Base‐free catalytic aerobic oxidation of mercaptans for gasoline sweetening over HTLcs‐derived CuZnAl catalyst

An aerobic oxidative removal of mercaptans from gasoline in the absence of liquid base has been demonstrated for gasoline sweetening over CuZnAl catalyst. This process could proceed at large WHSV of gasoline (50–70 h^?1) with >95% mercaptan conversion at 150°C (or 300°C) using an O₂/S molar ratio of 20–40. At 150°C, dimerization of mercaptans occurred dominantly to form their disulfides. At 300°C, deep oxidation of the mercaptans to SO₂ was the dominant process in the first tens of hours, but it decreased then with prolonged time on stream and meanwhile the dimerization increased. The spent catalyst could be restored to its fresh activity level only through a calcination treatment in air. This process was also demonstrated to be effective and efficient for sweetening of a real cracking gasoline. © 2009 American Institute of Chemical Engineers AIChE J, 2009     

Zncl2 catalyzed flash hydropyrolysis of +525°C pitch from cold lake bitumen

Flash hydropyrolysis experiments have been performed on the vacuum bottoms fraction of Cold Lake bitumen, using zinc chloride as a catalyst. Milligram size samples of vacuum bottoms resid were heated rapidly (120–400°C/s) by passing a large electric current through the reactor tube. The variables studied included temperature, heating rate, catalyst/pitch ratio, vapour phase residence time and pressure. Temperature and catalyst/pitch ratio caused major changes in yields. In contrast pressure had little effect. It was found that high conversions could be obtained at hydrogen pressures which are much lower than those normally used in catalytically hydrocracking residual oils.     

Hydrodesulfurization and hydroconversion of heavy FCC gasoline on PtPd/H-USY zeolite

In the search for catalysts suitable for upgrading fractions of FCC gasoline, PtPd/USY zeolite was investigated. The objectives of the work were to reduce simultaneously the sulfur, nitrogen and aromatic contents of heavy FCC gasoline having various sulfur (30–203 ppmw) and 28 ppmw nitrogen contents. The process conditions were the following: temperature: 200–300 °C; pressure: 30 bar; liquid hourly space velocity: 1.0–3.0 h⁻¹; H₂/hydrocarbon ratio: 500 m³/m³. The results indicated that PtPd/H-USY zeolite catalyst can be applied for the desulfurization of heavy FCC gasoline up to 203 ppm sulfur content. When a base heavy FCC gasoline fraction of 30 ppmw sulfur content was used the catalyst was able to reduce the aromatic content by 14 abs.% as well as sulfur and nitrogen contents to <1 ppmw in one step. Blending calculations were made to evaluate the quality of a full range FCC gasoline obtained by mixing the desulfurized heavy FCC gasoline and the untreated light cut.     

Catalytic hydrocracking of bitumen at mild experimental condition

Mo-containing catalysts were prepared by impregnation method using silica-based porous supports and their physical properties were characterized by BET, XRD and TEM. Catalytic hydrocracking of bitumen extracted from oil sand was carried out in a high pressure reactor using Athabasca oil sand over 5 wt% Mo containing catalyst supported on SiO₂, MCF(Meso Cellular Foam) and SBA-15, respectively, under the conditions of 200 °C, 20 h and 10 atm of H₂ gas. Catalytic hydrocracking activity was estimated by analyzing H/C mole ratio based on EA data, and TGA was employed to compare the thermal behavior of bitumen before and after reaction. Upon hydrocracking over Mo/MCF catalyst, H/C was increased from 1.50 (bitumen itself) to 1.66.     

