Hydrotreating Catalyst Oil-Additive Impregnation
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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 concentration limits in diesel fuels, as existing catalysts face challenges in deep hydrodesulfurization and require costly calcination and sulfidation steps.
Innovation Solution
A catalyst composition comprising a metal-incorporated support material impregnated with hydrocarbon oil and a polar additive, where the support material is uncalcined and nonsulfided, filled with a blend of hydrocarbon oil and polar additive, and treated with hydrogen followed by a sulfur compound, utilizing Group 9 and Group 10 metals like cobalt and nickel, Group 6 metal molybdenum, and phosphorus, to enhance catalytic properties for hydrodesulfurization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hydrotreating catalysts are used to meet stringent sulfur concentration limits, then deep hydrodesulfurization activity is required, but the manufacturing process requires costly calcination and sulfidation steps
Solution Approach 1:
The catalyst support is pre-impregnated with a blend of hydrocarbon oil and polar additive before catalyst formation, eliminating the need for subsequent calcination and sulfidation steps. This preliminary impregnation action prepares the catalyst in its final active state during manufacturing, reducing both cost and processing steps while maintaining high hydrodesulfurization activity
Solution Approach 2:
The invention changes the chemical state parameters of the catalyst by using uncalcined and nonsulfided support materials impregnated with specific oil-additive blends. This parameter change allows the catalyst to achieve its active state without traditional high-temperature calcination and sulfidation, reducing manufacturing costs while maintaining effectiveness
2Reliability
If calcination and sulfidation steps are performed to activate the catalyst, then catalytic activity is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The catalyst is prepared with the active blend of hydrocarbon oil and polar additive impregnated into the support material before catalyst formation. This preliminary action eliminates the need for subsequent calcination and sulfidation steps, reducing manufacturing process complexity from multiple high-temperature treatment steps to a single impregnation step, while ensuring the catalyst achieves its active state in situ
Solution Approach 2:
The invention extracts and eliminates the calcination and sulfidation steps from the traditional catalyst activation sequence. By using uncalcined and nonsulfided support materials pre-impregnated with the active blend, the harmful and complex high-temperature treatment steps are removed, simplifying the manufacturing process while maintaining catalyst reliability
3Manufacturing precision
If traditional catalyst activation methods are used, then catalyst performance is achieved, but time-consuming processing steps are required
Solution Approach 1:
The support material is pre-impregnated with the active blend of hydrocarbon oil and polar additive before catalyst formation, performing the activation function in advance. This eliminates the need for time-consuming post-formation calcination and sulfidation steps, reducing total processing time from multiple days to a single impregnation step, while maintaining catalyst performance
Solution Approach 2:
The invention skips the traditional multi-step activation process (calcination followed by sulfidation) by using uncalcined and nonsulfided support materials that are pre-impregnated with the active blend. This rushing through of the activation function during the impregnation step itself dramatically reduces processing time while achieving the same catalyst 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 catalyst composition exhibits significantly improved hydrodesulfurization activity and reduced manufacturing costs by eliminating the need for calcination and sulfidation, allowing for in situ activation and achieving ultra-low sulfur distillate products with enhanced catalytic performance.
Implementation Method 1
at least 75% of the pore volume of the metal-incorporated support material is filled with the hydrocarbon oil and polar additive
Implementation Method 2
wherein the metal-incorporated support material is impregnated with the hydrocarbon oil and the polar additive before it is treated with hydrogen followed by treatment with a sulfur compound
Implementation Method 3
treated with hydrogen followed by treatment with a sulfur compound
Data Source
Figure 1~2
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Figure 5
AI summary
A composition that comprises a support material having incorporated therein a metal component and impregnated with both hydrocarbon oil and a polar additive. The composition that is impregnated with both hydrocarbon oil and polar additive is useful in the hydrotreating of hydrocarbon feedstocks, and it is especially useful in applications involving delayed feed introduction whereby the composition is first treated with hot hydrogen, and, optionally, with a sulfur compound, prior to contacting it with a hydrocarbon feedstock under hydrodesulfurization process conditions.