加氢精制催化剂RS-1000器外再生技术应用及效果

广州石化加氢精制Ⅲ装置采用石油化工科学研究院开发的RS-1000催化剂,其活性组分主要是镍、钨、钼。该催化剂对4,6-DMDBT类稠环位阻硫化物的转化能力远远超过常规加氢精制催化剂,具有优异的柴油超深度脱硫能力。在装置运行1035d后,进行首次大修,并对RS-1000催化剂进行器外再生和活化,补充了部分新剂。催化剂器外再生技术的主要优点,是再生过程不易产生局部过热;催化剂活性恢复程度较高;可以增加加氢装置的开工时数;加氢装置设备不再承受再生含硫气体的腐蚀;经济效益好。RS-1000催化剂器外再生及工业应用结果表明,在原料性质、体积空速相近的条件下,产品质量满足国Ⅲ柴油质量指标要求,且反应器入口温度明显下降,催化剂再生效果好,各项物化性质与新鲜催化剂基本相当,降低了生产成本,节省了检修时间,实现了催化剂长周期使用的目标。     

Deep regeneration of activated carbon catalyst and autothermal analysis for chemical looping methane thermo-catalytic decomposition process

The application of a chemical looping process to methane thermo-catalytic decomposition using activated carbon (AC) as a catalyst has been recognized as a promising technology for continuous high-purity H₂ production in a carbon constrained world. However, it usually needs an external heat supply for the endothermic decomposition reactions. By taking advantage of the chemical looping combustion (CLC) technology, this study proposed a deep regeneration approach using H₂O and O₂ as regeneration agents to overcome the issues with maintaining catalytic activity and producing the heat needed for the endothermic reactions of H₂ production from methane. TG-DTA and bench scale fluidized bed experimental results indicate that a deep regeneration degree of 30% or above could completely reactivate the spent AC catalyst and simultaneously generate sufficient heat than required in the methane decomposition reaction. Characterization study implies that the deep regenerated AC catalyst could maintain its physical properties within a certain number of cycles. Based on the experimental results, the chemical looping methane thermo-catalytic decomposition process was further optimized and assessed by Aspen Plus^® thermodynamic simulation. The results indicate that heat and mass balances could be attained, and the circulation of the AC catalyst with a temperature difference of 262 °C between the decomposer and the regenerator enabling the process to run autothermally.     

One-pot sol–gel synthesis of Ni/TiO2 catalysts for methane decomposition into COx free hydrogen and multiwalled carbon nanotubes

A series of mesoporous Ni/TiO₂ catalysts with different loadings of nickel from 10 to 50 wt% was successfully prepared via a facile one-pot sol–gel route; characterized for its structural, textural and redox properties; and tested for the non-oxidative thermocatalytic decomposition of undiluted methane for the first time. The characterization results reveal the presence of both NiO and NiTiO₃ and metallic nickel as active metal phase in the fresh and reduced catalysts, respectively. Spherical catalyst particles were found to be highly inter-aggregated and to provide a porous texture to the catalyst. All of the prepared catalysts exhibited high catalytic activity and stability for methane decomposition. It is due to the fine dispersion of active nickel nanoparticles on the surface of the TiO₂ support with proper metal-support interaction. Moreover, with increasing nickel loading and reaction temperature, the yields of hydrogen and nanocarbon were found to be significantly increased. A maximum hydrogen yield of 56% and a final carbon yield of 1544% were obtained for the 50% Ni/TiO₂ catalyst at 700 °C with an undiluted methane feed of 150 ml/min for 360 min of time on stream. The catalyst showed high catalyst stability, for a period of 960 min of time on stream and ～24% hydrogen yield was observed at the end of long-term run using the 50% Ni/TiO₂ catalyst. Moreover, irrespective of the nickel loading involved, bulk amount of multiwalled carbon nanotubes were deposited on the surface of the catalyst. XRD and Raman analyses of the spent catalysts showed that the crystallinity of nanocarbon increased with increasing nickel loadings, whereas the graphitization degree remained unaffected, with an I_D/I_G value of 0.88.     