Conversion of isopropanol and mixed alcohols to hydrocarbons using HZSM‐5 catalyst in the MixAlco™ process. Part 2: Studies at 5000 kPa (abs)

This study employed HZSM‐5 (SiO₂/Al₂O₃ = 280 mol/mol) to produce hydrocarbons from reagent‐grade isopropanol and mixed alcohols made from lignocellulosic biomass (waste office paper and chicken manure) using the MixAlco? process. All studies were performed at P = 5000 kPa (abs). The experiments were conducted in two sets: (1) vary temperature (300–450°C) at weight hourly space velocity (WHSV) = 1.92 h^?1, and (2) vary WHSV (1.92–11.52 h^?1) at T = 370°C. For isopropanol at higher temperatures, the olefins undergo more cracking reactions to produce smaller molecules and more aromatics. At low temperatures, the molecules have less energy so they do not crack and therefore form larger molecules. At T = 300°C, the carbon distribution is bimodal at C9 and C12, which shows trimerization and tetramerization of propene. At 300°C, propene was the only gas produced, cracking did not occur and therefore preserved high‐molecular‐weight molecules. For mixed alcohols, higher temperatures show significant catalyst deactivation; however, isopropanol did not show any catalyst deactivation. © 2016 American Institute of Chemical Engineers AIChE J, 62: 1707–1715, 2016     

Intensification of the processes of dehydrogenation and dewaxing of middle distillate fractions by redistribution of hydrogen between the units

The dehydrogenation and dewaxing of hydrocarbons of middle-distillate fractions, which proceed in the hydrogen medium, are of great importance in the petrochemical and oil refining industries. They increase oil refining depth and allow producing gasoline, kerosene, and diesel fractions used in the production of hydrocarbon fuels, polymer materials, synthetic detergents, rubbers, etc. Herewith, in the process of dehydrogenation of hydrocarbons of middle distillate fractions (C₉–C₁₄) hydrogen is formed in the reactions between hydrocarbons, and the excess of hydrogen slows the target reaction of olefin formation and causes the shift of thermodynamic equilibrium to the initial substances. Meanwhile, in the process of hydrodewaxing of hydrocarbons of middle distillate fractions (C₅–C₂₇), conversely, hydrogen is a required reagent in the target reaction of hydrocracking of long-chain paraffins, which ensures required feedstock conversion for production of low-freezing diesel fuels. Therefore, in this study we suggest the approach of intensification of the processes of dehydrogenation and dewaxing of middle distillate fractions by means of redistribution of hydrogen between the two units on the base of the influence of hydrogen on the hydrocarbon transformations using mathematical models. In this study we found that with increasing the temperature from 470 °C to 490 °C and decreasing the hydrogen/feedstock molar ratio in the range of 8.5/1.0 to 6.0/1.0 in the dehydrogenation reactor, the production of olefins increased by 1.45–1.55%wt, which makes it possible to reduce hydrogen consumption by 25,000 Nm³/h. Involvement of this additionally available hydrogen in the amount from 10,000 to 50,000 Nm³/h in the dewaxing reactor allows increasing the depth of hydrocracking of long-chain paraffins of middle distillate fractions, and, consequently improving low-temperature properties of produced diesel fraction. In such a way cloud temperature and freezing temperature of produced diesel fraction decrease by 1–4 °C and 10–25 °C (at the temperature of 300 °C and 340 °C respectively). However, when the molar ratio hydrogen/hydrocarbons decreases from 8.5/1.0 to 6.0/1.0 the yield of side products in the dehydrogenation reactor increases: the yield of diolefins increases by 0.1–0.15%wt, the yield of coke increases by 0.07–0.18%wt depending on the feedstock composition, which is due to decrease in the content of hydrogen, which hydrogenates intermediate products of condensation (the coke of amorphous structure). This effect can be compensated by additional water supply in the dehydrogenation reactor, which oxidizes the intermediate products of condensation, preventing catalyst deactivation by coke. The calculations with the use of the model showed that at the supply of water by increasing portions simultaneously with temperature rise, the content of coke on the catalyst by the end of the production cycle comprises 1.25–1.56%wt depending on the feedstock composition, which is by 0.3–0.6%wt lower that in the regime without water supply.     

