Analysis and deep hydrodesulfurization reactivity of Saudi Arabian gas oils

Gas oils obtained from Arabian Light (AL-GO), Arabian Medium (AM-GO) and Arabian Heavy (AH-GO) crude oils were subjected to detailed analysis in terms of reactive and refractory sulfur, nitrogen, as well as aromatic species. Deep hydrodesulfurization (HDS) of these gas oils over SiO₂–Al₂O₃-supported CoMo and NiMo catalysts was studied using autoclave reactor either in one- or two-stage operations. AL-GO was easily and deeply desulfurized to 15 ppm over CoMo/Al₂O₃–SiO₂ (catalyst X) at 340 °C and 5 MPa (H₂) for 2 h. At the same conditions, AM-GO and AH-GO could be desulfurized to 70 and 78 ppm, respectively. Two-staged HDS, by combining CoMo and NiMo catalysts, in successive steps resulted in effective deep HDS. The replacement of hydrogen atmosphere after the first-stage (1 h) enhanced the AH-GO HDS during the second-stage (1 h) to 9 ppm. However, replacing the hydrogen in the second-stage with 5% H₂S in hydrogen inhibited the HDS, resulting in product sulfur content of 15 ppm. Analysis of sulfur species indicate that significant fraction of reactive and refractory sulfur species were removed during the first-stage whereas the remaining refractory sulfur species were removed during the second-stage. Kinetic analysis indicates overwhelming influence of refractive sulfur species on the overall HDS. The results from this study show that two-stage scheme with optimum catalysts in series can be applied to overcome the difficulty to achieve deep HDS of AH-GO.     

Direct conversion of syngas to DME as a green fuel in a high pressure microreactor: Influence of slurry solid content on characteristics and reactivity of washcoated CuO–ZnO–Al2O3/HZSM-5 nanocatalyst

Microchannels of a stainless steel microreactor were successfully washcoated with slurry of Cu–ZnO–Al₂O₃/HZSM-5 (CZAZ) nanocatalyst with different concentrations (10, 20 and 30 wt.%). The properties of nanocatalyst and the washcoated microchannels were investigated by XRD, FESEM, N₂ physisorption, FTIR, EDX-Dot mapping and EDX-Line mapping analysis. The best adherence was observed for 20 wt.% catalyst which has a uniform coating, almost no cracks and homogenous dispersion of copper and zinc. Trend of weight gain during 10 soaks in catalyst slurry was very slow for 10 wt.% but faster for 20 and 30 wt.%. Low amount of weight gain was observed for the last soaks of catalyst slurry in the case of 30 wt.% washcoating. The performance of microreactor with different slurry concentrations were evaluated in direct synthesis of DME at 200–300 °C, 60–150 cm³/min and 40 bar. Regardless of slurry concentration, the microreactor exhibited a better reactivity in comparison to fixed-bed reactor performance. Among three different slurry concentrations, 20 wt.% catalyst slurry revealed the best reactivity in direct DME synthesis. The reduction in reactor performance at higher flow rates was significant in the fixed-bed reactor while microreactor, particularly 20 wt.% washcoated channels, revealed less drastic reduction.     

Fischer–Tropsch synthesis in slurry-phase reactors over Mn- and Zr-modified Co/SiO2 catalysts

Fischer–Tropsch (F–T) synthesis was carried out in a gas-flowed slurry-phase reaction system over Mn- and Zr-modified Co/SiO₂ catalysts. A 0.5 L stirred tank slurry reactor (STSR) was used for catalyst screening and a 12.5 L slurry bubble column reactor (SBCR) was used for trial pilot operation. While using the 0.5 L reactor for catalyst screening, Co supported on the SiO₂ with an average pore size of 10 nm showed a high catalytic performance for the F–T synthesis due to the suitable Co particle size in the catalyst. Zr promoter improved the activity and Mn promoter improved the stability of Co/SiO₂ catalyst for the F–T synthesis. H₂-TPR profiles indicated that Zr and Mn promoters improved the reduction degree of Co₃O₄ particles (on SiO₂ surface) to Co⁰ active species in H₂ flow at low temperature. While using the 12.5 L reactor for trial pilot operation over Mn–Zr–Co/SiO₂ catalyst, the space-time yield (STY) of C₅₊ hydrocarbons (liquid fuel) showed almost the same values when various solvents (n-C₁₆H₃₄, n-C₁₄H₃₀, diesel from petrol station, F–T crude oil) were used. Diesel and F–T crude oil are suitable for using in a large-scaled F–T synthesis plant owing to the low prices. Mn–Zr–Co/SiO₂ catalyst achieved a STY of C₅₊ hydrocarbons larger than 1000 g-C₅₊ kg-cat^? 1 h^? 1 in the 12.5 L reactor. The production capacity of liquid fuel from the 12.5 L reactor reached to 15.6 L per day (assumed for 24 h continuous operation). The stirring was very important for the F–T synthesis both reaction in the 0.5 L reactor and reaction in the 12.5 L reactor. The shape of slurry reactor also influenced the CO conversion for the F–T synthesis: reaction in the 12.5 L SBCR gave a higher CO conversion than that of reaction in the 0.5 L STSR (at the same W/F value under the same stirring speed) because the slender column reactor (SBCR) extended the residue time of reaction gas in the slurry-phase containing catalyst.     

