Mixed Metal Oxide Catalyst for Ultra-Deep Desulfurization
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Solution Overview
Problem
Current hydroprocessing catalysts face challenges in achieving deep desulfurization and denitrification, particularly with the increasing use of sour crudes and stringent environmental regulations, as they struggle to reduce sulfur and nitrogen compounds to ultra-low levels efficiently.
Innovation Solution
A unique mixed metal oxide catalyst with the formula MMoxWyOz, where 'M' is selected from metals like Mg, Mn, Fe, Co, Ni, Cu, Zn, and their mixtures, is synthesized and optionally sulfided, exhibiting a specific x-ray powder diffraction pattern and prepared through a method involving a crystalline bis-ammonia transition metal molybdotungstate precursor, which is thermally decomposed to enhance hydroprocessing activities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional hydroprocessing catalysts are used, then basic sulfur and nitrogen removal is achieved, but ultra-deep desulfurization and denitrification to ppm levels cannot be attained
Solution Approach 1:
The patent employs a trimetallic composite material comprising nickel, molybdenum, and tungsten in a broadly amorphous mixed metal oxide structure. This composite approach combines the synergistic effects of multiple metals to achieve ultra-deep desulfurization and denitrification activities that exceed the performance of conventional single-metal or bimetallic catalysts, enabling reduction of sulfur and nitrogen to ppm levels.
Solution Approach 2:
The invention utilizes controlled sulfidation treatment to transform the mixed metal oxide precursor into its active sulfided form. This parameter change from oxide to sulfide state activates the catalytic sites, dramatically enhancing the catalyst's ability to perform hydrodesulfurization and hydrodenitrification reactions at ultra-low concentration levels.
2Reliability
If supported catalysts are used, then catalyst stability is improved, but active phase loading in the reactor is limited
Solution Approach 1:
The patent eliminates the traditional support material (such as alumina) from the catalyst system, creating an unsupported bulk mixed metal oxide catalyst. This extraction of the support component removes the limitation on active phase loading, allowing maximum concentration of catalytic materials in the reactor while the inherent structural stability of the mixed metal oxide phase maintains catalyst reliability.
3Productivity
If amorphous mixed metal oxide is used, then catalytic activity is enhanced, but structural definition and characterization are compromised
Solution Approach 1:
The broadly amorphous mixed metal oxide structure comprising nickel, molybdenum, and tungsten provides high catalytic activity due to its disordered structure with abundant defect sites and variable coordination environments. While the amorphous nature complicates traditional crystallographic characterization, advanced techniques such as X-ray absorption spectroscopy and electron microscopy enable structural definition, revealing the composite material's unique properties that drive enhanced hydroprocessing productivity.
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 demonstrates superior performance in hydroprocessing, achieving enhanced sulfur and nitrogen removal, outperforming conventional catalysts by providing a unique x-ray powder diffraction pattern and improved structural chemistry, leading to increased active phase loading and alternative chemistry for ultra-deep desulfurization and denitrification.
Implementation Method 1
A unique mixed metal oxide catalyst with the formula MMoxWyOz... is synthesized and optionally sulfided, exhibiting a specific x-ray powder diffraction pattern and prepared through a method involving a crystalline bis-ammonia transition metal molybdotungstate precursor, which is thermally decomposed to enhance hydroprocessing activities.
Implementation Method 2
A unique mixed metal oxide catalyst with the formula MMoxWyOz... is synthesized and optionally sulfided... leading to increased active phase loading and alternative chemistry for ultra-deep desulfurization and denitrification.
Implementation Method 3
The mixed metal oxide having a unique x-ray powder diffraction pattern showing peaks at the d-spacings listed in Table A
Data Source
AI summary
A unique mixed metal molybdotungstate material has been developed. The material may be used as a hydroprocessing catalyst. The hydroprocessing may include hydrodenitrification, hydrodesulfurization, hydrodemetallation, hydrodearomatization, hydrodesilication, hydroisomerization, hydrotreating, hydrofining, and hydrocracking.