Transition Metal Tungstate Catalysts for Deep Hydroprocessing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current hydroprocessing catalysts face challenges in achieving deep desulfurization and denitrification of petroleum products, particularly with the increasing use of sour crudes and stringent environmental regulations, as they struggle to maintain activity and stability over time.
Innovation Solution
A crystalline transition metal tungstate material, characterized by a unique x-ray powder diffraction pattern, is synthesized and optionally sulfided to produce active hydroprocessing catalysts, which are used in hydrocarbon conversion processes such as hydrodenitrification, hydrodesulfurization, and hydrocracking, enhancing catalyst performance through specific metal composition and sulfidation conditions.
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 deep desulfurization and denitrification to ppm levels cannot be achieved
Solution Approach 1:
The patent changes the chemical composition parameters by incorporating multiple metal components (Ni, Mo, W, Co) in specific ratios, and modifies the physical-chemical parameters through controlled sulfidation treatment to create an amorphous catalyst structure with superior deep desulfurization and denitrification activity
Solution Approach 2:
The patent creates a composite catalyst material combining nickel, molybdenum, tungsten, and cobalt metals in an amorphous matrix, which synergistically enhances both the deep desulfurization capability and catalyst stability, achieving removal to ppm levels while maintaining reliability
2Stability of the object's composition
If support materials like Al2O3 are used in catalysts, then catalyst structure is stabilized, but active phase loading is limited
Solution Approach 1:
The patent extracts and eliminates the Al2O3 support material from the catalyst system, creating an unsupported amorphous catalyst where the active metal phases themselves form the catalyst matrix, thereby removing the limitation on active phase loading while maintaining structural stability through the amorphous network
Solution Approach 2:
The amorphous catalyst structure serves multiple functions simultaneously: it provides the active sites for deep desulfurization and denitrification, maintains structural stability without requiring separate support materials, and enables high active phase loading through its homogeneous composition
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 catalysts demonstrate improved activity and stability, achieving superior performance in deep desulfurization and denitrification, enabling the production of ultra-low sulfur fuels and meeting stringent environmental standards.
Implementation Method 1
The crystalline transition metal tungstate material has been produced and optionally sulfided, to yield an active hydroprocessing catalyst
Implementation Method 2
at least one reaction catalyzed by at least one metal sulfide resulting from the decomposition by sulfidation of a material comprising a crystalline transition metal tungstate
Data Source
AI summary
A hydroprocessing catalyst has been developed. The catalyst is a crystalline transition metal tungstate material or metal sulfides derived therefrom, or both. The hydroprocessing using the crystalline transition metal tungstate material may include hydrodenitrification, hydrodesulfurization, hydrodemetallation, hydrodesilication, hydrodearomatization, hydroisomerization, hydrotreating, hydrofining, and hydrocracking. A data system comprising at least one processor; at least one memory storing computer-executable instructions; and at least one receiver configured to receive data of a conversion process comprising at least one reaction catalyzed by the catalyst or a metal sulfide decomposition product of the catalyst has been developed.