Effect of process conditions on the composition of products in the conventional and deep catalytic cracking of oil fractions

With the purpose of increasing the yield of light C₂-C₄ olefins in comparison with that in conventional catalytic cracking, we experimentally study the effect of temperature and catalyst-to-oil ratio on the distribution of the basic products of oil catalytic cracking on the bizeolite and industrial LUX catalysts. The bizeolite catalyst contains ZSM-5 and ultrastable Y zeolites in equivalent amounts, while the LUX catalyst contains 18 wt % of Y zeolite in the HRE form. As shown by the results of our tests, the yield of C₂-C₄ olefins and gasoline in the deep catalytic cracking of hydrotreated vacuum gasoil on the bizeolite catalyst within a range of catalyst-to-oil ratios of 5–7 and temperatures of 540–560°C reaches 32–36 and nearly 30 wt %, respectively. In cracking on the LUX catalyst under similar conditions, the yield of light olefins and gasoline is 12–16 and 37–45 wt %, respectively. The distribution of target products in the deep catalytic cracking of different hydrocarbon fractions (vacuum gasoil, gas condensate, its fraction distilled from the cut boiling below 216°C, and the hydrocracking heavy residue) on the bizeolite catalyst is studied. It is shown that the fractions of gas condensate and hydroc-racking residue can serve as an additional source of hydrocarbon raw materials in the production of olefins.     

Thermal and catalytic degradation of waste high-density polyethylene (HDPE) using spent FCC catalyst

Thermal and catalytic degradation using spent fluid catalytic cracking (FCC) catalyst of waste high-density polyethylene (HDPE) at 430 °C into fuel oil were carried out with a stirred semi-batch operation. The product yield and the recovery amount, molecular weight distribution and paraffin, olefin, naphthene and aromatic (PONA) distribution of liquid product by catalytic degradation using spent FCC catalyst were compared with those by thermal degradation. The catalytic degradation had lower degradation temperature, faster liquid product rate and more olefin products as well as shorter molecular weight distributions of gasoline range in the liquid product than thermal degradation. These results confirmed that the catalytic degradation using spent FCC catalyst could be a better alternative method to solve a major environmental problem of waste plastics. This paper is dedicated to Dr. Youn Yong Lee on the occasion of his retirement from Korea Institute of Science and Technology.     

Effect of air oxidation on coal hydrogenation

Japanese Taiheiyo coal (75.9%C) was oxidized with air at 250 °C for 3–40 h and at 300 °C for 3–10 h. The weight decreased from 16.3 to 46.5% at 250 °C and from 21.7 to 41.3% at 300 °C. Carbon loss and yield of NaOH soluble were obtained. The resultant oxidation products were hydrogenated at 370 °C for 1 h under 10 MPa hydrogen pressure using red mud with sulphur as catalyst and wash oil as solvent. Conversion to pyridine, benzene and n-hexane soluble fraction shows a minimum for the coal oxidized 10 h at 250 °C and for the coal oxidized for 3 h at 300 °C. Initial oxidation makes a network structure which contributes to a reduction in conversion, but in later stages of oxidation, splitting of bridge linkages and/or ring opening of aromatic structures, contribute to increases in conversion.     

Thermo-catalytic decomposition of waste lubricating oil over carbon catalyst

The thermo-catalytic decomposition of waste lubricating oil over a carbon catalyst was investigated in an I.D. of 14.5mm and length of 640mm quartz tube reactor. The carbon catalysts were activated carbon and rubber grade carbon blacks. The decomposition products of waste lubricating oil were hydrogen, methane, and ethylene in a gas phase, carbon in a solid phase and naphthalene in a liquid phase occurring within the temperature ranges of 700 °C-850 °C. The thermo-catalytic decomposition showed higher hydrogen yield and lower methane yield than that of a non-catalytic decomposition. The carbon black catalyst showed higher hydrogen yield than the activated carbon catalyst and maintained constant catalytic activity for hydrogen production, while activated carbon catalyst showed a deactivation in catalytic activity for hydrogen production. As the operating temperature increased from 700 °C to 800 °C, the hydrogen yield increased and was particularly higher with carbon black catalyst than activated carbon. As a result, carbon black catalyst was found to be an effective catalyst for the decomposition of waste lubricating oil into valuable chemicals such as hydrogen and methane.     

