Multi-Metallic Catalyst Precursor for Hydroprocessing Fouling
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Solution Overview
Problem
Current hydroprocessing catalysts face challenges with fouling, require toxic chelating agents, and are not suitable for low-pressure hydroconversion processes, necessitating the development of catalysts with improved fouling resistance and environmentally friendly chelating agents for efficient hydrodesulfurization, hydrodearomatization, and hydrodenitrogenation of heavy hydrocarbon feedstocks.
Innovation Solution
A charge-neutral catalyst precursor composition of the formula A v [(M P< )(OH) x (L) n< y ] z (M VIB< O 4 ) is developed, where A comprises monovalent cations, M P< includes Group VIII, IIB, or IVA metals, and M VIB< is a Group VIB metal, with a specific atomic ratio and oxygen-containing organic ligands, which upon sulfidation, exhibits enhanced hydrodenitrogenation, hydrodearomatization, and hydrodesulphurization activity, and is synthesized using non-toxic, biodegradable ligands like maleic acid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydroprocessing catalysts are used, then hydrodesulfurization, hydrodearomatization, and hydrodenitrogenation activity is achieved, but fouling occurs and product quality deteriorates over time
Solution Approach 1:
The patent modifies the catalyst composition by introducing specific metal combinations (Group VIII metals with Group VIB metals) and controlling their atomic ratios to optimize both activity and fouling resistance. The catalyst precursor composition includes specific ratios of metals and ligands that create a catalyst with improved stability against fouling while maintaining high hydroprocessing activity.
Solution Approach 2:
The patent employs composite catalyst materials combining multiple metal components (Group VIII metals such as Fe, Co, Ni with Group VIB metals such as Mo, W) and supporting ligands to create a synergistic effect that simultaneously provides high catalytic activity and resistance to fouling, resolving the contradiction between productivity and reliability.
2Ease of manufacture
If toxic chelating agents are used in catalyst synthesis, then catalyst formation is achieved, but environmental harm increases
Solution Approach 1:
The patent replaces expensive and toxic chelating agents with cheaper, non-toxic organic ligands that can be easily removed or degraded. The new ligands fulfill the necessary function of forming the catalyst precursor but without the harmful environmental effects, aligning with the principle of using disposable or easily disposed materials that complete their function and can be discarded or degraded without harm.
Solution Approach 2:
The patent converts the potentially harmful toxic chelating agents into beneficial non-toxic ligands that serve the same catalytic formation function but with improved environmental profile. The harmful aspect (toxicity) is eliminated while maintaining the essential manufacturing function, effectively converting a harmful element into a beneficial one.
3Productivity
If high hydrogen pressure is used in hydroconversion, then catalytic activity is maintained, but process cost increases
Solution Approach 1:
The patent optimizes the catalyst composition parameters (metal ratios, ligand types) to enhance the catalyst's intrinsic activity, allowing the hydroconversion process to proceed at lower hydrogen pressures while maintaining high productivity. This parameter optimization enables reduced energy input without sacrificing catalytic performance.
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 precursor composition demonstrates improved catalytic activity and fouling resistance, maintaining product quality and nitrogen concentration at lower hydrogen pressures, and is more environmentally friendly due to the use of non-toxic ligands, effectively addressing the limitations of existing catalysts in hydroprocessing.
Implementation Method 1
upon sulfidation, exhibits enhanced hydrodenitrogenation, hydrodearomatization, and hydrodesulphurization activity
Implementation Method 2
hydrotreating processes, i.e., treating with hydrogen of various hydrocarbon fractions, or whole heavy feeds, or feedstocks, in the presence of hydrotreating catalysts to effect conversion of at least a portion of the feeds to lower molecular weight hydrocarbons
Data Source
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AI summary
A catalyst precursor composition and methods for making such a catalyst precursor are disclosed. The catalyst precursor comprises at least a promoter metal selected from Group VIII, Group IIB, Group IIA, Group IVA and combinations thereof having an oxidation state of +2 or +4, at least one Group VIB metal having an oxidation state of +6, and at least one organic oxygen-containing ligand. Catalysts prepared from the sulfidation of such catalyst precursors are used in the hydroprocessing of hydrocarbon feeds.