Hydroprocessing Catalyst Precursor Organic Modification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current hydroprocessing catalysts face challenges in efficiently desulfurization and denitrogenation, particularly with high-sulfur and high-nitrogen crude processing, and require improved nanostructural morphology control to enhance activity and selectivity.
Innovation Solution
A catalyst precursor composition is developed by impregnating a metal oxide component with an amide reaction product formed from an amine and a carboxylic acid, followed by thermal treatment to induce additional unsaturation and oxygen incorporation, resulting in a sulfided catalyst with reduced stack number and improved promoter metal positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional sulfide precursors without organic groups are used, then catalyst preparation is simpler, but catalyst activity is lower
Solution Approach 1:
The patent uses composite materials by combining metal oxide precursors with organic compounds (amines, carboxylic acids, or amino acids) to form organically modified catalyst precursors. This composite approach allows the organic components to influence the nanostructural morphology of the sulfided catalyst, creating a more active catalyst while maintaining a manageable preparation process through impregnation and thermal treatment steps.
Solution Approach 2:
The patent applies parameter changes by modifying the chemical composition of the catalyst precursor through the addition of organic compounds. The organic components (amines, carboxylic acids, or amino acids) change the physical and chemical parameters of the precursor, which subsequently affect the nanostructure of the sulfided catalyst, leading to improved catalytic activity without significantly complicating the preparation process.
2Adaptability or versatility
If inorganic components are substituted into Group 6/Groups 8-10 oxide precursors, then catalyst composition is modified, but nanostructure of resulting bulk sulfide catalysts is not significantly changed
Solution Approach 1:
The patent introduces organic compounds (amines, carboxylic acids, or amino acids) as intermediary substances during the catalyst preparation process. These organic intermediaries mediate between the inorganic oxide precursor and the final sulfided catalyst structure, enabling precise control over the nanostructure (crystallite size, stack number) that cannot be achieved by inorganic substitution alone. The organic components are subsequently removed or transformed during thermal treatment and sulfidation.
3Reliability
If higher pressure capability is not available in existing units, then operating constraints are maintained, but desulfurization and denitrogenation efficiency is limited
Solution Approach 1:
The patent changes the intrinsic parameters of the catalyst itself rather than changing operating conditions. By modifying the nanostructural morphology through organic modification of precursors, the catalyst achieves higher activity and selectivity for desulfurization and denitrogenation reactions, enabling efficient processing within existing pressure constraints while improving productivity without violating operating constraints.
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 enhances the hydroprocessing catalyst's activity and selectivity, leading to increased hydrodenitrogenation and hydrodesulfurization performance, with improved catalyst density and surface area, effectively addressing the limitations of existing catalysts.
Implementation Method 1
an amide reaction product of (i) a first organic compound containing at least one amine group, and (ii) a second organic compound separate from the first organic compound and containing at least one carboxylic acid group
Implementation Method 2
followed by thermal treatment to induce additional unsaturation and oxygen incorporation
Implementation Method 3
The process enhances the hydroprocessing catalyst's activity and selectivity, leading to increased hydrodenitrogenation and hydrodesulfurization performance
Data Source
AI summary
The precursor of a hydroprocessing catalyst is made by impregnating a metal oxide component comprising at least one metal from Group 6 of the Periodic Table and at least one metal from Groups 8-10 of the Periodic Table with an amide formed from a first organic compound containing at least one amine group, and a second organic compound containing at least one carboxylic acid group. Following impregnation heat treatment follows to form in situ generated unsaturation additional to that in the two organic compounds. The catalyst precursor is sulfided to form an active, sulfide hydroprocessing catalyst.