λ-Al_2O_3和活性炭(AC)负载Co-Mo催化剂的对比研究

以λ-Al2O3和活性炭(AC)为载体分别负载Co、Mo制备了粗苯加氢催化剂(CoO,MoO3质量分数分别为2%,8%),利用BET和XRD技术对2Co8Mo/λ-Al2O3和2Co8Mo/AC的物化性能进行表征,在固定床微型反应装置上对比考察了Co-Mo/AC在HDS中的活性。结果表明:活性组分在AC中孔内高度分散,2Co8Mo/AC在T=300℃、P=3.0 MPa、LHSV=2 h-1及氢油体积比为600时对噻吩硫脱除率达到99%以上。     

Silica-alumina based nickel-molybdenum catalysts for vacuum gas oil hydrocracking aimed at a higher diesel fraction yield

Nickel-molybdenum hydrocracking catalysts based on amorphous silica-aluminas (ASAs) with Si/Al = 0.3–1.5 have been prepared using chemicals and methods available for catalyst plants. The acidic properties of the ASA surface have been investigated by IR spectroscopy of adsorbed CO, and it has been demonstrated that the Si/Al ratio has an effect on the concentration and strength of Brønsted and Lewis acid sites in the ASA. The catalysts have been characterized by low-temperature nitrogen adsorption and transmission electron microscopy, and it was found that the Si/Al ratio in the ASA has a considerable effect on the textural properties of the catalysts and only a slight effect on the particle size of the sulfide active component. The catalysts have been tested in vacuum gas oil hydrocracking in a laboratory-scale high-pressure flow reactor under typical industrial hydrocracking conditions. The highest diesel fraction yield (>60 wt % at 400°C) has been obtained with the catalyst based on the Si/Al = 0.9 ASA, which has the strongest Brønsted acid sites. With the catalysts based on the Si/Al = 0.3 and 1.5 ASAs, the diesel fraction yield is much lower. This may be due to the lower concentration and strength of acid sites in these catalysts and their smaller specific surface area. The NiMo catalyst based on Si/Al ≈ 0.9 ASA is recommended for industrial use in refineries aimed at obtaining the maximum possible yield of low-sulfur, high-cetane, diesel fuels.     

Catalytic coprocessing of LDPE with coal and petroleum resid using different catalysts

Catalytic coprocessing of low density polyethylene (LDPE) with coal and heavy petroleum resid was investigated using four different catalysts that included both hydrotreating and hydrocracking catalysts. Reaction systems that were evaluated included LDPE alone; LDPE with coal; and LDPE, coal, and resid. The catalysts used were NiMo/Al₂O₃, a hydrotreating catalyst with some hydrocracking activity, and the hydrocracking catalysts Zeolyst 753, NiMo/zeolite, and HZSM-5. These catalysts were reacted individually or in combinations of 10 wt.% of each hydrocracking catalyst in NiMo/Al₂O₃. The catalytic reactions were performed at two temperatures, 400 and 430°C, using 1 wt.% of each catalyst or a combination of catalysts on a total feed basis. The effects of the different catalysts on the reaction products were measured in terms of solvent fractionation and total boiling point distribution. Reactions at the higher reaction temperature of 430°C resulted in substantially higher conversion and production of lighter products than the reactions at 400°C. The LDPE reaction system was sensitive to the catalyst type, and yielded increased conversion and lighter products when Zeolyst 753 and NiMo/zeolite were used. By contrast, the conversion and product slate obtained from the LDPE and coal systems were low and showed no effect due to the different types of catalyst. Introduction of resid to the LDPE/coal system increased the reactivity of the system and allowed the catalysts to have a larger effect. The hydrocracking catalysts were the most active in producing more conversion and hexane soluble material. Comparison of the effect of increasing the reaction time up to 5 h with 1 wt.% catalyst loading to the effect of increasing the catalyst loading from 1 wt.% to 10 wt.% for a reaction time of 1 h showed that increased reaction time was much more effective than catalyst loading in converting the solid LDPE to liquid reaction products.     

