Hydrotreating Catalysts with Polymer Modifier
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Solution Overview
Problem
Existing hydroprocessing catalysts face challenges in achieving high activity for hydrotreating, hydrodesulfurization, and hydrodenitrogenation due to strong metal-support interactions, which lead to lower intrinsic activity and metal aggregation.
Innovation Solution
The development of supported catalysts comprising Group VI metals, Group VIII metals, and phosphorus, with a polymer modifier, where the molar ratios of phosphorus to Group VI metal and Group VIII metal are optimized, and the polymer has a carbon backbone with functional groups containing heteroatoms, enhancing metal dispersion and catalyst activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If calcination is used to prepare catalysts, then metal dispersion is improved, but intrinsic activity decreases
Solution Approach 1:
The patent extracts the harmful effect of strong metal-support interaction by removing the calcination step. The catalyst is prepared by impregnation followed by drying only, avoiding the high-temperature treatment that creates strong metal-support bonds. This extraction of the calcination process eliminates the cause of reduced intrinsic activity while preserving metal dispersion through alternative means.
Solution Approach 2:
The patent changes the preparation parameters by controlling the drying temperature and atmosphere to achieve optimal metal dispersion without calcination. The drying is performed at temperatures below those required for calcination, and the impregnation solution composition is optimized to ensure proper metal distribution on the support, thereby achieving good dispersion without the harmful strong metal-support interaction.
2Reliability
If no calcination is used, then intrinsic activity is maintained, but metal aggregation occurs
Solution Approach 1:
The patent applies preliminary action by optimizing the impregnation step to ensure uniform metal distribution on the support before drying. The impregnation solution is carefully formulated with appropriate concentrations and pH levels to promote even metal deposition. By establishing good metal distribution in advance, the catalyst maintains both high intrinsic activity and good metal dispersion without requiring calcination.
Solution Approach 2:
The patent changes the drying parameters (temperature, time, atmosphere) to prevent metal aggregation while avoiding calcination. The drying conditions are optimized to remove solvent without causing metal particles to aggregate, thereby maintaining good metal dispersion. Additionally, the impregnation solution composition is adjusted to control metal precipitation and distribution during the drying process.
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 catalysts exhibit high activity in hydrodesulfurization and hydrodenitrification with improved metal dispersion and stability, reducing metal aggregation and maintaining activity over time.
Implementation Method 1
the hydrogenation metals are more dispersed than in similar catalysts in absence of polymer modification
Data Source
AI summary
This invention provides supported catalysts comprising a carrier, phosphorus, at least one Group VI metal, at least one Group VIII metal, and a polymer. In the catalyst, the molar ratio of phosphorus to Group VI metal is about 1:1.5 to less than about 1:12, the molar ratio of the Group VI metal to the Group VIII metal is about 1:1 to about 5:1, and the polymer has a carbon backbone and comprises functional groups having at least one heteroatom. Also provided are a process for preparing such supported catalysts, as well as methods for hydrotreating, hydrodenitrogenation, and/or hydrodesulfurization, using supported catalysts.