Integrated Hydrotreating Catalyst for Sulfur and Mercury Removal
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Solution Overview
Problem
Conventional methods for removing sulfur and mercury from hydrocarbon materials require additional processes, increasing costs and complexity, and existing catalysts are sensitive to both elements, necessitating separate treatments.
Innovation Solution
A hydrotreating process using a catalyst with supported metals like cobalt, molybdenum, nickel, or tungsten converts sulfur and mercury into hydrogen sulfide and mercury sulfide, which are then adsorbed on the catalyst's active sites, allowing simultaneous removal in a single step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate processes are used to remove sulfur and mercury from hydrocarbon materials, then each element can be effectively removed, but the process complexity and cost increase
Solution Approach 1:
The patent combines sulfur removal and mercury removal into a single integrated hydrotreating process using one catalyst bed. The catalyst contains metal active sites (Co, Ni, Mo, or W) that simultaneously catalyze both sulfur conversion to H2S and mercury conversion to HgS, which is then adsorbed on the catalyst surface. This eliminates the need for separate removal processes while maintaining effectiveness for both contaminants.
Solution Approach 2:
The catalyst is designed with multi-functionality to perform both sulfur removal and mercury removal functions. The metal active sites serve dual purposes: converting sulfur to hydrogen sulfide and converting mercury to mercury sulfide for adsorption. This universal catalyst replaces what would traditionally require two separate processing systems.
2Reliability
If additional mercury removal processes are added, then mercury can be removed from hydrocarbon materials, but installation and operation costs increase
Solution Approach 1:
The patent merges mercury removal with the existing sulfur removal hydrotreating process. By incorporating mercury-active metal sites into the catalyst formulation, the same reactor and processing conditions used for sulfur removal also achieve mercury removal, eliminating the need for additional equipment and operational steps.
Solution Approach 2:
The catalyst performs self-service by simultaneously removing both sulfur and mercury during the hydrotreating process. The metal active sites on the catalyst surface automatically convert and adsorb mercury compounds along with sulfur compounds, without requiring external mercury-specific treatment systems or additional operational interventions.
3Adaptability or versatility
If reforming catalysts are used with high sulfur content feed, then processing flexibility is maintained, but catalyst performance deteriorates due to sulfur poisoning
Solution Approach 1:
The patent applies preliminary action by removing sulfur from the hydrocarbon feed before it enters the reforming process. The hydrotreating catalyst converts sulfur to H2S, which is then separated, ensuring that the subsequent reforming catalyst is not exposed to sulfur that would cause poisoning. This preliminary sulfur removal protects downstream catalyst performance.
Solution Approach 2:
The hydrotreating catalyst acts as an intermediary between the crude feed and the reforming catalyst. It performs the function of sulfur removal and protection, allowing the reforming catalyst to operate with high flexibility on various feeds without suffering from sulfur poisoning. The intermediary catalyst handles the sulfur burden before it reaches the sensitive reforming catalyst.
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
This method effectively and economically removes sulfur and mercury without additional processes, maintaining catalyst efficiency by adsorbing mercury sulfide on the catalyst, even with low mercury concentrations.
Implementation Method 1
the sulfur and the mercury in the hydrocarbon material, respectively, are converted into hydrogen sulfide and metal mercury
Implementation Method 2
the converted metal mercury reacts with the metal active sites in the catalyst or the converted hydrogen sulfide to form mercury sulfide
Implementation Method 3
the formed mercury sulfide is adsorbed on the metal active sites of the catalyst or the carrier of the catalyst
Data Source
AI summary
Disclosed herein is a method of simultaneously removing sulfur and mercury from a hydrocarbon material, including: hydrotreating the hydrocarbon material containing sulfur and mercury in the presence of a catalyst including a metal supported with a carrier to convert sulfur into hydrogen sulfide, and adsorb mercury on a metal active site or a carrier of the catalyst in the form of mercury sulfide.