Ni-W/SSY-Beta-Al_2O_3柴油加氢转化催化剂研究

采用SSY型分子筛、不同硅铝比Beta分子筛与大孔氢氧化铝干胶混捏制备SSY-Beta-Al_2O_3载体,等体积浸渍法制备Ni-W/SSY-Beta-Al_2O_3加氢转化催化剂,采用BET、Py-IR、XRD、NH_3-TPD对制备的催化剂及载体进行表征。在100 mL固定床加氢装置上,工业Ni-Mo型柴油加氢精制催化剂与Ni-W/SSY-Beta-Al_2O_3加氢转化催化剂级配装填,以劣质催化裂化柴油为原料,对加氢转化催化剂进行活性评价。结果表明,随着Beta分子筛硅铝比的增加,催化剂表面的L酸中心先减少后增多,B酸中心先增加后减少,催化剂的弱酸酸量先增多后减少,中强酸与强酸酸量变化不明显。在氢油体积比700∶1、反应压力8.0 MPa、精制段反应温度360℃,体积空速1.25 h^(-1),转化段反应温度400℃,体积空速1.35 h^(-1)的条件下,CYB-3催化剂加氢转化产品液相收率高达97.73%,汽油馏分收率63.72%,辛烷值91.66,柴油馏分收率33.69%,十六烷值比原料提高8.96,凝点小于-35℃。     

Influence of the nature of the activating molecules on the catalytic activity of cobalt—molybdenum/alumina catalysts

The effectiveness of the activation of a commercial CoMo/Al₂O₃ catalyst was evaluated using five different sulphiding agents (carbon disulphide, dimethyldisulphide, butanethiol, thiophene and hydrogen sulphide) at high pressure (3 MPa) in the 300–450°C temperature range. The results indicate that the behaviour of the cobalt—molybdenum catalysts depends strongly on the nature of the activating molecule as well as the pretreatment temperature. The catalyst exhibited two different patterns, below and above 400°C. At 300°C, differences in the degree of sulphidation and in activities were observed when using different activating molecules. The most efficient of the sulphiding agents used was butanethiol while the least efficient one was thiophene. The activity of the catalyst was a maximum when carbon disulphide was used at 350°C or the other sulphiding agents at 400°C. We attributed the differences of effects of the various molecules to coupling effects between reduction and sulphidation reactions. Under the activation giving excellent activities, the coupling effect is optimal. Using carbon disulphide or thiophene at temperatures higher than 400°C, a catalyst with strongly decreased activity was produced. This behaviour is attributed to coke formation during sulphidation.     

Effect of temperature in the conversion of methanol to olefins (MTO) using an extruded SAPO-34 catalyst

The methanol-to-olefin (MTO) reaction was investigated in a bench-scale, fixed-bed reactor using an extruded catalyst composed of a commercial SAPO-34 (65 weight percentage, wt-%) embedded in an amorphous SiO₂ matrix (35 wt-%). The texture properties, acidity and crystal structure of the pure SAPO-34 and its extruded form (E-SAPO-34) were analyzed and results indicated that the extrusion step did not affect the properties of the catalyst. Subsequently, E-SAPO-34 was tested in a temperature range between 300 and 500 °C, using an aqueous methanol mixture (80 wt-% water content) fed at a weight hour space velocity (WHSV) of 1.21 h⁻¹. At 300 °C, a low conversion was observed combined with catalyst deactivation, which was ascribed to oligomerization and condensation reactions. The coke analysis showed the presence of diamandoid hydrocarbons, which are known to be inactive molecules in the MTO process. At higher temperatures, a quasi-steady state was reached during a 6 h reaction where the optimal temperature was identified at 450 °C, which incidentally led to the lowest coke deposition combined with the highest H/C ratio. Above 450 °C, surges of ethylene and methane were associated to a combination of H-transfer and protolytic cracking reactions. Finally, the present work underscored the convenience of the extrusion technique for testing catalysts at simulated scale-up conditions.     