Hydrogen production from steam reforming of kerosene over Ni–La and Ni–La–K/cordierite catalysts

Ni–La and Ni–La–K catalysts supported on cordierite were prepared for steam reforming of kerosene to produce hydrogen. All these catalysts were tested in a fixed-bed reactor under different conditions. The catalysts obtained under different calcination temperatures and different reaction temperatures were characterized by TG–DTG and XRD techniques respectively. The influence of NiO and La₂O₃ contents on the activity of catalysts for steam reforming of kerosene to produce hydrogen was also investigated in our experiments. The experimental results indicate that the calcination temperature has much more influence on catalyst activity. The catalyst supported the promoter 5 wt% K₂O, 25 wt% NiO and 10 wt% La₂O₃, is the optimal catalyst under 773 K of reaction temperature and 2300 h⁻¹ of space velocity. Composition of Ni is highly dispersed on the catalyst surface. And through the duration test, the catalyst activity and stability are very satisfactory at 873 K of the reaction temperature.     

Deep oxidative desulfurization of model fuel using ozone generated by dielectric barrier discharge plasma combined with ionic liquid extraction

The dielectric barrier discharge (DBD) is often used to prepare ozone. In this study, a novel room temperature oxidative desulfurization method involving ozone oxidation produced in the DBD reactor combined with ionic liquid (IL) [BMIM]CH₃COO ([BMIM]Ac) extraction was developed. The method was suitable for the deep removal of sulfur (S)-containing compounds from model fuel. By this desulfurization technology, 4,6-dimethyldibenzothiophene (4,6-DMDBT), dibenzothiophene (DBT), benzothiophene (BT) and thiophene (TS) were efficiently removed. Normally, the removal of TS and BT from fuel is highly difficult. However, using the proposed method of this study without any catalyst, the removal rate of TS and BT reached 99.9%. When TiO₂/MCM-41 was used as a catalyst, the S-removal of DBT and 4,6-DMDBT increased to 98.6 and 95.2%, respectively. The sulfur removal activity of the four sulfur compounds decreased in the order of TS > BT >> DBT > 4,6-DMDBT.     

Middle distillates from hydrocracking of FT waxes: Composition,characteristics and emission properties

A light cobalt catalyzed Fischer–Tropsch (FT) wax was subjected to hydrocracking in the range of temperature 319–351 °C and hydrogen pressure between 3.5 and 6.0 MPa. The catalyst used was platinum on amorphous silica–alumina. Hydrocracking reaction led to an increase of middle distillate yield up to 85% with a contemporary increase of iso-paraffins concentration which resulted in a remarkable improvement of cold flow properties of the products. The freezing point of C₁₀–C₁₄ fraction passed from ?23 to ?45 °C while the pour point of C₁₅–C₂₂ fraction decreased from 13 to ?23 °C. The latter fraction displayed high cetane numbers ranging between 75 and 80. Changes in carbon distribution and molecular structure of products during hydrocracking have been rationalized in the light of the accepted hydrocracking mechanism where n-paraffins undergo to consecutive isomerization reactions leading to isomers with progressively higher branching degree and concomitant cracking reaction. Experimental evidences support the view that apparent reactivity of n-paraffins is chain length dependent, increasing with the molecular weight. Detailed characterization by NMR and GC showed that branching groups abundance in the middle distillate products was the following: methyl ? ethyl > propyl.Emission tests carried out with FT diesel and commercial ultra low sulfur diesel showed that FT diesel has excellent combustion properties and leads to a reduction of emissions.     

