Hydrotreating Catalyst with Heterocyclic Additives for Low Hydrogen Consumption
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Solution Overview
Problem
There is a need for improved hydrotreating catalysts with higher activity and more economical manufacturing methods to meet stringent sulfur and nitrogen removal specifications in diesel fuels, as existing catalysts require costly calcination and sulfidation steps and have limited catalytic performance.
Innovation Solution
A catalyst composition comprising a support material loaded with a metal component and a heterocyclic additive, which can be impregnated with a metal-containing solution and a heterocyclic compound, eliminating the need for prior calcination or sulfidation, and allowing in situ activation, enhancing hydrodesulfurization and hydrodenitrogenation activities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hydrotreating catalysts are used with calcination and sulfidation steps, then catalytic activity is achieved, but manufacturing cost and process complexity increase
Solution Approach 1:
The catalyst precursor is prepared in advance with metal salts and heterocyclic compounds impregnated onto the support material, eliminating the need for subsequent calcination and sulfidation steps. This preliminary preparation achieves the desired catalytic state without expensive post-processing
Solution Approach 2:
The invention changes the chemical parameters of the catalyst formulation by using metal salts instead of metal oxides and adding heterocyclic compounds, which allows the catalyst to achieve high catalytic activity without requiring calcination and sulfidation treatment
2Reliability
If conventional catalyst formulations are used, then basic hydrodesulfurization activity is achieved, but hydrogen consumption increases for high endpoint gas oils
Solution Approach 1:
The catalyst uses a composite formulation combining metal salts (such as molybdenum and cobalt salts) with heterocyclic compounds (such as thiazole or triazole derivatives) on a porous support, creating synergistic effects that enhance hydrodesulfurization activity while reducing hydrogen consumption
Solution Approach 2:
The invention changes the chemical composition parameters by introducing heterocyclic compounds with specific molecular structures that facilitate sulfur removal reactions, thereby improving catalytic efficiency and reducing hydrogen demand
3Reliability
If existing catalysts are used for deep hydrodenitrogenation, then nitrogen removal is achieved, but catalytic performance and activity are limited
Solution Approach 1:
The catalyst employs a composite material system with metal salts and heterocyclic compounds that work synergistically to enhance both hydrodesulfurization and hydrodenitrogenation activities, achieving deep nitrogen removal with superior catalytic performance
Solution Approach 2:
The heterocyclic compounds act as intermediaries that facilitate nitrogen removal reactions by forming temporary complexes with nitrogen-containing compounds, enhancing the catalyst's ability to perform deep hydrodenitrogenation
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 catalyst composition exhibits significantly improved hydrodesulfurization and hydrodenitrogenation activities without the need for pre-calination or sulfidation, reducing manufacturing costs and enabling the production of ultra-low sulfur diesel with enhanced catalytic performance.
Implementation Method 1
a catalyst composition that comprises a support material that is loaded with an active metal precursor and a heterocyclic additive
Implementation Method 2
a catalyst composition that comprises a support material that is loaded with an active metal precursor and a heterocyclic additive
Data Source
AI summary
A process and catalyst that provides for the upgrading of a high endpoint gas oil feedstock that contains significant concentrations of organic sulfur compound and organic nitrogen compounds. Included among the sulfur compounds are the dimethyl-dibenzothiophenes and derivative thereof. The catalyst of the process is an additive impregnated composition or a derivative thereof that further comprises cobalt and molybdenum. The process provides for the upgrading the high endpoint gas oil feedstock by significantly reducing the difficult to remove thiophene and nitrogen compounds and the process does this with a significantly reduced hydrogen consumption relative to processes using comparative catalysts.