency is insufficient under limited pressure capability
Solution Approach 1:
The patent changes the structural parameters of the catalyst by controlling the number of stacks in the sulfide crystallites. By reducing the number of stacks through specific synthesis methods (using organic impregnation aids or controlling precipitation conditions), the catalyst achieves higher surface area and improved activity, allowing efficient desulfurization and denitrogenation at lower pressures.
Solution Approach 2:
The patent creates composite catalyst structures by incorporating promoter metals (Co, Ni, Fe) into the MoS2 or WS2 matrix. This composite approach enhances the catalytic activity and selectivity, enabling the catalyst to handle high sulfur and nitrogen content crude oils more effectively under limited pressure conditions.
2Adaptability or versatility
If crude oils with high sulfur and nitrogen content are processed, then feedstock flexibility is improved, but catalyst poisoning occurs downstream
Solution Approach 1:
The patent implements preliminary hydroprocessing treatment that more completely removes sulfur and nitrogen before downstream processing. By using the improved catalyst with reduced stack number, the pre-treatment is more effective, preventing the poisoning of downstream catalysts and allowing processing of high heteroatom crude oils.
3Productivity
If catalysts with reduced stacks are produced, then surface area and activity are improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses organic impregnation aids (such as amines, amino acids, or other organic compounds) as intermediaries during the catalyst synthesis process. These intermediaries control the formation of sulfide stacks during sulfidation, leading to reduced stack numbers and higher surface area. The intermediary facilitates the complex structural control without requiring overly complex synthesis procedures.
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 produces catalysts with increased hydroprocessing activity and improved promoter metal coordination, leading to enhanced desulfurization and denitrogenation capabilities, even under challenging conditions.
Implementation Method 1
heated to form in situ unsaturated carbon atoms
Implementation Method 2
sulfiding the catalyst precursor composition containing the reaction product
Implementation Method 3
treated with organic compounds containing carboxylic acid and amine groups
Data Source
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AI summary
Described herein is a catalyst precursor composition comprising at least one metal from Group 6 of the Periodic Table of the Elements, at least one metal from Groups 8-10 of the Periodic Table of the Elements, and a reaction product formed from (i) a first organic compound containing at least one amine group and at least 10 carbon atoms or (ii) a second organic compound containing at least one carboxylic acid group and at least 10 carbon atoms, but not both, wherein the reaction product contains additional unsaturated carbon atoms, relative to the first or second organic compound, wherein the metals of the catalyst precursor composition are arranged in a crystal lattice, and wherein the reaction product is not located within the crystal lattice. A process for preparing the catalyst precursor composition is also described, as is sulfiding the catalyst precursor composition to form a hydroprocessing catalyst.