Polymer-Modified Supported Hydrotreating Catalysts Against Metal Aggregation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydroprocessing catalysts face challenges with low intrinsic activity due to strong metal-support interactions in calcined catalysts and metal aggregation in non-calcined catalysts, leading to reduced effectiveness in hydrotreating, hydrodesulfurization, and hydrodenitrogenation processes.
Innovation Solution
The development of supported catalysts using concentrated solutions of Group VI and Group VIII metals, modified with polymers, which enhance metal dispersion and reduce metal-support interaction, eliminating phosphorus as an additive, and utilizing peroxomolybdocobaltate compounds to improve catalyst activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If calcination is performed to strengthen metal-support interaction and improve metal dispersion, then metal dispersion is improved, but intrinsic catalyst activity decreases
Solution Approach 1:
The invention changes the chemical composition parameters by incorporating polymers with specific functional groups (carboxyl, hydroxyl, amino, etc.) that modify the metal-support interaction strength. This allows the catalyst to maintain good metal dispersion without requiring strong calcination treatment, thereby preserving intrinsic catalyst activity.
Solution Approach 2:
The invention creates a composite catalyst system combining metal particles, support material, and polymer additives. The polymer component acts as a mediator that optimizes both metal dispersion and catalytic activity, resolving the contradiction between these two properties through material composition design.
2Reliability
If non-calcination is used to maintain high intrinsic activity, then intrinsic catalyst activity is improved, but metal aggregation occurs reducing metal dispersion
Solution Approach 1:
The polymer acts as an intermediary substance that facilitates metal dispersion without requiring calcination. The functional groups on the polymer chains interact with metal particles to prevent aggregation, enabling good dispersion to be achieved while maintaining the non-calcined state and high intrinsic activity.
Solution Approach 2:
The invention modifies the chemical environment parameters by introducing polymers with specific functional groups that change how metals interact with the support. This allows dispersion improvement through chemical modification rather than thermal treatment, preserving catalyst activity.
3Stability of the object's composition
If phosphorus is added as an impregnated additive to improve catalyst performance, then catalyst stability is improved, but catalyst activity decreases due to phosphorus impurity effects
Solution Approach 1:
The invention removes phosphorus from the catalyst composition entirely, replacing it with polymer additives that provide stability without the harmful impurity effects. This extraction of the problematic element allows activity improvement while maintaining stability through alternative mechanisms.
Solution Approach 2:
The invention replaces long-term stable but harmful phosphorus additives with polymers that provide equivalent stability functions without the negative side effects. The polymer additives achieve catalyst stabilization through different chemical mechanisms that do not involve phosphorus-related activity reduction.
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 polymer-modified catalysts exhibit enhanced activity in hydrotreating, hydrodesulfurization, and hydrodenitrogenation, with increased metal dispersion and stability, suitable for applications like hydrocarbon cracking pretreatment and ultra-low sulfur diesel production.
Implementation Method 1
Chelating polymers can be synthesized in the pore structure of a carrier material (e.g. an inorganic oxide) in the presence of metals (e.g. Co, Ni, Mo). The presence of these chelating polymers enhances the activity of hydroprocessing catalysts
Implementation Method 2
A variety of catalysts for hydrotreating, hydrodesulfurization, and/or hydrodenitrogenation are known and/or are commercially available. Many of these catalysts, some of which contain molybdenum, nickel or cobalt, and phosphorus, are supported on carriers
Data Source
AI summary
This invention provides supported catalysts comprising a carrier, at least one Group VI metal, at least one Group VIII metal, and a polymer. In the supported catalyst, 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.