Investigation into the effect of the intermediate carbon carrier on the catalytic activity of the HDS catalysts prepared using heteropolycompounds

The effect of the intermediate activated carbon covering the alumina carrier on catalytic activity of the supported transition metal sulfides (TMS) prepared from heteropolycompounds (HPCs) in thiophene hydrodesulfurization (HDS), benzene hydrogenation (HYD) and hydrotreating (including HDS of S-containing and HYD of polyaromatic compounds) of diesel oil fractions was investigated. Carbon content on the alumina carrier varied from 0 to 3.8 wt.%. It was found that the structure of carbon coating the alumina surface changes depending on the presence/absence of the active phase on the intermediate activated carbon. Total catalytic activity of the catalysts in HDS and HYD reactions was maximal for carbon content of 1–2 wt.% and fell down for catalysts with 3.8 wt.% of carbon. The specific catalytic activity grew proportionally to the carbon content on the catalyst. The experimental data showed that a rise of the reaction temperature leads to a decrease in the amount of adsorbed hydrogen whose deficiency limits the formation of H₂S. It was supposed that the intermediate carbon placed between the alumina carrier and the active phase accumulates hydrogen inside carbon pores. Besides, the intermediate C-carrier of the catalysts synthesized from Co(Ni) salts of heteropolycompounds promotes rising of stacking number in nanoslabs of the active CoMoS phase of the second type.     

Influence of reduction temperature and metal loading on the performance of molybdenum phosphide catalysts for dibenzothiophene hydrodesulfurization

Two series of alumina-supported molybdenum phosphide (MoP) catalysts with low and high metal loadings were prepared by temperature-programmed reduction of the oxidic catalyst precursors in hydrogen to different temperatures (823, 923, 1023 and 1123 K, respectively). Effects of reduction temperature and metal loading on the surface distribution and the type of species formed were studied by TPR, S_BET, XRD, HRTEM, ³¹P NMR, ²⁷Al NMR and in the reaction of dibenzothiophene (DBT) hydrodesulfurization (HDS) performed in a flow reactor at 553 K and total hydrogen pressure of 3.4 MPa. HRTEM and ³¹P NMR confirmed formation of MoP phase on all catalysts. The 9.9 wt% Mo catalyst activated at lowest reduction temperature (823 K) was found to be most active among the catalysts studied. The presence of a low amount of Mo⁰ species on the surface of this catalyst does not appear to be a drawback for the catalytic activity. The increase in both metal loading (from 9.9 to 15 wt% Mo and from 3.2 to 4.8 wt% P) and reduction temperature (from 823 to 1123 K) was found to be detrimental for HDS activity due to sintering of active phase, and also to decrease in specific area and formation of phosphate species.     

Kinetic behavior of hydrogenation of aromatics in diesel fuel over silica–alumina-supported bimetallic Pt–Pd catalyst

The kinetics and long-term stability test of the aromatic hydrogenation of diesel fuel were studied on SiO₂–Al₂O₃ supported bimetallic Pt–Pd catalyst. The tests on the influence of operating parameters and kinetics studies were carried out using Pt (0.5 wt.%)–Pd (1.0 wt.%)/SiO₂–Al₂O₃, which provided the highest catalytic activity in a previous paper [Applied Catalysis A: General, 192 (2000) 253] with hydrotreated light cycle oil (LCO)/straight-run light gas oil (SRLGO) feedstocks containing 30 vol.% aromatics/100 wppm sulfur and 34 vol.% aromatics/420 wppm sulfur under numerous conditions. The results on this catalyst obtained at different LHSV showed an excellent fit to first-order kinetics. The apparent activation energy was determined to be 92 kJ/mol. Long-term stability test demonstrated the excellent stability of this catalyst. The products during the long-term stability test are of good quality, with the upgraded color, the increased cetane index, and sufficiently decreased sulfur content.     

Two-step adsorption process for deep desulfurization of diesel oil

An integrated adsorption process for deep desulfurization of diesel fuel was proposed and examined. Conventionally hydrodesulfurized straight run gas oil (HDS-SRGO) having less than 50 ppm sulfur was also adsorptively treated with activated carbon fiber (ACF) to attain the ultra low sulfur gas oil having less than 10 ppm sulfur. The ACF, used in cleaning-up HDS-SRGO, was successively examined in straight run gas oil (SRGO) treatment to enhance its hydrodesulfurization (HDS) reactivity over conventional CoMo catalyst by removing the nitrogen and refractory sulfur species contained in SRGO. Such integrated adsorption–reaction process makes it possible to utilize the maximum adsorption capacity of ACF and achieve ultra deep desulfurization og SRGO. Regeneration of used ACF with a conventional solvent was proved very effective in restoring its adsorption capacity.     