Coking behavior of nickel and a rhodium based catalyst used in steam reforming for power-to-gas applications

This paper proposes partial steam reforming of natural gas as a chemical storage option for excess electricity. Thermodynamic simulations with Aspen Plus^® show that highest process efficiencies are reached at low steam-to-carbon (S/C) ratios in the feed. However, coke deposition due to unwanted side or follow-up reactions and thus catalyst deactivation is likely in this operation range. In an experimental evaluation three catalysts were selected to test their resistance towards coking: two nickel based and one rhodium based noble metal catalyst. They were tested regarding their long-term stability at S/C ratios as low as 0 to 0.1 and reaction temperatures between 450 and 500 °C. A different reaction and deactivation behavior was observed for nickel and the noble metal catalysts. The measured life times of the noble metal catalyst were by a factor of at least 100 higher than for the two selected nickel catalysts at the applied reforming conditions. Furthermore, after each reforming experiment, a temperature-programmed oxidation (TPO) analysis was performed for the spent catalysts. Based on literature data, the measured CO₂ peaks at corresponding temperatures were related to the different forms of solid carbon depositions. Main carbonaceous species found on the nickel catalysts were of filamentous nature, whereas one or two more reactive C species with monoatomic or polymeric structure at much lower amount were detected on the noble metal catalyst. Further SEM analysis confirmed these findings.     

Comparison and effect of Cinder supported with Manganese and Lanthanum oxide for biodiesel production

In this study, comparison and effect of Cinder supported with Lanthanum and Manganese oxide as catalyst for transesterification of triglyceride to methyl ester is proposed. The reaction mechanism along with the effects of methanol to oil molar ratio, amount of catalyst to oil, reaction temperature were also discussed. Moreover reusability of catalyst, catalyst resistance toward Free Fatty Acid and water were also discussed. The results show that yield of biodiesel produced with Mn:La:Cinder catalyst was 99% at ≥150 °C in 6 h. Cinder supported with Mn shows conversion of triglycerides from soybean oil in reaction with methanol after 6 h was over 99% at 150 °C. For both catalyst 3wt% of catalyst based on oil, 24:1 methanol/oil molar ratio was reused for 7 times with regeneration. The catalysts displayed great resistance toward 2.5% water and 1% wt fatty acids.     

Applicability of a TSA/ZrO2 catalytic membrane for the production of ethyl levulinate as raw material of gamma-valerolactone

The aim of this study is to synthesize of ethyl levulinate as raw material by the green catalytic membrane process for the produce of gamma-valerolactone by hydrogenation. Production of zirconium oxide supported tungstosilicic acid loaded hydroxyethyl cellulose catalytic membrane was done by solution casting method. Zirconium oxide supported tungstosilicic acid, which used as the catalyst, was prepared by the wet impregnation method in the laboratory. Catalyst and catalytic membrane were characterized by XRD and SEM. The reaction was carried out in the batch reactor by using catalytic membrane pieces as the catalyst. Optimum conditions were determined as the reaction temperature of 75 °C, molar feed ratio of 6:1, catalyst concentration of 2 wt.% and catalytic membrane amount of 4 wt.%. The conversion value of levulinic acid to ethyl levulinate was obtained as 86% under these conditions and catalytic membrane was used for five times without losing catalytic activity. As a result of the study, catalytic membrane was found as an efficient catalyst for the synthesis of ethyl levulinate.     

Investigation on salisylaldimine-Ni complex catalyst as an alternative to increasing the performance of catalytic hydrolysis of sodium borohydride

In this study, 5-amino-2, 4-dichlorophenol-3, 5-ditertbutylsalisylaldimine-Ni complex catalyst is synthesised and used as an alternative to previous studies to produce hydrogen from hydrolysis of sodium borohydride. The resulting complex catalyst is characterised by XRD, XPS, SEM, FT-IR and BET surface area analyses. Experimental works are carried out at 30 °C with 2% NaBH₄, 7% NaOH and 5 mg of catalyst. The maximum hydrogen production rate from hydrolysis of sodium borohydride with nickel-based complex catalyst compared to the pure nickel catalyst is increased from 772 ml min^?1g^?1 to 2240 ml min^?1g^?1 by an increase of 190%. At the same time, the hydrolysis reaction with pure nickel catalyst is completed in 145 min while the hydrolysis reaction with nickel-based complex catalyst is completed in 50 min. The activation energy of this hydrolysis reaction was calculated as 18.16 kJ mol^?1. This work also includes kinetic information for the hydrolysis of NaBH₄.The reusability of the nickel-based complex catalyst used in this study has also been studied. The nickel-based complex catalyst is maintained the activity of 72% after the sixth use, compared to the first catalytic use.     

