Type II USY Hydrotreating Catalyst for Refractory Sulfur Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydrotreating catalysts struggle to efficiently remove refractory sulfur-containing compounds from hydrocarbon fuels to achieve ultra-low sulfur levels required by stringent environmental regulations, particularly due to the steric hindrance of sulfur atoms in aromatic molecules, making it costly and difficult to retrofit existing facilities.
Innovation Solution
A hydrotreating catalyst comprising a post-framework modified ultra-stable Y-type (USY) zeolite with zirconium and/or titanium substitution, combined with a chelating agent to form type II active sites, which enhances the catalyst's activity for desulfurization by maintaining the hydrotreating metal components as a chelating complex without calcination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hydrotreating catalysts are used, then existing facilities can operate under mild conditions, but they cannot achieve ultra-low sulfur levels required by stringent environmental regulations
Solution Approach 1:
The patent changes the chemical composition parameters of the catalyst by incorporating post-framework modified USY zeolite with specific SiO2/Al2O3 ratios and metal component concentrations, enabling the catalyst to achieve ultra-low sulfur levels while maintaining stability under mild operating conditions
Solution Approach 2:
The patent creates a composite catalyst system combining post-framework modified USY zeolite with specific metal components (Co, Ni, Mo, W) and chelating agents, where the synergistic interaction between components enhances desulfurization efficiency for refractory sulfur compounds while maintaining mild operating conditions
2Manufacturing precision
If more active catalyst compositions are used to achieve ultra-low sulfur levels, then desulfurization efficiency improves, but facility retrofitting costs and complexity increase
Solution Approach 1:
The patent optimizes catalyst composition parameters including metal component ratios, chelating agent types, and zeolite framework modifications to achieve high desulfurization activity without requiring changes to existing reactor design, operating pressure, or temperature conditions
Solution Approach 2:
The patent develops a catalyst formulation that can be directly applied in existing facilities without expensive retrofitting, treating the catalyst as a consumable component that provides ultra-low sulfur performance through optimized chemistry rather than capital-intensive hardware modifications
3Manufacturing precision
If higher temperature and pressure are applied to remove refractory sulfur compounds, then desulfurization efficiency improves, but operational requirements and energy consumption increase
Solution Approach 1:
The patent changes the catalyst's chemical properties through post-framework modification and metal component selection to enable refractory sulfur compound removal at lower temperatures and pressures, reducing energy consumption while maintaining desulfurization efficiency
Solution Approach 2:
The patent replaces the need for high mechanical energy input (high temperature and pressure) with chemically active catalyst components that selectively facilitate sulfur removal through chemical reactions under milder conditions
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 effectively desulfurizes hydrocarbon fuels to ultra-low sulfur levels, improving the efficiency and reducing the cost of upgrading existing facilities by maintaining high activity without the need for extensive retrofitting.
Implementation Method 1
a post-framework modified ultra-stable Y-type (USY) zeolite in which a portion of aluminum atoms constituting a zeolite framework thereof is substituted with zirconium atoms and/or titanium atoms and/or hafnium atoms
Implementation Method 2
The hydrotreating metal component forms a metal complex via the chelating agent, and is carried on said support as chelating complex type II active sites
Implementation Method 3
The catalyst effectively desulfurizes hydrocarbon fuels to ultra-low sulfur levels
Data Source
AI summary
Hydrotreating catalyst material and/or hydrotreating catalyst particles are provided having at least two hydrotreating metal components and a chelating agent carried on a support. The support comprises an inorganic oxide binder and a post-framework modified ultra-stable Y-type (USY) zeolite in which a portion of aluminum atoms constituting a zeolite framework thereof is substituted with zirconium atoms and/or titanium atoms and/or hafnium atoms. The hydrotreating metal components form a metal complex via the chelating agent, and are carried on said support as chelating complex type II active sites.