Catalyst for selective hydrotreating of catalytic cracking gasoline without preliminary fractionation

A new CoMo catalyst for selective hydrotreating of FCC gasoline has been developed; the catalyst is intended for the production of hydrotreated gasoline with up to 10 ppm of sulfur and with a research octane number decreased by less than 1.0. The new catalyst allows hydrotreating of FCC gasoline without its preliminary separation into the light and heavy fractions. The hydrotreating conditions were as follows: hourly space velocity 2.2 h^–1, temperature 270°C, pressure 2.5 MPa, H₂/feed = 150 m³/m³. The high degree of hydrodesulfurization at minimum decrease in the octane number is achieved due to the high activity of the developed catalyst in hydrodesulfurization of the sulfur-containing components of the feedstock and conversion of reactive high-octane olefins of FCC gasoline into less reactive derivatives with high octane numbers. The catalyst is a CoMoS phase deposited on a support containing amorphous aluminosilicate and γ-Al₂O₃. The method for the preparation of the catalyst is adapted to the equipment of Russian plants and feedstocks. The parameters of hydrotreating using this catalyst ensure the hydrotreating of FCC gasoline to a residual sulfur content of less than 10 ppm with minimum redesign of the equipment currently available at Russian refineries.     

加氢裂化生产高辛烷值汽油组分技术研究

主要研究了使用加氢裂化技术直接生产高辛烷值汽油组分.考察了工艺流程及使用不同类型加氢裂化催化剂对轻石脑油辛烷值的影响.结果表明:使用合适的加氢裂化工艺技术和催化剂体系可以直接生产高辛烷值,且硫含量≯10μg/g的汽油或者汽油调和组分.     

Ni-W/SSY催化裂化生物正构烷烃制备航空燃料

以超稳SSY分子筛负载Ni-W制得加氢裂化催化剂,用于加氢裂化生物正构烷烃(C16、C18),得到以煤油和汽油为主的液体生物燃料,可以提高中油组分收率。通过氮气物理吸附,扫描电镜(SEM),X射线光电子能谱(XPS)等分析手段对催化剂进行了表征。在微型固定床连续加氢裂化反应器上,考察了反应条件对单程转化率和煤油/汽油质量比的影响规律。结果表明:255℃、1.0 MPa、质量空速为0.33 h-1、氢油比为4 000:1的反应条件下,单程转化率达到60%以上,煤油与汽油质量比超过2.0。Ni-W/SSY催化剂活性高,可以用于长链烷烃加氢裂化制备煤油组分为主的液体燃料。     

Conversion of used vegetable oils to liquid fuels and chemicals over HZSM-5, sulfated zirconia and hybrid catalysts

Thailand’s food manufacturing uses about 47 Million liters per year of vegetable oil. Used vegetable oil is classified as waste, but has potential for conversion into liquid fuel. This research studied the catalytic conversion of used vegetable oil to liquid fuel, where investigation was performed in a batch microreactor over a temperature range of 380–430 °C, initial pressure of hydrogen gas over 10–20 bars, and reaction time of 45–90 minutes. Catalysts such as HZSM-5, Sulfated Zirconia and hybrid of HZSM-5 with Sulfated Zirconia were used to determine the conversion and yield of gasoline fraction. The major products obtained were liquid products, hydrocarbon gases and small amounts of solids. Liquid products were analyzed by simulated distillation gas chromatograph and the product distribution was obtained. Hybrid catalyst HZSM-5 with Sulfated Zirconia showed the highest yield of gasoline with a 26.57 wt% at a temperature of 430 °C, initial hydrogen pressure at 10 bars, and reaction time of 90 minutes in the ratio of hybrid HZSM-5 with Sulfated Zirconia at 0.3: 0.7.