Regeneration of CO poisoned Pt black anode catalyst in PEMFC using break-in procedure and KMnO4 solution

In the present work, an experimental procedure is developed based on break-in procedure and use of dilute KMnO₄ solution to regenerate the CO poisoned Pt black anode electro-catalyst of a PEMFC. To understand the effect of operating temperature on extent of CO poisoning and regeneration of CO poisoned Pt black anode electro-catalyst, PEMFC is operated at 30 °C, 50 °C and 70 °C. At lower cell operating temperature (30 °C), KMnO₄ solution regenerates CO poisoned Pt black anode catalyst, whereas contribution of break-in procedure towards regeneration is negligible. At 50 °C and 70 °C, break-in procedure contributes towards recovering the initial performance i.e. 74.6% and 78.8% of the initial current density at 0.2 V respectively and rest is regenerated by use of dilute KMnO₄ solution.     

The effect of ceria content in nickel–ceria composite anode catalysts on the discharge performance for solid oxide fuel cells

Optimum ceria content in nickel–ceria composite anode catalyst from the point of discharge performance is discussed. The ohmic loss increased when the ceria content was higher than 30 mol%. Even though the electrical conductivity of the anode decreased with increasing ceria content in the anode catalyst in association with decreasing nickel content, the ohmic loss was kept low until the ceria content was ≤30 mol% because the semiconducting ceria compensated for the decreased current path owing to the decreasing nickel content. The lowest activation loss was observed when the ceria content in the nickel anode catalyst was 30 mol% and the maximum activation loss was obtained for ceria content of 2 mol%. Ceria content in nickel anode influenced microstructure of the anode matrix. When the CeO₂ content was 2 mol%, sintering of anode catalyst was evident and the porosity of anode matrix was almost 57% - highest in this study. Whereas sintering of anode catalyst was not evident and the porosity of anode matrix was 46% when the ceria content in the nickel anode catalyst was 30 mol%. Activation loss was strongly influenced by microstructure of anode matrix, and highest activation loss when the CeO₂ content was 2 mol% was owing to the inappropriate microstructure for electrochemical reaction: sintering of the anode catalyst and excessive porosity of the anode.     

Utilization of NiO/porous ceramic monolithic catalyst for upgrading biomass fuel gas

Catalytic steam reforming for producing high quality syngas from biomass fuel gas was studied over monolithic NiO/porous ceramic catalysts in a fixed-bed reactor. Effects of reaction temperature, steam to carbon (S/C) ratio, and nickel loading content on catalyst performance were investigated. Results indicated that the NiO/porous ceramic monolith catalyst had a good ability to improve bio-fuel gas quality. H₂ yield, H₂ + CO content, and H₂/CO ratio in produced gas were increased when reaction temperature was increased from 550 to 700 °C. H₂ yield was increased from 28.1% to 40.2% with S/C ratio increased from 1 to 2. And the yield of hydrogen was stabilized with the further increase of S/C ratio. Catalyst activity was not always enhanced with increased nickel content, when NiO loading content reaches 5.96%, serious aggregation and sintering of active composition on catalyst surface occur. The best performance, in terms of H₂ yield, is obtained with 2.50% NiO content at reaction temperature of 700 °C and S/C ratio of 2.     

Catalytic performance and characterization of Neodymium-containing mesoporous silica supported nickel catalysts for methane reforming to syngas

Ordered mesoporous silica materials based on nickel and other elements have been extensively studied because controlling the size of metal nanoparticles is an effective method to tune the superficial physicochemical process. Neodymium (Nd)-promoted mesoporous silica xNdMS (x: molar ratio of Nd/Si = 0.01, 0.02, 0.04, 0.06) were prepared through a sol–gel strategy. Nickel-based catalysts with high dispersion by using xNdMS as supports were investigated for methane reforming with carbon dioxide and/or oxygen to produce syngas. xNdMS supports and nickel catalysts were examined by combining textural, structural, local and surface information. The characterization results showed that Nd was successfully incorporated into the mesoporous framework of MS and Nd was beneficial to improve the metal dispersion. All Nd-promoted Ni/MS catalysts were effective for the methane reforming reaction. Ni/0.04NdMS catalyst exhibited the highest initial catalytic activity during 12 h time on stream, which was attributed to its high metal dispersion, more basic sites and the strengthened nickel-support interaction. The readily deactivation and poorest catalytic activity of Ni/MS catalyst were due to the serious oxidation of metallic nickel under reaction medium.     

