Hydrotreating Catalyst Pore Structure Optimization
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Solution Overview
Problem
Conventional hydrotreating catalysts face challenges in efficiently removing sulfur and nitrogen from heavy hydrocarbon feedstocks at lower temperatures, leading to increased energy costs and catalyst deactivation, due to the high concentrations of contaminating compounds in these feedstocks.
Innovation Solution
A catalyst composition with a gamma alumina support having a median pore diameter of 100-120 Å, a surface area of 290-235 m²/g, and a total mercury pore volume less than 0.85 cc/g, impregnated with Group 6 and Group 10 metal components, which is heat-treated to enhance hydrodesulfurization and hydrodenitrogenation activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hydrotreating catalysts are used to remove sulfur and nitrogen from heavy hydrocarbon feedstock, then the impurity removal function is achieved, but higher reaction temperatures are required which increases energy consumption and causes rapid catalyst deactivation
Solution Approach 1:
The patent employs a gamma alumina support with specifically controlled pore structure (median pore diameter 100-120 Å, surface area 290-235 m²/g, total mercury pore volume <0.85 cc/g) to enhance catalyst performance. The optimized porosity facilitates better mass transfer and accessibility of active sites, enabling effective hydrodesulfurization and hydrodenitrogenation at lower temperatures while maintaining catalyst stability and reducing energy consumption.
Solution Approach 2:
The catalyst comprises a composite structure combining gamma alumina support with Group 6 metal component (molybdenum or tungsten) and Group 10 metal component (nickel or cobalt). This composite material synergistically enhances catalytic activity for sulfur and nitrogen removal, allowing operation at reduced temperatures with improved energy efficiency and sustained catalyst performance.
2Productivity
If the alumina support surface area is reduced to maintain pore volume control, then the pore structure for mass transfer is optimized, but catalyst activity typically decreases
Solution Approach 1:
The patent optimizes multiple parameters simultaneously: median pore diameter (100-120 Å), surface area (290-235 m²/g), and total mercury pore volume (<0.85 cc/g). By precisely controlling these parameters within specific ranges, the catalyst achieves high productivity for sulfur and nitrogen removal while maintaining the appropriate balance between surface area and pore structure for effective mass transfer and active site accessibility.
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 achieves a 10% increase in relative volumetric activity for nitrogen and sulfur removal at 10 ppm levels compared to conventional catalysts, reducing reaction temperatures and energy consumption while maintaining high activity despite a smaller surface area.
Implementation Method 1
a porous refractory inorganic oxide material
Implementation Method 2
The hydrotreating catalysts used in these processes generally are composed of an active phase that can include a component from the Group 6 metals and a component from the Group 10 metals
Implementation Method 3
the hydrocarbon feedstock is contacted with a hydrotreating catalyst in the presence of hydrogen
Data Source
AI summary
A method of hydrotreating a heavy hydrocarbon feedstock using a hydrotreating catalyst having specific properties that make it effective in removing nitrogen and sulfur from the feedstock is disclosed. The catalyst is composed of an alumina support particle having a specific pore diameter distribution which is achieved in part, by the use of pseudo-boehmite as the alumina source and specific calcining temperatures. The hydrotreatment catalyst also comprises a Group 6 metal component (e.g., molybdenum) and a Group 10 metal component (e.g., nickel), and optionally, a phosphorus metal component, which are supported by the alumina support particle.