Multimetallic 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 to manage crude oils with higher sulfur and nitrogen concentrations.
Innovation Solution
A novel mixed transition metal oxide material with a specific X-ray diffraction pattern and composition is developed, which can be sulfided to yield an active hydroprocessing catalyst, characterized by a broad peak between 2θ of 55° and 58° with sharp peaks between 5° and 32°, prepared through co-precipitation using a protic solvent and short-chain alkyl quaternary ammonium halide compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional supported NiMo or CoMo hydrotreating catalysts are used, then catalyst cost is controlled, but intrinsic activity per mass is insufficient to meet stringent fuel sulfur and nitrogen limitations
Solution Approach 1:
The patent employs composite materials by combining multiple metal components (Ni, Mo, W, and other transition metals) to create a multi-metallic catalyst system. This composite approach leverages synergistic effects between different metals to achieve high intrinsic activity per mass, resolving the contradiction between maintaining controlled metal loading and achieving sufficient catalytic performance for stringent fuel specifications.
Solution Approach 2:
The patent applies parameter changes by optimizing the atomic ratios and compositions of multiple metal components in the catalyst. By adjusting these compositional parameters and controlling the synthesis conditions (pH, temperature, precursors), the catalyst achieves enhanced intrinsic activity per mass without proportionally increasing total metal loading, thereby meeting stringent fuel sulfur and nitrogen limitations efficiently.
2Reliability
If unsupported hydrotreating catalysts with high metal content are used to achieve high activity, then intrinsic activity per mass is improved, but catalyst cost increases significantly
Solution Approach 1:
The patent optimizes compositional parameters by precisely controlling the ratios of multiple metal components and their oxidation states. This parameter optimization enables the catalyst to achieve high intrinsic activity per mass at reduced metal loadings, directly addressing the cost issue while maintaining superior catalytic performance for hydroprocessing applications.
Solution Approach 2:
The patent applies local quality by creating heterogeneous metal distributions and varying local compositions within the catalyst structure. Different regions of the catalyst possess optimized metal ratios and phases tailored for specific catalytic functions, maximizing intrinsic activity per mass locally while minimizing overall metal content and cost.
3Productivity
If reactor temperature is increased to meet fuel sulfur and nitrogen limitations, then conversion efficiency is improved, but catalyst lifetime is shortened
Solution Approach 1:
The patent changes the catalytic activity parameter by incorporating multiple transition metals with complementary electronic and geometric properties. This parameter change in catalyst composition enables high conversion efficiency at lower operating temperatures, thereby preserving catalyst lifetime while meeting stringent fuel specifications.
Solution Approach 2:
The multi-metallic composite catalyst provides synergistic effects that enhance activity at lower temperatures. The combination of metals with different properties (e.g., Ni for hydrogenation, Mo and W for hydrodesulfurization) creates a catalyst that achieves high conversion efficiency without the thermal stress that would otherwise shorten catalyst lifetime.
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 material achieves the same or better intrinsic activity as previous catalysts without sharp peaks, indicating the presence of structures with long-range order, while maintaining amorphous or nanoparticle phases, thus requiring less metal loading and reducing costs.
Implementation Method 1
A method of making a mixed transition metal oxide material... prepared through co-precipitation using a protic solvent and short-chain alkyl quaternary ammonium halide compounds
Implementation Method 2
which can be sulfided to yield an active hydroprocessing catalyst
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.