Steam reforming of ethanol on Rh/SiCeO2 washcoated monolith catalyst: Stable catalyst performance

The performance of a new Rh/CeSiO₂ catalyst supported on a ceramic monolith for steam reforming (SR) of ethanol for hydrogen generation was investigated. It provides several advantages over a traditional pellet based catalyst in that it will reduce weight, size and pressure drop in the reactor. The effect of steam to ethanol molar ratio and temperature were first investigated on a powdered catalyst in order to establish the preferred reaction conditions to be used for tests on the monolith. The optimum temperature for coke free, high selectivity and stable catalyst operation was 1073 K at a steam to ethanol molar ratio of 3.5. The monolith supported catalyst was evaluated for aging stability, on/off performance and coke regeneration using steam gasification. After 96 h of SR of ethanol at 1028 K and water/ethanol molar ratio of 3.5 the monolith supported catalyst retained stable performance throughout the entire time on stream with the only products being H₂, CO, CO₂. Some coke formation was observed using Raman spectra, however, it did not cause any permanent deactivation. Regeneration via steam gasification at 973 K with 20% steam in N₂ was successful for coke removal and complete catalyst regeneration.     

Unsupported nickel catalyst prepared from nickel foam for methane decomposition and recycling the carbon deposited spent catalyst

Catalytic methane decomposition (CMD) receives increasing attention for co-production of CO_x-free hydrogen and valuable carbon by-product, and the catalyst plays a crucial role on methane conversion and the product features. Unsupported nickel catalysts derived from commercial nickel foam (NF) were prepared for CMD by mild pre-treatment. Effects of the pre-treatment method (acid treatment, thermal treatment, acid-thermal treatment and hydrogen reduction) and reaction temperature were explored on the NF morphology and CMD reactivity in a fixed-bed reactor. It is found that catalytic performance of the NF-based catalyst is highly dependent on the pre-treatment and reaction temperature. The thermal and acid-thermal treatments could greatly promote the catalytic activity (with methane conversion up to 74.6% and 91.8%, respectively) at 850 °C. To fully release potential abilities of the catalyst, the carbon deposited spent catalyst was recycled as a fresh catalyst in the CMD test by several strategies. High and stable methane conversion (up to around 90%–93%) can be achieved by simulating the operation model in a fluidized-bed reactor for a continuous CMD process. Besides, the carbon deposited spent catalyst could serve as a promising candidate of supercapacitor electrode material.     

Effect of reaction conditions on regeneration performance of spent CeY sorbent used for thiophene adsorption

The CeY sorbent prepared by NaY zeolite ion-exchanging by cerium ion has been proved an excellent adsorption desulfurization ability. Thus, it is necessary to investigate its regeneration behavior after underwent desulfurization. In this paper, the spent CeY sorbent adsorbing thiophene in benzene (TBY) was regenerated by thermal treatment under various conditions. The desulfurization efficiency of regenerated TBY samples was measured by static adsorption experiment. The results show that the regeneration temperature, regeneration time and oxygen content are the main influence factors for the regeneration of TBY samples. The regenerated performance of sorbents is mainly affected by the retained contents of sulfur and carbon, and the strong B acid sites in TBY sorbent are not conducive to the recovery capacity of regenerated sorbents for the decrease of surface area and pore volume caused by relatively stable thiophene oligomers. The optimized regeneration condition is air atmosphere with the space velocity of 1000 h^?1 at 500°C for 1 h, and the corresponding desulfurization efficiency of regenerated TBY sample is over 96% of the fresh sample.     

Two-step steam pyrolysis of biomass for hydrogen production

In this study, different char based catalysts were evaluated in order to increase hydrogen production from the steam pyrolysis of olive pomace in two stage fixed bed reactor system. Biomass char, nickel loaded biomass char, coal char and nickel or iron loaded coal chars were used as catalyst. Acid washed biomass char was also tested to investigate the effect of inorganics in char on catalytic activity for hydrogen production. Catalysts were characterized by using Brunauer–Emmet–Teller (BET) method, X-ray diffraction (XRD) analyzer, X-ray fluorescence (XRF) and thermogravimetric analyzer (TGA). The results showed that the steam in absence of catalyst had no influence on hydrogen production. Increase in catalytic bed temperature (from 500 °C to 700 °C) enhanced hydrogen production in presence of Ni-impregnated and non-impregnated biomass char. Inherent inorganic content of char had great effect on hydrogen production. Ni based biomass char exhibited the highest catalytic activity in terms of hydrogen production. Besides, Ni and Fe based coal char had catalytic activity on H₂ production. On the other hand, the results showed that biomass char was not thermally stable under steam pyrolysis conditions. Weight loss of catalyst during steam pyrolysis could be attributed to steam gasification of biomass char itself. In contrast, properties of coal char based catalysts after steam pyrolysis process remained nearly unchanged, leading to better thermal stability than biomass char.     

