Effect of phosphorus on activity of hydrotreating catalyst of Maya heavy crude

The effect of phosphorus on physical properties of the catalyst and on activity of hydrotreating of Maya crude was studied in this work. Catalysts were prepared by the co-impregnation method. Alumina-titania binary oxide was used as a support material. The presence of phosphorus in the catalyst decreases the percentage of micropores, and it results in a decrease of specific surface area. Temperature program reduction (TPR) shows that phosphates reduce metal support interaction. It leads to the formation of polymolybdate phases in expense of strongly bonded tetrahedral molybdates. At higher P loading, polymolybdates may be present with quasi crystalline MoO₃. However, the TPR experiment is not sufficiently sensitive to distinguish several phases present on the catalysts used by the authors. A slight increment of HDM activity is observed, but HDS activity is lower in the P containing catalyst compared with the P free catalyst. The changes of physical properties of the spent catalysts are mainly due to the coke formation on the catalyst. The presence of phosphorus on hydrotreating catalysts inhibits coke formation during the hydrotreating reaction.     

Study of accelerated deactivation of hydrotreating catalysts by vanadium impregnation method

The main causes of catalysts deactivation for hydrotreating are coking and metals deposition. In this present work, accelerated deactivation of hydrotreating catalysts was studied. In this respect, vanadium which is deposited with nickel during hydrotreating reaction was impregnated into the fresh hydrotreating catalyst. Different percentage of vanadium was impregnated and their hydrodemetalization (HDM) and hydrodesulfurization (HDS) activities were studied in bench-scale reactor of heavy crude oil. Accelerated deactivations for both HDM and HDS were observed on vanadium impregnated catalysts. The rate of HDS deactivation was faster than that of HDM reaction. The rapid deactivation of HDS may be due to the coverage of active sites by impregnated vanadium atom. The deactivation is slower when the V loading is low; but above 10 wt% loading a rapid deactivation is observed. A comparison of deactivation is made in between normal deactivation and the deactivation by vanadium impregnation. It was found that deactivation by vanadium impregnation is lower than that of normal deactivation. It suggests that at initial stage the formation of coke causes deactivation of the catalyst whereas at later stage when metals sulfides deposition is quite high, these sulfides take part in deactivation.     

Effects of organic nitrogen compounds on hydrotreating and hydrocracking reactions

A major issue encountered in hydrotreating and hydrocracking reactions, as in many others fixed bed catalytic processes, is the decrease of catalytic activity with time on stream. The organic nitrogen compounds act as temporary poisons in hydroprocessing catalysts besides being coke precursors. The inhibiting effects of nitrogen compounds present in crude oil have been studied on SRGO hydrotreating reactions and VGO hydrocracking reactions. The results show that selective removal of nitrogen by adsorption using silica and alumina in varying proportions, would not only increase the HDS catalyst activity by more than 60%, but would also reduce hydrogen consumption. This step of nitrogen removal can be installed additionally in the upstream of an existing SRGO HDS reactor to achieve higher desulphurization or can be designed with the grass roots units.

The inhibition effects of nitrogen on VGO hydrocracking have been studied at different temperatures and the reaction has been found to be highly non-linear in nature and the conversion rapidly drops and the slope becomes less steep as the nitrogen level increases. At higher reaction temperature, the drop in activity or conversion with feed nitrogen is less than that in lower temperatures due to the higher rate of desorption of nitrogen compounds at elevated temperatures. The drop in conversion with nitrogen compounds present in VGO indicates the presence of organo nitrogen compounds having higher basicity compared to the nitrogen compounds by pyridine doping. The hysteresis exists in adsorption/desorption of nitrogen compounds and it indicates that desorption is a very slow process. With the increase of nitrogen compounds in the feed, the conversion drops rapidly and it takes long time to reach an equilibrium value. Similarly, with the step increase in reactor temperature, nitrogen desorption takes place at a slow rate and the conversion level comes to an equilibrium value after 8 days.

The observed effects of nitrogen inhibition on SRGO hydrotreating and VGO hydrocracking conversion are explained reasonably well by kinetic models.     

Support effects in the hydrotreatment of model molecules

The support effect on the activity of hydrotreating catalysts using model molecules was analyzed for catalysts supported on TiO₂, SiO₂ and MgO. The results reported in the literature indicate that adequate design of the characteristics of the catalytic support is of great importance in the development of better hydrotreating catalysts. It was shown that by means of an adequate support design it is possible to increase significantly the HDS, HYD and HDN functionalities of hydrotreating catalysts. Semiconducting supports like TiO₂ can improve the HDS and HYD activities by exerting electronic effects on the active phase, helping in this way the formation of sulfur vacancies. Alumina supports modified by SiO₂ can facilitate the sulfidation of the active species, leading to better-promoted type II active sites with increased HDS and HYD catalyst functionalities. The nature of the support affects the sulfidation and dispersion of the catalysts even when chelating agents are used during catalyst preparation.     

