Hydroprocessing Catalyst Single-Step Metal Chelant Incorporation
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Solution Overview
Problem
Current hydroprocessing catalysts face challenges in achieving high activity and stability when treating petroleum-derived hydrocarbon streams with high sulfur and nitrogen concentrations, necessitating the development of improved catalyst compositions for effective hydrodesulfurization and hydrodenitrogenation.
Innovation Solution
A method for creating a hydroprocessing catalyst composition involving a metal-containing support with incorporated metal components and a chelating agent, further loaded with a polar additive, which involves a single-step impregnation process and specific calcination and drying conditions to achieve enhanced catalytic performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional multi-step impregnation methods are used to incorporate metals and chelating agents, then catalyst composition can be achieved, but manufacturing complexity and process time increase
Solution Approach 1:
The patent combines the incorporation of metal components and chelating agents into a single impregnation step, eliminating the need for separate treatment steps. The impregnation solution contains both metal salts and chelating agents that are simultaneously incorporated into the support material, reducing manufacturing complexity and process time while achieving the desired catalyst composition.
Solution Approach 2:
The support material is pre-treated with specific drying and calcination conditions before impregnation to optimize pore structure and surface properties. The drying step at 50-200°C and calcination at 250-900°C prepare the support in advance to receive both metal components and chelating agents efficiently in the subsequent single impregnation step.
2Productivity
If high metal loading is applied to increase catalytic activity, then hydrodesulfurization and hydrodenitrogenation performance improves, but metal aggregation and stability decrease
Solution Approach 1:
Chelating agents serve as intermediaries between metal components and the support material. These agents form stable complexes with metal ions during impregnation, controlling metal distribution and preventing aggregation. The chelating agents act as mediators that facilitate uniform metal dispersion while maintaining catalyst stability during hydrodesulfurization and hydrodenitrogenation reactions.
Solution Approach 2:
The patent optimizes multiple parameters including drying temperature (50-200°C), calcination temperature (250-900°C), and the molecular structure of chelating agents to control metal dispersion. By adjusting these parameters, the catalyst achieves high metal loading with uniform distribution, maintaining both high catalytic activity for hydrodesulfurization and long-term stability.
3Productivity
If support pore size is increased to improve mass transfer, then reaction efficiency improves, but metal dispersion and catalytic performance decrease
Solution Approach 1:
The patent optimizes support pore size parameters to achieve an optimal balance between mass transfer and metal dispersion. The support is designed with specific pore size ranges that facilitate adequate mass transfer for hydrodesulfurization reactions while providing sufficient surface area and confinement for uniform metal component dispersion, achieving both high reaction efficiency and high catalytic performance.
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 resulting catalyst composition exhibits exceptional hydrodesulfurization and hydrodenitrogenation activity and stability, outperforming prior art catalysts, with the combination of chelating agents and polar additives believed to enhance metal dispersion and catalytic performance.
Implementation Method 1
a single step impregnation of the shaped support with a solution of chelating agent and metal component
Implementation Method 2
loaded with a polar additive
Implementation Method 3
drying the metal-incorporated support to provide a dried metal-incorporated support
Implementation Method 4
calcined at a calcination temperature of 250 °C to 900 °C
Implementation Method 5
calcined at a calcination temperature of 250 °C to 900 °C
Data Source
AI summary
A hydroprocessing catalyst composition that comprises a metal-incorporated support having incorporated therein a metal component and a chelating agent, and, further comprising a polar additive. The catalyst composition is prepared by incorporating in a single step at least one metal component and a chelating agent into a support material to form a metal-incorporated support followed by drying the metal-incorporated support and thereafter incorporating therein a polar additive.