Crystalline Transition Metal Tungstate Catalyst for Deep Desulfurization
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Solution Overview
Problem
Current hydroprocessing catalysts face challenges in achieving deep desulfurization and denitrification, particularly with the increasing use of sour crudes and stringent environmental regulations, as they struggle to reduce sulfur and nitrogen compounds to ultra-low levels effectively.
Innovation Solution
A unique crystalline transition metal tungstate material with a specific x-ray powder diffraction pattern is developed and optionally sulfided, serving as an active catalyst for hydroprocessing, which includes hydrodenitrification, hydrodesulfurization, and other processes, by forming a reaction mixture of ammonia, water, and metal sources, and reacting them under controlled conditions to produce a material with the formula (NH4)xMWyOz, where 'x' and 'y' vary within specified ranges, and 'z' satisfies the valences of 'x' and 'M', showing unique diffraction peaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional hydroprocessing catalysts are used, then basic sulfur and nitrogen removal is achieved, but ultra-low level desulfurization and denitrification cannot be achieved
Solution Approach 1:
The patent changes the chemical composition parameters by incorporating multiple metal components (Ni, Mo, W, and other transition metals) in specific ratios, and modifies the physical state by creating a controlled amorphous structure. These parameter changes enable the catalyst to achieve ultra-low sulfur and nitrogen removal efficiency while maintaining stable activity, resolving the contradiction between removal efficiency and catalyst stability.
Solution Approach 2:
The patent creates a composite catalyst material combining nickel, molybdenum, tungsten, and other transition metals in a controlled amorphous structure. This composite material synergistically enhances both the sulfur/nitrogen removal efficiency and the catalyst stability, allowing simultaneous achievement of ultra-low level desulfurization/denitrification and reliable catalytic performance.
2Quantity of substance
If supported catalysts are used, then catalyst stability is improved, but active phase loading is limited
Solution Approach 1:
The patent extracts and eliminates the support material from conventional catalyst structures, creating unsupported bulk materials. This extraction removes the limitation on active phase loading that supports impose, while the controlled amorphous structure and composite composition provide inherent stability, thus achieving both high active phase loading and catalyst stability.
Solution Approach 2:
The patent creates a controlled amorphous structure with locally optimized metal distribution and coordination environments. This local structural quality enhancement allows maximum active phase loading throughout the bulk material while maintaining catalytic stability through the specific amorphous configuration, resolving the contradiction between loading and stability.
3Quantity of substance
If deep desulfurization is pursued, then sulfur concentration is reduced to ppm level, but catalyst deactivation occurs
Solution Approach 1:
The patent incorporates multiple metal components (Ni, Mo, W, and other transition metals) in specific ratios within a controlled amorphous structure before the catalytic process begins. This preliminary structural configuration provides resistance against deactivation mechanisms, enabling the catalyst to maintain activity throughout extended operation while achieving deep desulfurization to ppm levels, thus extending catalyst lifespan.
Solution Approach 2:
The composite amorphous catalyst structure combining multiple transition metals provides synergistic effects that enhance both deep desulfurization capability and resistance to deactivation. The diverse metal components work together to maintain catalytic activity over extended periods, resolving the contradiction between achieving ppm-level sulfur concentration and maintaining catalyst lifespan.
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 crystalline transition metal tungstate catalyst exhibits superior performance in hydroprocessing, achieving enhanced sulfur and nitrogen removal, outperforming conventional catalysts by providing a stable and active phase for deep desulfurization and denitrification, suitable for ultra-low sulfur fuel production.
Implementation Method 1
A unique crystalline transition metal tungstate material has been produced and optionally sulfided, to yield an active hydroprocessing catalyst
Implementation Method 2
The crystalline transition metal tungstate material has a unique x-ray powder diffraction pattern showing strong peaks at 9.65, 7.3 and 5.17 Å
Data Source
AI summary
A hydroprocessing catalyst has been developed. The catalyst is a unique transition metal tungstate material. The hydroprocessing using the crystalline ammonia transition metal dimolybdotungstate material may include hydrodenitrification, hydrodesulfurization, hydrodemetallation, hydrodesilication, hydrodearomatization, hydroisomerization, hydrotreating, hydrofining, and hydrocracking.