Alumina-silica binary mixed oxide used as support of catalysts for hydrotreating of Maya heavy crude

Alumina-silica binary mixed oxide support is used to prepare catalysts for hydrotreating of Maya heavy crude. Support is prepared by urea hydrolysis. Sequential incipient wetness and co-impregnation techniques are employed for preparation of catalysts. Ammonium heptamolybdenum is used as precursor of MoO₃. Catalysts are characterized by X-ray diffraction (XRD), temperature-programmed reduction (TPR) and the pore size distribution. Hydrodemetallation (HDM), hydrodesulfurization (HDS), hydrodenitrogenation (HDN), and asphaltene conversion (HDAsp) reactions are studied on these catalysts. One reference catalyst is also taken for comparison. Coke and metals depositions on spent catalysts are measured. The catalyst deactivation rate is also studied. The X-ray diffraction (XRD) results reveal that molybdenum atoms are well dispersed into CoMo catalyst, whereas MoO₃ crystalline phases are found in PCoMo and PNiMo catalysts. TPR reduction profiles are different for different catalysts. The laboratory made catalyst is reduced at one temperature, whereas the reference catalyst shows two reduction profiles. The reference catalyst shows the highest activities among four catalysts. The highest HDM and HDAsp activities of the reference catalyst may be due to its bigger pore diameter. The presence of TiO₂ in the reference catalyst enhances HDS and HDN activities. The CoMo catalyst shows higher activities than those of PCoMo and PNiMo catalysts. The presence of crystalline MoO₃ causes for lower activities of catalysts PCoMo and PNiMo.     

Cumene hydrocracking and thiophene HDS on niobia-supported Ni, Mo and Ni–Mo catalysts

Results are reported on the XPS characterization and catalytic activity in cumene hydrocracking (2.8 MPa, 623 K) and thiophene HDS (2.8 MPa, 523–573 K) of sulfided Ni, Mo and Ni–Mo catalysts supported on alumina and on pure and phosphated niobia. From the XPS results, evidence was obtained for the formation of a surface niobium sulfide with stoichiometry close to NbS₂ during catalyst sulfidation. Sintering of supported nickel during sulfidation occurred to a much smaller extent with the niobia-supported catalysts than with the alumina-supported ones. The dispersion of alumina-supported molybdenum was little influenced by sulfidation, whereas, with the niobia supports, the molybdenum surface concentration increased with sulfidation. With the alumina support, the Ni–Mo combination caused the dispersion of the sulfided nickel to be improved, possibly due to formation of a NiMoS phase. This was not observed with the niobia-supported catalysts.

Reasonable linear correlations were also found between the intrinsic activity for cumene hydrocracking and the amount of sulfided niobium in the catalysts, but the catalysts supported on phosphated niobia had a higher intrinsic activity than the ones supported on pure niobia. In thiophene HDS, the activity of the niobia-supported nickel catalysts was much larger than the activity of the alumina-supported ones. The activity of the niobia-supported molybdenum catalysts was smaller than that of the alumina-supported catalyst. With the bimetallic catalysts, little or no synergy was observed with the niobia-supported catalysts, in sharp contrast with the alumina case.     

FF-46再生催化剂在航煤加氢装置中的应用

FF-46是抚顺石油化工研究院开发的高活性加氢处理催化剂,该催化剂具有较高的脱硫、脱氮活性,工业运转后的催化剂经再生后同样具有较好的活性。主要介绍FF-46再生催化剂在扬子石化航煤加氢装置的使用情况。从催化剂选型、装填、活化、航煤初期生产情况、经济效益等几个方面做出了分析,证明FF-46再生催化剂可用于航煤加氢装置,在航煤产品质量达到国标要求的前提下,既使FF-46再生催化剂得到充分合理利用,又大幅度节省新催化剂采购费用,并拓宽了加氢裂化预处理催化剂再生后的使用范围。     

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.     

NiMo/Al2O3加氢精制催化剂上操作变量对HDN和HDS反应性能的影响

Using the JQ-Ⅱ high pressure hydrogenation micro-reactor unit, the reactivity of Athabasca bitumen derived heavy gas oil was studied over commercial and homemade hydrotreating catalysts. The effects of catalyst preparation variables and the influences of operation conditions, such as pressure, temperature, hydrogen/oil ratio and space velocity were also examined. It was shown that the optimal concentrations of the active components were 5% of NiO, 20% of MoO3 and 3.5% of phosphorus (by mass), and the suitable operation conditions were determined experimentally.     