A wall-coated catalytic capillary microreactor for the direct formation of hydrogen peroxide

The direct formation of hydrogen peroxide from H₂ and O₂ was successfully carried out in a capillary microreactor at room temperature and atmospheric pressure. A key element in sustaining the activity of the catalyst is the incarceration of the palladium nanoparticles in a cross-linkable amphiphilic polystyrene-based polymer, prepared following the protocol of Kobayashi [R. Akiyama, S. Kobayashi, J. Am. Chem. Soc. 125 (2003) 3412–3413]. The immobilization effectively reduced the leaching of palladium under acidic conditions. Applying the catalyst as a coating on the inner walls of a capillary enabled the sustained production of 1.1% hydrogen peroxide over at least 11 days. The highest catalyst utilization in a 2 mm capillary reactor was 0.54 mol_H2O2/h g_Pd. When the inner diameter of the reactor capillary was reduced to 530 μm, the rate was enhanced fourfold to 2.28 mol_H2O2/h g_Pd corresponding to a turnover frequency of 0.067 s^?1.     

Kinetic study of CO hydrogenation over co-precipitated iron–nickel catalyst

The kinetic of the Fischer–Tropsch synthesis over a Fe–Ni/Al₂O₃ catalyst was investigated in a fixed bed micro reactor. Experimental conditions were varied as follow: reaction pressure 2–10 bar, H₂/CO feed ratio of 2/1 and space velocity of 96–450 cm³(STP)/h/gram_catalyst at the temperature range 523–573 K. On the basis of carbide-enol mechanism and Langmuir–Hinshelwood–Hougen–Watson (LHHW) type rate equations, seventeen kinetic expressions for CO consumption were tested and interaction between adsorption HCO and dissociated adsorption hydrogen as the controlling step gave the most plausible kinetic model. The activation energy was 46.5 kJ/mole for optimal kinetic model.     

Ultra-deep oxidative desulfurization of diesel fuel by the Mo/Al2O3-H2O2 system: The effect of system parameters on catalytic activity

This work presents the results obtained in the development of Mo/γ-Al₂O₃ catalysts and their evaluation in the oxidative desulfurization (OD) process of diesel fuel using hydrogen peroxide as the oxidizing reagent. The catalysts were prepared by equilibrium adsorption using several molybdenum precursors and aluminas with different acidity values. They were characterized by Raman spectroscopy. The effect of the reaction time, reaction temperature, nature of solvent, concentration of solvent and hydrogen peroxide, content of molybdenum and phosphate in the catalysts were investigated. The results showed that the activity for sulfur elimination depends mainly on the presence of hepta- and octamolybdates species on the catalyst support and the use of a polar aprotic solvent. Likewise, the presence of phosphate markedly increases the sulfur elimination. In this way, it is possible to reduce sulfur level in diesel fuel from about 320 to less than 10 ppmw at 333 K and atmospheric pressure. Additionally, on the basis of the results obtained a mechanistic proposal for this reaction is described, as an oxidation mechanism by nucleophilic attack of the sulfur atom on peroxo species of hepta- and octamolybdates, but a mechanism involving the singlet oxygen presence can be discarded.     

Low-pressure DME synthesis with Cu-based hybrid catalysts using temperature-gradient reactor

Dimethyl ether (DME), the target product of this study, has many advantages as diesel fuel. The aim of this study is to develop a catalytic process in which 90% CO conversion to DME and CO₂ from syngas (3CO+3H₂→DME+CO₂) is attained at 1–3 MPa. In such a process, both recycling loop and compression of syngas can be omitted resulting in an economic process based on unused, dispersed and small-scale carbon resources. To overcome the equilibrium conversion limit we designed temperature-gradient reactor (TGR). In TGR, the temperature of the catalyst bed decreases along with the down flow of reaction gas. The performance of the catalyst in TGR was much higher than that in a conventional isothermal fixed bed reactor. For example, 90% CO conversion and high STY (1.1 kg MeOH eqiv./kg cat./h) was attained at the same time in TGR at 550–510 K, 3 MPa.     

Kinetics of reductive alkylations of phenylenediamines: Influence of substrates isomeric structure

Reductive alkylation of ortho-, meta- and para-phenylenediamines (PDAs) with methyl ethyl ketone (MEK) has been studied in a semi-batch slurry reactor in the presence of a commercial 3% Pt/Al₂O₃ catalyst. It was observed that the PDA isomers differ remarkably from each other in their activity in reductive alkylation and product distribution. The activity was found to decrease in the following order: PPDA>OPDA>MPDA. To understand the substrate structure–activity correlation, the homogeneous equilibrium reactions involved in the alkylation step and the overall catalytic reactions were studied separately. Kinetics of reductive alkylation of PDAs with MEK as a solvent and alkylating agent with 3% Pt/Al₂O₃ catalyst was studied in a semi-batch slurry reactor over a temperature range of 373–453 K and pressure range of 2.07–6.21 MPa. Semi-batch slurry reactor models were developed and kinetic parameters were estimated by fitting the integral batch reactor data at different temperatures to understand the influence of different reaction steps on the activity and selectivity of different products.     

