Mixed Transition Metal Oxide Catalyst for Hydroprocessing
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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 to efficiently process crude oils with higher sulfur and nitrogen concentrations.
Innovation Solution
A novel mixed transition metal oxide material with the formula [R1R2R3R4-N]x(NH4)y(MIa)m(MIIb)n(MIIIc)o(MIVd)p(MVe)qOr(OH)s is developed, which can be sulfided to yield an active hydroprocessing catalyst, characterized by specific X-ray diffraction patterns and prepared through co-precipitation with alkyl quaternary ammonium hydroxide compounds, offering improved intrinsic activity per mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If reactor temperature is increased to meet stringent fuel sulfur and nitrogen limitations, then hydroprocessing activity is improved, but catalyst lifetime is shortened
Solution Approach 1:
The invention changes the chemical composition parameters of the catalyst by incorporating specific ratios of Group VIII metals (Ni, Co), Group VIB metals (Mo, W), and Group VB metals (V, Nb, Ta) to optimize catalytic activity at lower operating temperatures, thereby extending catalyst lifetime while maintaining productivity
Solution Approach 2:
The invention uses composite catalyst materials combining multiple metal phases (oxides, sulfides, or carbides) with complementary functions - Group VIII metals provide hydroprocessing activity, Group VIB metals enhance sulfur and nitrogen removal, and Group VB metals improve structural stability, achieving high activity without excessive temperature
2Reliability
If space velocity is decreased to meet fuel specifications, then hydroprocessing efficiency is improved, but production rate is reduced
Solution Approach 1:
The invention optimizes the metal composition ratios and particle size distribution to maximize surface area and active sites per unit volume, enabling high hydroprocessing efficiency at higher space velocities and maintaining production rates
3Productivity
If metal content is increased to achieve high intrinsic activity, then catalyst activity is improved, but catalyst cost is increased
Solution Approach 1:
The invention optimizes the metal content parameters within specific ranges (e.g., Group VIII metals: 1-20 wt%, Group VIB metals: 5-30 wt%, Group VB metals: 1-15 wt%) to achieve high intrinsic activity while minimizing metal loading and catalyst cost
Solution Approach 2:
The invention creates localized high-concentration active sites through controlled metal distribution and phase formation, where small amounts of precious metals are concentrated in highly active regions, maximizing intrinsic activity per mass without uniform increase in overall metal content
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 novel catalyst achieves high activity in hydroprocessing applications such as hydrodenitrification and hydrodesulfurization, maintaining production rates while reducing metal content and catalyst costs, effectively processing crude oils with high sulfur and nitrogen levels.
Implementation Method 1
adding sources of MI, MII, MIII, MIV and MV, and at least one short-chain alkyl quaternary ammonium hydroxide compound... reacting the reaction mixture at a temperature from about 25° C. to about 200° C. for a period of time from about 30 minutes to 200 hours to generate the mixed transition metal oxide material
Implementation Method 2
The material can be sulfided to yield an active hydroprocessing catalyst
Implementation Method 3
characterized by specific X-ray diffraction patterns
Implementation Method 4
The material is further characterized by an x-ray diffraction pattern comprising the peaks in Table A if MV is Al or Table S if MV is Si
Data Source
AI summary
A highly active quaternary mixed transition metal oxide material has been developed. The material may be sulfided to generate metal sulfides which are used as a catalyst in a conversion process such as hydroprocessing. The hydroprocessing may include hydrodenitrification, hydrodesulfurization, hydrodemetallation, hydrodesilication, hydrodearomatization, hydroisomerization, hydrotreating, hydrofining, and hydrocracking.