ODSO Peptization for Stronger Solid Catalyst Particles

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Solution Overview

Problem

There is a need for an efficient and economical process to treat large volumes of disulfide oil (DSO) by-products from the mercaptan oxidation process in refineries, which are difficult to handle due to their foul smell and high sulfur content, and to modify their properties for environmentally acceptable disposal and utilization.

Innovation Solution

A peptization agent comprising oxidized disulfide oil (ODSO) compounds is used to manufacture solid catalyst particles and support particles, replacing conventional acids, resulting in improved adhesion and increased crush strength of the final catalyst particles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional acids (hydrochloric acid, sulfuric acid, nitric acid or acetic acid) are used as peptization agents to deagglomerate particles, then the particles can be effectively deagglomerated, but the process becomes economically less viable and environmentally less acceptable due to the need to treat large volumes of sulfur-containing by-products

Engineering Contradiction:

Improveeconomic viability of DSO disposalVSAvoidfoul smell and high sulfur content of DSO

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent converts the harmful DSO by-product into a beneficial peptization agent through oxidation. The DSO is oxidized to form ODSO compounds (sulfoxides, sulfonates, sulfinates, sulfones) which serve as effective peptization agents in catalyst manufacturing, thereby eliminating the need to dispose of DSO as waste while gaining a functional chemical reagent

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent changes the chemical state of DSO from reduced disulfide compounds to oxidized forms (ODSO). This parameter change in oxidation state transforms DSO from a foul-smelling waste product into a water-soluble or water-dispersible peptization agent with improved handling properties and environmental acceptability

Inventive Principle:

Principle #35Parameter changes

2Strength

If ODSO compounds are used as peptization agents, then the adhesion and crush strength of catalyst particles are improved, but the process requires an additional oxidation step to convert DSO to ODSO

Engineering Contradiction:

Improvecrush strength of catalyst particlesVSAvoidprocess complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent employs self-service by using the refinery's own DSO by-product as the raw material for producing the peptization agent. The oxidation process converts the waste DSO into the active ODSO compounds needed for catalyst manufacturing, making the system self-sufficient and eliminating external chemical purchases

Inventive Principle:

Principle #25Self-service

3Ease of manufacture

If DSO is disposed of by adding to fuel oil pool, then the disposal is simple, but the sulfur content of the fuel pool increases which is not environmentally acceptable

Engineering Contradiction:

Improvesimplicity of DSO disposalVSAvoidsulfur content increase in fuel pool

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

Instead of disposing of DSO by adding it to fuel oil (which increases sulfur content), the patent converts DSO into a valuable peptization agent through oxidation. This transforms a harmful waste stream into a beneficial chemical reagent that improves catalyst particle strength while avoiding environmental pollution

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 use of ODSO as a peptization agent enhances the mechanical properties of catalyst particles, particularly their crush strength, while providing an economically viable solution for DSO disposal and utilization.

Implementation Method 1

a peptization agent used to peptize an inorganic oxide material as a binder component in the manufacture of solid catalyst particles and/or solid catalyst support particles

Methodology Applied

Scientific EffectPeptization:

Data Source

PatentUS12491505B2Composition including peptization agent

Publication Date: 2025.12.09 SAUDI ARABIAN OIL CO

AI summary

A composition is provided for use in solid catalyst manufacture including an inorganic oxide and a peptization agent, for forming solid catalyst materials having improved structural properties are provided. The peptization agent includes one or more oxidized disulfide oil (“ODSO”) compounds. These ODSO compounds as peptization agents serve to improve the adhesion characteristics of the binder material, and as a result increase the particle strength of the final catalyst particles.