Polymer-Modified Hydrotreating Catalysts for Metal Dispersion
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Solution Overview
Problem
Current hydroprocessing catalysts face challenges with low intrinsic activity due to strong metal-support interactions, leading to metal aggregation and reduced dispersion, which affects their performance in hydrotreating, hydrodesulfurization, and hydrodenitrogenation processes.
Innovation Solution
The development of supported catalysts using concentrated solutions comprising Group VI metals, Group VIII metals, and phosphorus, with the incorporation of chelating polymers that enhance metal dispersion and activity, specifically through the synthesis of polymers within the pore structure of a carrier material, optimizing the molar ratios and using specific metal compounds and solvents to improve catalyst performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If calcination is performed to create strong metal-support interaction, then metal dispersion is improved, but intrinsic catalyst activity decreases
Solution Approach 1:
The patent applies preliminary action by incorporating the polymer into the catalyst structure before the metals are deposited. The polymer is synthesized within the pore structure of the carrier material first, creating a pre-formed network that will subsequently hold the metal particles in a dispersed state without requiring calcination, thus preserving intrinsic metal activity while maintaining dispersion.
Solution Approach 2:
The polymer acts as an intermediary between the metal particles and the support carrier. It provides a binding matrix that holds metal particles in a dispersed state without creating strong metal-support interactions through calcination. This intermediary layer allows the metals to maintain their intrinsic activity while still achieving good dispersion through the polymer network.
2Productivity
If polymer modification is applied to enhance metal dispersion, then catalyst activity increases, but device complexity increases
Solution Approach 1:
The patent utilizes the porous structure of the carrier material and fills it with polymer during the impregnation process. The polymer conformally coats the internal surfaces of the pores, creating a dispersed metal distribution throughout the pore network. This approach enhances catalyst activity through improved metal dispersion while avoiding excessive structural complexity by using the existing porous framework.
Solution Approach 2:
The patent changes the physical and chemical parameters of the catalyst preparation process by using concentrated impregnation solutions and controlling polymerization conditions. By adjusting parameters such as solution concentration, polymerization temperature, and metal precursor selection, the patent achieves enhanced metal dispersion and catalyst activity without significantly complicating the overall catalyst structure.
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 resulting catalysts exhibit high activity in hydrodesulfurization and hydrodenitrogenation, with improved metal dispersion and stability, making them 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
It has been suggested that in the catalysts of the invention, which are polymer-modified, 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 supported 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 an amido group. Also provided are a process for preparing such supported catalysts, as well as methods for hydrotreating, hydrodenitrogenation, and/or hydrodesulfurization, using supported catalysts.