Nickel Tungsten Bulk Catalyst for Hydrodesulfurization
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Solution Overview
Problem
Conventional bulk bimetallic hydroprocessing catalysts are less effective compared to trimetallic catalysts in removing sulfur and nitrogen from hydrocarbon feeds, necessitating the development of more efficient bulk bimetallic catalysts that can match the performance of trimetallic catalysts.
Innovation Solution
A bulk catalyst comprising nickel tungsten metal oxidic particles is prepared by forming a slurry of nickel and tungsten compounds in a protic liquid, reacting them at elevated temperatures while maintaining the compounds in a solid state, and optionally incorporating binder materials or thermal treatment to enhance catalytic activity, resulting in a non-amorphous catalyst with improved hydrodesulfurization and hydrodenitrogenation capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional bulk bimetallic catalysts are used, then the catalyst structure is simpler and production is easier, but the hydrodesulfurization and hydrodenitrogenation activity is lower compared to trimetallic catalysts
Solution Approach 1:
The patent changes the physical and chemical parameters of the bimetallic catalyst by controlling the oxidation states of metals (using mixed valence states like Ni2+/Ni3+ and Mo5+/Mo6+), adjusting the metal ratio (e.g., Ni:Mo = 1:1 to 1:2), and controlling particle size distribution. These parameter changes enable the bimetallic catalyst to achieve activity levels comparable to trimetallic catalysts while maintaining manufacturing simplicity.
Solution Approach 2:
The patent creates a composite catalyst structure by combining nickel and molybdenum oxides in specific ratios and oxidation states, forming a synergistic bimetallic system. The composite nature of the catalyst, with mixed metal oxides in controlled particle sizes, provides enhanced catalytic activity for hydrodesulfurization and hydrodenitrogenation reactions.
2Productivity
If trimetallic catalysts are used, then the hydroprocessing performance is higher, but the device complexity and production difficulty increase
Solution Approach 1:
The patent extracts one metal component from the trimetallic system to create an optimized bimetallic catalyst. By removing one metal and carefully adjusting the ratios and oxidation states of the remaining two metals (Ni and Mo), the catalyst achieves comparable performance with reduced complexity in composition and manufacturing.
Solution Approach 2:
Instead of adding more metals to improve performance (the conventional trimetallic approach), the patent inverts the strategy by using fewer metals (bimetallic) but optimizing their properties through controlled oxidation states and particle size distribution, achieving high performance with simpler composition.
3Ease of repair
If bulk bimetallic catalysts are used, then metal recycling is easier, but the catalytic activity is inferior to bulk trimetallic catalysts
Solution Approach 1:
The patent optimizes the particle size distribution and oxidation state parameters of the bimetallic catalyst to enhance catalytic activity. By controlling these parameters, the catalyst achieves activity levels comparable to trimetallic catalysts while maintaining the bulk structure that facilitates easier metal recycling and recovery.
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 nickel tungsten bulk catalyst achieves high hydrodesulfurization and hydrodenitrogenation activity, reaching very low residual sulfur and nitrogen levels in hydrocarbon products, comparable to or exceeding the performance of trimetallic catalysts, with the added advantage of simpler production and easier metal recycling.
Implementation Method 1
reacting them at elevated temperatures while maintaining the compounds in a solid state
Implementation Method 2
The nickel tungsten bulk catalyst achieves high hydrodesulfurization and hydrodenitrogenation activity
Data Source
AI summary
The invention relates to a process for upgrading hydrocarbonaceous feedstreams by hydroprocessing using bulk bimetallic catalysts. More particularly, the invention relates to a catalytic hydrotreating process for the removal of sulfur and nitrogen from a hydrocarbon feed such as a fuel or a lubricating oil feed. The catalyst is a bulk catalyst comprising a Group VIII metal and a Group VIB metal.