Hydrothermal Bulk Bimetallic Catalyst Synthesis
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Solution Overview
Problem
Conventional hydroprocessing catalysts face challenges in achieving high activity with low metal molar ratios of Group VIII to Group VIB metals, leading to increased weight and reduced activity per unit weight, while also requiring improved catalytic performance for sulfur and nitrogen removal in hydrocarbons.
Innovation Solution
A bulk metal catalyst comprising only one Group VIII metal and one Group VIB metal, specifically nickel and tungsten, is synthesized using hydrothermal conditions to achieve low metal molar ratios and enhance catalytic activity, with the catalyst being made by combining metal compounds in a protic liquid and reacting under hydrothermal conditions to form metal oxidic particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the metal molar ratio of Group VIII to Group VIB metals is increased to achieve high catalytic activity, then the catalytic activity is improved, but the catalyst weight increases and activity per unit weight decreases
Solution Approach 1:
The patent applies parameter changes by modifying the synthesis conditions from atmospheric to hydrothermal conditions (temperature above boiling point of protic liquid, pressurized environment). This enables the formation of active catalyst phases at lower metal molar ratios (0.1-5), transforming the relationship between metal content and catalytic activity. The hydrothermal parameters allow achieving high activity with reduced metal loading, directly resolving the contradiction between catalytic activity and catalyst weight.
2Ease of manufacture
If conventional atmospheric synthesis conditions are used, then the synthesis process is simple, but low metal molar ratios cannot be achieved and catalytic activity is reduced
Solution Approach 1:
The patent changes the synthesis parameters from atmospheric conditions to hydrothermal conditions (heating above the boiling point of the protic liquid, typically water, under pressure). This parameter change enables the formation of highly active catalyst phases that cannot be obtained under atmospheric conditions, achieving superior catalytic activity despite the increased synthesis complexity. The hydrothermal treatment creates a unique chemical environment that promotes active phase formation at low metal ratios.
3Reliability
If high metal molar ratios are used to ensure adequate catalytic performance, then catalytic activity is maintained, but unnecessary weight is added and activity per unit weight is reduced
Solution Approach 1:
By implementing hydrothermal synthesis conditions, the patent achieves reliable catalytic performance with significantly reduced metal molar ratios (0.1-5 range). The elevated temperature and pressure conditions promote the formation of highly active crystalline phases and optimize metal dispersion, ensuring consistent catalytic performance for hydrodesulfurization and hydrodenitrogenation without requiring excessive metal content, thus reducing catalyst weight while maintaining reliability.
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 results in catalysts with improved hydrodesulfurization and hydrodenitrogenation activity, achieving higher activity levels than those synthesized under atmospheric conditions with the same molar ratios, while reducing the amount of catalyst material needed.
Implementation Method 1
reacting the compounds under hydrothermal conditions to form metal oxidic particles, wherein the hydrothermal conditions include heating the reaction mixture at a temperature above the atmospheric boiling point of the protic liquid
Data Source
AI summary
The invention relates to a process for upgrading hydrocarbonaceous feedstreams by hydroprocessing using bulk bimetallic catalysts. More particularly, the invention relates to a catalytic hydrotreating process for the removal of sulfur and nitrogen from a hydrocarbon feed such as a fuel or a lubricating oil feed. The catalyst is a bulk catalyst containing at leas one Group VIII metal and at least one Group VIB metal. The catalyst is prepared hydrothermally.