Oxidized Disulfide Oil Peptization Agent for Solid Catalyst
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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 sulfur content and unpleasant smell, and to modify their properties for environmentally acceptable disposal.
Innovation Solution
The use of oxidized disulfide oil (ODSO) compounds as a peptization agent in the manufacture of solid catalyst particles and support particles, replacing conventional acids, to facilitate the formation of catalysts with similar crush strength and properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional acids (hydrochloric acid, sulfuric acid, nitric acid or acetic acid) are used as peptization agents, then particles can be deagglomerated effectively, but the process becomes costly and generates harmful waste
Solution Approach 1:
The patent converts harmful DSO by-products (foul-smelling sulfur-containing compounds requiring disposal) into beneficial peptization agents. The DSO compounds, which were previously waste streams needing treatment, now serve as effective peptizing agents that deagglomerate catalyst particles without the harmful effects of conventional acids, thereby eliminating acid waste while maintaining peptization effectiveness
Solution Approach 2:
The invention changes the chemical parameters of the peptization agent from strong mineral acids to organic sulfur compounds (DSO). This parameter change maintains the peptization function (particle deagglomeration) while eliminating the harmful characteristics of acid waste, thus resolving the contradiction between manufacturing effectiveness and harmful factor generation
2Object-generated harmful factors
If DSO by-products are disposed of through traditional methods (adding to fuel oil pool or processing in hydrotreating unit), then disposal is achieved, but the process incurs higher costs and environmental concerns
Solution Approach 1:
Instead of treating DSO as harmful waste requiring costly disposal, the patent converts it into a useful peptization agent. This eliminates disposal costs entirely and even provides economic benefit by replacing expensive conventional acids with a free or low-cost by-product from the refinery's own processes
Solution Approach 2:
The refinery uses its own DSO by-products to manufacture catalysts, creating a self-service system where waste from one process becomes the raw material for another. This eliminates the need for external disposal services and reduces overall manufacturing costs
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
ODSO compounds effectively peptize catalyst components, enabling the formation of solid catalyst particles and support particles with comparable strength and properties to those made with traditional peptization agents, while providing a valuable industrial application for refinery waste, reducing raw material costs and environmental concerns.
Implementation Method 1
a peptization agent used to peptize a mixture of solid catalyst components in manufacture of solid catalyst particles and/or solid catalyst support particles
Data Source
AI summary
Methods of solid catalyst manufacture using a peptization agent, a peptization agent, and formed solid catalyst materials are provided. The peptization agent includes one or more oxidized disulfide oil (“ODSO”) compounds. These ODSO compounds peptization agents are used to replace conventional acids used as peptization agents.