Synthesis of polymer supported Ni (II)-Schiff Base complex and its usage as a catalyst in sodium borohydride hydrolysis

Influence of using as catalysis, Ni-Schiff Base complex which we previously synthesized [1] used to support with amberzyme oxirane resin (A.O.R.) polymer for increasing the catalytic activity in NaBH₄ hydrolysis reaction, to hydrogen generation was studied. The prepared catalyst was characterized by using SEM, XRD, BET, FT-IR analyze technique. Polymer supported Ni-Schiff Base complex catalyzed NaBH₄ hydrolysis reaction was investigated depending on concentration of NaBH₄, concentration of NaOH, temperature, percentage of Ni complex in total polymer supported Ni-Schiff Base complex and amount of catalyst factors. The maximum hydrogen production rate from hydrolysis of sodium borohydride with nickel-based complex catalyst compared to the pure nickel catalyst is increased from 772 mL H₂·g^?1 cat.·min^?1 to 2240 mL H₂ g^?1 cat.·min^?1 [1], and with supported amberzyme oxirane resin polymer this nickel based complex catalyst was increased to 13000 mL H₂·g^?1 cat.·min^?1 at 30 °C. The activation energy of complex catalyzed NaBH₄ hydrolysis reaction was found as 25.377 kJ/mol. This work also includes kinetic information for the hydrolysis of NaBH₄.     

Modeling and simulation of biphasic catalytic hydrogenation of a hydroformylated fuel

A model was developed based upon PR78 CEOS, Twu's alpha function and vdW mixing rules for simulating a pioneering chemical process of fuel upgrading. The chemical process of aqueous biphasic hydrogenation of a real hydroformylated fuel was experimentally conducted and simulated. The hydrogenation of the fuel occurred in aqueous media with in situ produced Ru-catalyst converting containing aldehydes to the corresponding alcohols. The above heterogenization of the homogeneous catalyst offered to the process an efficient and convenient way of catalyst recovery. The reaction temperature effect and the influence of hydrogen pressure in aqueous biphasic catalytic hydrogenation were examined. RuCl₃/TPPTS catalytic system proved to be an effective catalyst for fuel upgrading process, with the highest conversion of the aldehydes present in a hydroformylated fuel to reach 98.9% at 120 °C, 75 bar and at a short reaction time (2 h). A complete phase behavior of the fuel as well as a validation test of the simulation model were accomplished.     

Sustainable hydrogen production from steam reforming of bio-oil model compound based on carbon deposition/elimination

Steam reforming of crude bio-oil or some heavy component present in bio-oil is a great challenge for sustainable hydrogen production due to the extensive coke formation and catalyst deactivation. Catalyst regeneration will be an unavoidable operation in this process. In this paper, m-cresol (a model compound derived from bio-oil) was steam reformed on commercial Ni-based catalyst. Two conventional carbon elimination methods for coked catalyst were applied and the results showed that sustainable hydrogen production can be obtained based on carbon deposition/elimination. The carbon deposition can be gasified easily under certain temperature. The activity of regenerated catalyst samples can be nearly recovered as the fresh ones. Under the reaction conditions of 850 °C and steam to carbon ratio 5:1, >66% hydrogen mole fraction, >81% hydrogen yield, and >97% carbon conversion can be achieved based on regenerated catalyst. Catalyst characterization indicated that the loss of active metal can be considered as the main reason for tiny activity drop. Ni redispersion and Fe contamination may be another two factors that influence catalyst activity.     

Effect of phenols extraction on the behavior of Ni-spinel derived catalyst for raw bio-oil steam reforming

Alkyl-phenols and hydroxy- or methoxy-phenols (e.g., catechols, guaiacols and syringols) tend to polymerize into carbonaceous structures, causing clogging of reaction equipment and high coke deposition during bio-oil steam reforming (SR). In this work, removal of these phenolic compounds from raw bio-oil was addressed by accelerated aging and liquid-liquid extraction methods. The solvent-anti-solvent extraction with dichloromethane and water was suitable for obtaining a treated bio-oil appropriate for SR. The effect that phenols extraction has on the stability and regenerability of a NiAl₂O₄ spinel catalyst was studied by conducting reaction-regeneration cycles. Operating conditions were: 700 °C; S/C, 6; space-time, 0.15 g_catalysth/g_bio-oil (reaction step), and in situ coke combustion at 850 °C for 4 h (regeneration step). Fresh, deactivated and regenerated catalyst samples were analyzed by temperature programmed oxidation (TPO), temperature programmed reduction (TPR) and X-ray diffraction (XRD). Stability of the Ni-spinel derived catalyst was significantly improved by removing phenols due to attenuation of both coke deposition and Ni sintering. Regenerability of this catalyst was also slightly improved when reforming the treated bio-oil.