Hydrotreating Catalyst Sulfone Modification for Ultra-Low Sulfur
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Solution Overview
Problem
Conventional hydrotreating catalysts based on refractory oxides and metals from Groups VI and VIII face challenges in achieving low sulfur contents below 10 ppm, with high costs and reduced activity after regeneration, and existing modifications require costly chemicals and do not consistently meet stringent sulfur specifications.
Innovation Solution
A hydrotreating catalyst comprising refractory oxides, metals from Groups VI and VIII, and sulfone or sulfoxide compounds derived from benzothiophene compounds, which are formed through oxidation by peroxides or hydroperoxides, allowing for increased reaction temperature and improved desulfurization efficiency without the need for additional chemicals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional catalysts are used for desulfurization, then cost is reduced and ease of manufacture is improved, but sulfur content removal efficiency deteriorates and cannot achieve below 10 ppm
Solution Approach 1:
The catalyst is pre-modified with sulfone or sulfoxide compounds derived from benzothiophene before use. This preliminary modification enables the catalyst to achieve ultra-low sulfur content (<10 ppm) from the first regeneration without requiring complex post-preparation steps or additional chemical treatments during operation.
Solution Approach 2:
The invention changes the chemical state of the catalyst by introducing sulfone or sulfoxide functional groups derived from benzothiophene compounds. This parameter change in the catalyst's chemical composition dramatically improves its desulfurization activity, enabling it to achieve <10 ppm sulfur content while maintaining conventional catalyst simplicity and ease of manufacture.
2Duration of action of stationary object
If conventional catalysts are regenerated, then catalyst lifespan is extended, but activity deteriorates significantly compared to fresh state
Solution Approach 1:
The catalyst undergoes preliminary modification with sulfone or sulfoxide compounds before the first use. This pre-modification ensures that even after regeneration, the catalyst maintains high desulfurization activity comparable to or exceeding its fresh state performance, eliminating the typical activity loss after regeneration.
Solution Approach 2:
Instead of requiring expensive additional rejuvenation treatments or replacing catalysts after regeneration, the invention creates a catalyst that maintains its effectiveness through conventional regeneration cycles. The sulfone/sulfoxide modification makes the catalyst effectively 'renewable' without loss of performance, extending its operational life economically.
3Quantity of substance
If novel catalysts are developed to achieve <10 ppm sulfur, then desulfurization efficiency is improved, but cost increases and accessibility deteriorates
Solution Approach 1:
The invention modifies conventional, widely-available catalysts by introducing sulfone or sulfoxide functional groups. This parameter change transforms ordinary catalysts into ultra-effective desulfurization catalysts capable of achieving <10 ppm sulfur. The approach maintains accessibility because it starts with conventional catalysts that are already widely manufactured and available, rather than requiring entirely novel catalyst systems.
Solution Approach 2:
The invention creates a modified version of conventional catalysts that replicates and exceeds the performance of expensive proprietary catalysts. By copying the basic conventional catalyst structure and adding the sulfone/sulfoxide modification, the invention achieves comparable or superior performance to expensive novel catalysts while maintaining ease of manufacture and broad accessibility.
4Productivity
If additional specific rejuvenation treatment is applied to regenerated catalysts, then initial activity is recovered, but process complexity and cost increase
Solution Approach 1:
The catalyst is pre-modified with sulfone or sulfoxide compounds before first use and before any regeneration cycles. This preliminary action ensures that the catalyst maintains high activity through conventional regeneration without requiring additional rejuvenation treatments. The modification is stable enough to survive regeneration but active enough to ensure continuous high performance, eliminating the need for complex rejuvenation steps.
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 achieves sulfur contents below 10 ppm with enhanced activity and cost-effectiveness, suitable for use in refineries, and can be prepared from existing regenerated catalysts, maintaining performance comparable to or exceeding that of commercial catalysts.
Implementation Method 1
sulfone or sulfoxide compounds derived from benzothiophene compounds, which are formed through oxidation by peroxides or hydroperoxides
Data Source
AI summary
The invention relates to a process for hydrotreatment of a hydrocarbon feedstock, comprising the step of carrying out in situ or ex situ sulfurization of a catalyst and hydrotreating the hydrocarbon feedstock in the presence of the catalyst wherein at least one sulfur compound may be present in the feedstock; and a process for the purification of a hydrocarbon feedstock, comprising hydrotreating the hydrocarbon feedstock in the presence of a catalyst after sulfurization of the catalyst and oxidizing desulfurization of the hydrotreated feedstock; wherein the catalyst comprises a refractory oxide support, at least one metal of the Group VIII and at least one metal of the Group VI, both in an oxidized form, and at least one sulphone or sulphoxide compound derived from a benzothiophene compound.