Rey-zeolite and silica-alumina mixed support for hydrotreating heavy gas oil

Rare earth exchanged Y-type zeolite (REY-zeolite) was dispersed in a silica-alumina gel to prepare catalyst supports with better hydrogenolysis activity. Such support material showed improved hydrotreating properties compared to commercial catalysts, especially for heavy gas oils. Statistical experimental designs used to optimize the composition of such mixed supports suggested a composition of 10 wt.% silica, 25 wt.% zeolite and 65 wt.% alumina as optimum for hydrotreating a heavy gas oil (343°C to 525°C fraction) obtained from hydrocracking of Athabasca bitumen. The kinetic parameters were then evolved for the optimum catalyst.     

Catalytic Activity of Exfoliated MoS2 in Hydrodesulfurization, Hydrodenitrogenation and Hydrogenation Reactions

The activity of exfoliated MoS₂ in the hydrodesulfurization (HDS) of dibenzothiophene, the hydrodenitrogenation (HDN) of carbazole and the hydrogenation of naphthalene has been determined. The catalytic activity was compared to MoS₂ prepared by the decomposition of molybdenum naphthenate (MoNaph). Exfoliated MoS₂ was found to give better overall HDS activity compared to MoNaph derived MoS₂ catalyst, whereas MoNaph derived MoS₂ was found to give higher hydrogenation and HDN activity. These results are discussed in terms of the morphology of the two catalysts. The relative activity of the two catalysts in the hydrotreating reactions is shown to be different to that obtained during Cold Lake bitumen hydrocracking.     

A review of recent advances on process technologies for upgrading of heavy oils and residua

The term hydroconversion is used to signify processes by which molecules in petroleum feedstocks are split or saturated with hydrogen gas while tumbling boiling ranges and impurities content from petroleum fractions. Hydroprocessing is a broad term that includes hydrocracking, hydrotreating, and hydrorefining. To meet the gradual changes in petroleum stipulate, in particular a reduced demand for heavy fuel oil, advanced technologies for residue hydroprocessing are now extremely necessary. A refining process is needed for treating heavy petroleum fractions (atmospheric or vacuum oil residue) in the presence of catalysts and hydrogen at high pressure. In this article the different technologies for residua processing: thermal, catalytic fixed and ebullated types of hydroconversion are reviewed and discussed. A possibility of combining the advantages of these technologies together with suitable catalyst with enhanced and controlled cracking activity is also analyzed.     

Hydrodesulfurization of dibenzothiophene over alumina-supported nickel molybdenum phosphide catalysts

The activity of nickel molybdenum phosphide catalysts was studied for the hydrodesulfurization of dibenzothiophene at 573 K and total pressure of 2.0 MPa. The Al₂O₃-supported NiMo phosphide catalysts were prepared by successive and simultaneous methods. The effect of the reduction temperature on the catalyst activity was also studied. The simultaneous preparation was determined to be the best method for the preparation of the active supported catalyst for dibenzothiophene HDS. The 623 K-reduced catalyst had the highest HDS rate of the catalysts. Nickel migrated from the inside to the surface during the reaction and promoted the HDS activity. The active species in the dibenzothiophene HDS and the oxidation states of Mo, Ni and P in the catalyst before and after reaction and of S after the reaction were studied on the basis of an XPS analysis.     

Preparation of heavy oil hydrotreating catalyst from spent residue hydroprocessing catalysts

In recent years, increasing emphasis has been placed on recycling spent hydroprocessing catalysts due to environmental regulations which list them as hazardous waste materials. In the present work, the recycling of spent residue hydroprocessing catalysts that contained high levels of vanadium was investigated by using them in the preparation of active new hydrotreating catalyst after subjecting them to different treatments such as decoking, acid-leaching and hydrothermal treatment. Catalyst extrudates containing different levels of V, Mo and Ni on Al₂O₃ were prepared by mixing the spent catalyst powder with boehmite in different proportions followed by peptization, kneading and extrusion. The prepared catalyst extrudates were characterized by chemical analysis and surface area and porosity measurements. The HDS and HDM activities of the catalysts were tested using Kuwait atmospheric residue as feed and compared with that of a reference HDM catalyst. Partial leaching of vanadium from the spent catalyst opened up the pores, and the catalyst prepared by mixing the metal-leached spent catalyst (MLSC) with boehmite had higher surface area and pore volume and showed higher hydrotreating activity than that prepared from unleached spent catalyst. Hydrothermal treatment of the spent catalyst increased its porosity and surface area. Catalysts prepared from hydrothermally treated spent catalyst (HTSC) had higher surface area and pore volume and showed higher HDM and HDS activities than that prepared from the spent catalyst without hydrothermal treatment. The catalysts prepared from the treated spent catalysts also exhibited substantially higher HDM and HDS activities than the reference commercial HDM catalyst. The results indicate that spent catalysts containing high levels of vanadium together with Mo and Ni on Al₂O₃ can be used in the preparation of active HDM/HDS catalysts, and thereby, their environmental problem can be reduced.     

