Mixed Transition Metal Oxide Catalyst via Quaternary Ammonium Co-precipitation
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Solution Overview
Problem
Current hydroprocessing catalysts face challenges in meeting stringent fuel sulfur and nitrogen limitations without increasing reactor severity or reducing production rates, and there is a need for catalysts with higher intrinsic activity per mass and a manufacturing-friendly synthesis method that does not require ammonia, stirring, or pH adjustment.
Innovation Solution
A method for producing a mixed transition metal oxide material by co-precipitating sources of specific metals in a quaternary ammonium hydroxide solution, followed by sulfidation to generate metal sulfides, which can be used as catalysts in hydrocarbon conversion processes, eliminating the need for ammonia and pH adjustment and allowing for higher activity per mass without increasing reactor severity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional supported NiMo or CoMo hydrotreating catalysts are used, then the catalyst structure is stable and easy to manufacture, but the intrinsic activity per mass is insufficient to meet stringent fuel sulfur and nitrogen limitations without increasing reactor severity
Solution Approach 1:
The patent changes the chemical parameters of the catalyst by using quaternary ammonium hydroxide instead of conventional ammonia, and by controlling the metal-to-ligand ratio in the co-precipitation process. This creates a unique catalyst structure with higher intrinsic activity per mass while maintaining manufacturing simplicity through a single-step co-precipitation method
Solution Approach 2:
The patent creates a composite catalyst material containing multiple metals (Ni, Mo, W, and other transition metals) co-precipitated with quaternary ammonium hydroxide. This composite structure provides synergistic effects that enhance catalytic activity while the co-precipitation method ensures uniform distribution and simplifies manufacturing
2Productivity
If reactor temperature is increased to meet fuel specifications, then the catalytic activity increases, but the catalyst lifetime is shortened
Solution Approach 1:
The patent changes the intrinsic activity parameter of the catalyst through unique metal composition ratios and the use of quaternary ammonium hydroxide, enabling the catalyst to achieve higher activity at lower temperatures, thus extending catalyst lifetime while maintaining productivity
3Reliability
If space velocity is decreased to meet fuel specifications, then the conversion efficiency increases, but the production rate is reduced and reactor overhaul is required
Solution Approach 1:
The patent changes the catalytic performance parameters through unique metal combinations and quaternary ammonium hydroxide treatment, enabling high conversion efficiency at normal space velocities, thus maintaining both efficiency and production rate without requiring reactor overhaul
4Reliability
If unsupported hydrotreating catalysts with high metal content are used, then the catalytic activity is significantly increased, but the catalyst cost increases
Solution Approach 1:
The patent optimizes the metal content parameter by using specific metal-to-ligand ratios in the co-precipitation process and selecting appropriate transition metals, achieving high intrinsic activity per mass with reduced overall metal content, thus lowering catalyst cost while maintaining activity
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 method provides a highly active hydroprocessing catalyst with improved intrinsic activity per mass, enabling effective sulfur and nitrogen removal in fuels while maintaining production rates and simplifying the manufacturing process.
Implementation Method 1
adding sources of MII, MIII, MIV, and Mi, to a quaternary ammonium hydroxide such as tetramethyl ammonium hydroxide to form a slurry; reacting the slurry at a temperature from 25°C to 200°C for a period of time from 30 minutes to 200 hours to generate the mixed transition metal oxide material
Data Source
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AI summary
A method of making highly an active mixed transition metal oxide material has been developed. The method may include sulfiding the metal oxide material to generate metal sulfides which are used as catalyst in a conversion process such as hydroprocessing. The hydroprocessing may include hydrodenitrification, hydrodesulfurization, hydrodemetallation, hydrodesilication, hydrodearomatization, hydroisomerization, hydrotreating, hydrofining, and hydrocracking.