Hydroprocessing Catalysts via Seeded Sulfidation for Desulfurization
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Solution Overview
Problem
Current hydroprocessing catalysts face limitations in efficiently desulfurization and denitrogenation, particularly when processing crude oils with high heteroatom levels, and there is a need to control nanostructural morphology and lattice defects to enhance catalytic activity and selectivity.
Innovation Solution
A process involving the mixing of a particulate metal oxide composition with sulfide particles of Group 8 to 10 metals to produce a catalyst precursor, which is then sulfided to create layered metal sulfides with defect sites, controlling the morphology and defect density of MoS2/WS2 particles through seeding with NixS or CoxS particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydroprocessing catalysts are used, then basic catalytic function is provided, but catalytic activity and selectivity are insufficient for efficient desulfurization and denitrogenation
Solution Approach 1:
The invention changes the nanostructural parameters of the catalyst by controlling particle size, shape, and crystal structure. Specifically, it uses metal oxide precursors with controlled morphology that transform into sulfide catalysts with enhanced surface area and exposed active crystal planes, thereby improving catalytic activity and selectivity for desulfurization and denitrogenation
Solution Approach 2:
The invention creates a catalyst that performs multiple functions simultaneously - both hydrodesulfurization and hydrodenitrogenation - through a single catalyst formulation containing metal sulfides derived from oxide precursors. This multi-functional catalyst addresses the need for efficient removal of multiple heteroatoms from crude oil feedstocks
2Adaptability or versatility
If catalyst pressure capability is increased to handle high heteroatom crude oils, then processing capability improves, but equipment complexity and operating costs increase
Solution Approach 1:
The invention changes the chemical and structural parameters of the catalyst to enhance its intrinsic activity. By using metal oxide precursors with specific surface areas, pore distributions, and crystal orientations that transform into highly active sulfide phases, the catalyst achieves superior performance at lower operating pressures, avoiding the need for high-pressure equipment
3Device complexity
If MoS2/WS2 particles are grown as straight layered structures, then crystal structure is simple, but lattice defects and special active sites are minimized
Solution Approach 1:
The invention performs preliminary action by preparing metal oxide precursors with controlled morphology, surface area, and crystal structure before sulfidation. These pre-engineered oxide structures contain features that direct the formation of sulfide catalysts with enhanced surface area and exposed active crystal planes, creating lattice defects and special sites before the actual catalytic reaction begins
Solution Approach 2:
The invention changes the physical and chemical parameters of the catalyst particles including surface area, pore size distribution, and crystal orientation. By controlling these parameters during precursor preparation and sulfidation, the process generates lattice defects and special active sites that enhance catalytic activity while maintaining structural integrity
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
This approach results in hydroprocessing catalysts with improved activity and selectivity, enabling more efficient desulfurization and denitrogenation of hydrocarbon feedstocks, particularly in conditions with limited pressure capability.
Implementation Method 1
sulfiding the particulate catalyst precursor under conditions sufficient to at least partially convert the components of the particulate catalyst precursor into a layered metal sulfide having defect sites
Implementation Method 2
nucleation and growth of layered MoS2/WS2 structures with a curved morphology
Implementation Method 3
by 'seeding' a Mo(W) oxide precursor material with size and shape-controlled NixS particles, the NixS seeds can control the curvature of the MoS2/WS2 particles produced on subsequent sulfiding
Implementation Method 4
during sulfidation, hydrogen spillover at detrital NixS particle surfaces results in nucleation and growth of layered MoS2/WS2 structures with a curved morphology
Data Source
AI summary
In a process for producing a hydroprocessing catalyst, a particulate metal oxide composition comprising an oxide of at least one first metal selected from Group 6 of the Periodic Table of the Elements can be mixed with particles of a sulfide of at least one second metal selected from Groups 8 to 10 of the Periodic Table of the Elements to produce a particulate catalyst precursor. The particulate catalyst precursor can then be sulfided under conditions sufficient to at least partially convert the particulate catalyst precursor into a layered metal sulfide having defect sites associated with the second metal sulfide.