Tungsten Oxy-Hydroxide Catalyst for Ultra-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 often require complex synthesis and have limited stability and activity.
Innovation Solution
A unique transition metal tungsten oxy-hydroxide composition is developed, characterized by a poorly crystalline diffraction pattern with a broad peak between d-spacing 4.45-2.25 Å, which can be decomposed or sulfided to yield an active hydroprocessing catalyst, utilizing a reaction mixture with specific pH adjustment and metal sources like Mg, Mn, Fe, Co, Ni, and Zn, and sugars like glucose, fructose, and lactose.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hydroprocessing catalysts are used, then basic sulfur and nitrogen removal is achieved, but ultra-deep desulfurization and denitrification to ppm levels cannot be achieved
Solution Approach 1:
The patent changes the chemical composition parameters by incorporating multiple metals (Ni, Mo, W, Co) in specific ratios, and controls the crystallite size parameter at 2-5 nm through controlled synthesis. These parameter changes enable the catalyst to achieve ultra-deep desulfurization and denitrification to ppm levels, resolving the contradiction between basic removal efficiency and deep removal activity
Solution Approach 2:
The patent creates a composite catalyst material containing nickel, molybdenum, tungsten, and cobalt in a supported structure. This composite material combines the benefits of multiple metal components to achieve synergistic effects that enable ultra-deep desulfurization and denitrification, overcoming the limitations of conventional single-metal or binary catalysts
2Productivity
If catalyst loading is increased to improve activity, then removal efficiency increases, but catalyst stability and selectivity may deteriorate
Solution Approach 1:
The patent applies local quality by creating discrete crystallites with controlled size (2-5 nm) distributed on the support. This localized structure ensures that each crystallite maintains optimal activity while the overall distribution provides stability. The specific metal composition within each crystallite is optimized for high activity, while the supported structure provides stability, resolving the contradiction between activity and stability
Solution Approach 2:
The patent segments the catalyst into small crystallites (2-5 nm) rather than using large bulk materials. This segmentation increases the surface area to volume ratio, providing more active sites per unit mass while maintaining stability through the supported structure. The segmented crystallites can be optimally distributed on the support, achieving both high productivity and reliability
3Manufacturing precision
If complex synthesis procedures are used to achieve high performance, then catalyst activity improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges multiple metal precursors (nickel, molybdenum, tungsten, cobalt) into a single synthesis procedure where they co-precipitate and form the desired composite structure in one step. This combined approach achieves high-performance multi-metal catalysts without requiring separate synthesis steps for each metal, reducing manufacturing complexity while maintaining high catalyst performance
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 catalyst demonstrates superior hydrotreating activities, achieving ultra-deep desulfurization and denitrification, outperforming conventional catalysts by providing a stable and active phase for hydroprocessing, including hydrodenitrification, hydrodesulfurization, and other hydrocarbon conversion processes.
Implementation Method 1
A unique transition metal tungsten oxy-hydroxide composition is developed, characterized by a poorly crystalline diffraction pattern with a broad peak between d-spacing 4.45-2.25 Å, which can be decomposed or sulfided to yield an active hydroprocessing catalyst
Implementation Method 2
The removal of sulfur (hydrodesulfurization—HDS) and nitrogen (hydrodenitrification—HDN) containing compounds from fuel feed stocks is targeted during the hydrotreating steps of refining and is achieved by the conversion of organic nitrogen and sulfur to ammonia and hydrogen sulfide respectively
Implementation Method 3
The removal of sulfur (hydrodesulfurization—HDS) and nitrogen (hydrodenitrification—HDN) containing compounds from fuel feed stocks is targeted during the hydrotreating steps of refining and is achieved by the conversion of organic nitrogen and sulfur to ammonia and hydrogen sulfide respectively
Implementation Method 4
utilizing a reaction mixture with specific pH adjustment and metal sources like Mg, Mn, Fe, Co, Ni, and Zn
Data Source
AI summary
A hydroprocessing catalyst or catalyst precursor has been developed. The catalyst is a unique transition metal tungsten oxy-hydroxide material. The hydroprocessing using the transition metal tungsten oxy-hydroxide material or the decomposition product thereof may include hydrodenitrification, hydrodesulfurization, hydrodemetallation, hydrodesilication, hydrodearomatization, hydroisomerization, hydrotreating, hydrofining, and hydrocracking.