Photocatalytic degradation of phenol in a rotating annular reactor

Batch photocatalytic degradation studies of phenol were conducted in an annular slurry reactor, to evaluate its performance under different operating and design conditions. The reactor had two concentric cylinders with the inner one rotating at specified revolutions per minute. The reactor also had provisions for aerating the slurry present in the annular gap. The inner cylinder housed the UV-lamps. The effects of catalyst loading (0–8 g/L), inner cylinder rotation speed (0–50 rpm), annular gap-width (7.5, 17.5 and 32.5 mm), initial pollutant concentration (10–50 mg/L) and mode of illumination (continuous or periodic) were studied. Light intensity received by the slurry was measured using Actinometry. Depending on the catalyst loading, annular gap-width and number of illuminated lamps the intensity values ranged from 0.58×10^?4 to 6.4×10^?4 Einsteins/L min. Under well mixed conditions, the reactor performance was found to increase with increase in catalyst loading. At low/medium annular gap width configurations, agitation induced by continuous aeration was found to provide sufficient mixing even when the inner cylinder was stationary. Rotation of the inner cylinder was required only in the high gap width configuration at high catalyst loadings. Scale-up of the reactor was investigated by increasing the gap-width of the annulus and hence increasing the quantity of feed processed. Controlled periodic illumination created by Taylor vortices did not show any improved performance over the regular continuous illumination. Modeling of reaction kinetics was investigated with different approaches and their efficacy in fitting the concentration–time trends of both the primary pollutant and the intermediates are discussed.     

Photocatalytic activity of Cu2O supported on multi layers graphene for CO2 reduction by water under batch and continuous flow

The photocatalytic activity of Cu₂O supported on multi-layers graphene for CO₂ reduction by water was studied under two hydrodynamic environments, in a slurry batch reactor and in a capillary reactor with the catalyst immobilized on the wall. Under both conditions, the major photoproduct was hydrogen observed in the gas phase, accompanied by lesser amounts of ethanol present in the aqueous solution. The maximum production rates were 2031 and 545 μmol g^− 1 h^− 1 for H₂ and CH₃CH₂OH, respectively, and were found under the hydrodynamic mode attained in the capillary reactor.     

Method of catalyst coating in micro-reactors for methanol steam reforming

Micro-channels of silicon-based micro-reactors were successfully coated with deionized (DI) water-based Cu–ZnO–Al₂O₃ catalyst slurry by a fill-and-dry coating method, applicable to pre-assembled micro-reactors, for steam reforming of methanol. The 10–20 μm thick catalyst layers could be formed on the inner walls of the micro-channels after the micro-channels were fully filled with catalyst slurry, because the catalyst particles in the slurry cohered to the walls of micro-channels by surface tension during drying and calcinations. The adhesion between the catalyst layer and silicon surface was improved by pre-coating the micro-channels with an alumina adhesion layer. The addition of polyvinyl alcohol (PVA) in the alumina sol resulted in better adhesion of the alumina layer at the corners of the channels. The critical minimum thickness of the alumina layer for catalyst coating was 0.15 μm. The highest catalytic activity without loss of intrinsic catalytic activity was obtained using 1:5 (catalyst to solvent) DI water-based catalyst layers coated by fill-and-dry coating. The maximum H₂ production rate was 85 ccm with 1650 ppm of CO measured at 300 °C using a methanol feed rate of 9 ml/h.     

Phosphorus-containing activated carbon as acid support in a bifunctional Pt–Pd catalyst for tire oil hydrocracking

A bifunctional Pt–Pd catalyst supported on phosphorus-containing activated carbon has been prepared, characterized and tested in the hydrocracking of a hydrotreated tire pyrolysis oil. The product has a very interesting composition: 48–78 wt% naphtha and 19–42 wt% diesel fractions, with moderate amounts of aromatics (< 40 wt%) and sulfur (< 250 ppm). The challenge was to prepare a stable, porous, selective and acid carbonaceous catalyst from a waste (olive stone), which has been confirmed from the catalytic properties and product distribution point of view. In fact, phosphate groups in the activated carbon are stable hydrocracking sites, with comparable performance to that of the acid sites present in amorphous SiO₂–Al₂O₃.