Magnesium Aluminosilicate Clay Catalyst Synthesis
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Solution Overview
Problem
There is a need for improved magnesium aluminosilicate clays with enhanced characteristics for use as catalysts or components in hydrodemetallization catalysts and processes, particularly for handling heavier feedstocks with increasing heteroatom content, which require more effective removal of metals like vanadium and nickel.
Innovation Solution
A process for synthesizing magnesium aluminosilicate clay by combining silicon, aluminum, and magnesium components under acidic aqueous conditions, followed by pH adjustment with an alkali base and subsequent reaction to form a magnesium aluminosilicate clay, which can be further modified with catalytically active metals and calcination to create a hydrodemetallization catalyst with specific silicon to aluminum ratios and NMR peak profiles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional magnesium aluminosilicate clays are used as catalysts, then catalytic activity is provided, but metal dispersion is insufficient and catalyst deactivation occurs rapidly
Solution Approach 1:
The patent applies parameter changes by precisely controlling the Si/Al ratio (greater than 3) and conducting the synthesis at specific pH conditions (adding alkali base to achieve pH greater than the first reaction mixture). These parameter optimizations improve metal dispersion and catalyst stability, resolving the contradiction between reliability and manufacturing precision.
Solution Approach 2:
The patent creates a composite magnesium aluminosilicate clay catalyst by combining silicon, aluminum, and magnesium components in specific ratios, with Si/Al greater than 3. This composite structure enhances both metal dispersion and catalytic stability, simultaneously addressing the contradiction between reliability and manufacturing precision.
2Productivity
If synthesis conditions are not optimized, then manufacturing is simpler, but catalytic activity and metal removal efficiency are insufficient
Solution Approach 1:
The patent optimizes synthesis parameters including pH control (adding alkali base to the acidic first reaction mixture), temperature, and reaction time. These parameter changes enhance metal removal efficiency while maintaining a manageable synthesis process, resolving the contradiction between productivity and ease of manufacture.
Solution Approach 2:
The patent employs preliminary action by first creating an acidic reaction mixture with silicon, aluminum, and magnesium components, then systematically adding alkali base to adjust pH before the final reaction. This staged approach improves metal removal efficiency while keeping the synthesis process organized and manageable.
3Manufacturing precision
If the silicon to aluminum ratio is not controlled, then synthesis is easier, but catalytic performance and metal dispersion are reduced
Solution Approach 1:
The patent specifies precise parameter control with Si/Al ratio greater than 3 and controlled pH adjustment during synthesis. This parameter optimization achieves improved metal dispersion and catalytic performance while maintaining a systematic synthesis approach, resolving the contradiction between manufacturing precision and device complexity.
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 synthesized magnesium aluminosilicate clay catalysts exhibit improved catalytic activity, increased metal dispersion, and reduced catalyst deactivation, effectively upgrading heavier feedstocks by enhancing the removal of vanadium and nickel, leading to more valuable products such as gasoline, diesel, and lube oil.
Implementation Method 1
hydrodemetallization catalysts and processes employing a magnesium aluminosilicate clay... effectively upgrading heavier feedstocks by enhancing the removal of vanadium and nickel
Implementation Method 2
hydrodemetallization catalysts can comprise various components... magnesium aluminosilicate clays have a negative layer charge which can be balanced by cations... catalytically active metals
Data Source
AI summary
This invention is directed to hydrodemetallization catalysts and hydrodemetallization processes employing a magnesium aluminosilicate clay. The magnesium aluminosilicate clay has a characteristic 29Si NMR spectrum. The magnesium aluminosilicate clay is the product of a series of specific reaction steps. Briefly, the magnesium aluminosilicate clay employed in the catalyst and process of the invention is made by combining a silicon component, an aluminum component, and a magnesium component, under aqueous conditions and at an acidic pH, to form a first reaction mixture and subsequently the pH of the first reaction mixture is adjusted to greater than about 7.5 to form a second reaction mixture. The second reaction mixture is allowed to react under conditions sufficient to form the magnesium aluminosilicate clay. The resulting magnesium aluminosilicate clay combines high surface area and activity for use in hydrodemetallization catalysts and processes.