Hydrocracking of heavy oil using zeolites Y/Al-SBA-15 composites as catalyst supports

A series of Y/Al-SBA-15 composites were prepared by a two-step synthesis procedure in mild acidic medium. The materials were characterized by powder X-ray diffraction (XRD), N₂ sorption isotherms and TEM techniques. Catalytic cracking of cumene and 1,3,5-tri-isopropylbenzene was carried out as the probing reactions on these composites. The XRD results showed that these materials are composites of Al-SBA-15 and Y zeolite. N₂ sorption isotherms and TEM displayed that these composites were abundant in micropores and mesopores. At the same time, the mesopores may communicate with the␣micropores in some domains, which may result in the high catalytic activities of Y/Al-SBA-15 composites for the␣cracking of both small-molecule (cumene) and large-molecule (1,3,5-tri-isopropylbenzene) hydrocarbons. The existence of mesopores may also make the acid sites easily accessible for reactants. Catalysts of W–Ni supported on Y/Al-SBA-15 and modified Y zeolites with mesopores were prepared by impregnation method, and the hydrocracking of heavy oil was performed on these catalysts. The catalyst using zeolite Y/mesoporous Al-SBA-15 composites as support gave higher yield of diesel compared to the catalysts using modified zeolite Y as support. In addition, the higher aromatics potential of heavy naphtha and the significantly lower BMCI (U.S. Bureau of Correlation Index) of tail oil revealed Y/Al-SBA-15 composite catalyst possessed integrated performance in the hydrocracking of heavy oil. These results proved that the combination of Y zeolites and mesoporous Al-SBA-15 plays a great role in improving the performance of catalysts for hydrocracking heavy oils.     

Performance of CoMoS catalysts supported on nanoporous carbon in the hydrodesulfurization of dibenzothiophene and 4,6-dimethyldibenzothiophene

A new type of nanoporous carbon with a large surface area and mesoporosity was prepared and used as a support for a hydrodesulfurization (HDS) catalyst. The overall activity of CoMoS catalysts for the HDS of dibenzothiophene (DBT) and 4,6-dimethyldibenzothiophene (4,6-DMDBT) is affected by the type of support used for preparing the catalyst and decreases in the order of CoMo/(nanoporous carbon)>CoMo/(activated carbon)>CoMo/Al₂O₃. The surface area of activated carbon is the largest among these three types of supports but is significantly lowered after metal loading during the preparation of the catalyst. On the other hand, the surface areas of the other two supports are largely preserved after metal loading. The intrinsic activity of the catalysts, estimated by dividing the overall HDS rate by the amount of NO adsorbed on the catalyst, shows a trend that is different from that for the overall activity, and follows the order of CoMo/(nanoporous carbon)≈CoMo/Al₂O₃>CoMo/(activated carbon). The low intrinsic activity of CoMo/(activated carbon) compared to that of the other two catalysts, particularly in the case of 4,6-DMDBT HDS, is obtained because the diffusion of reactants into the catalyst pores is significantly limited. This is not observed with other catalysts supported on nanoporous carbon and alumina. From the results of this study, we conclude that nanoporous carbon is a promising support for HDS catalysts, compared to conventional supports such as alumina and activated carbon, because it has a large surface area and a high mesoporosity, both of which are beneficial to the preparation of highly dispersed metal catalysts without significant pore blocking due to the dispersed metal particles.     

国外石油炼制催化剂的技术进展

以国外炼油催化剂生产具有代表性的大公司推荐的新产品为例,综述了催化裂化、加氢精制、加氢处理、加氢裂化和催化重整五类石油炼制催化剂的技术发展近况,并列举了部分应用实例。同时介绍了石油炼制催化新材料研制的进展情况,并分析了其应用前景。     

Studies on recycling and utilization of spent catalysts: Preparation of active hydrodemetallization catalyst compositions from spent residue hydroprocessing catalysts

Spent catalysts form a major source of solid wastes in the petroleum refining industries. Due to environmental concerns, increasing emphasis has been placed on the development of recycling processes for the waste catalyst materials as much as possible. In the present study the potential reuse of spent catalysts in the preparation of active new catalysts for residual oil hydrotreating was examined. A series of catalysts were prepared by mixing and extruding spent residue hydroprocessing catalysts that contained C, V, Mo, Ni and Al₂O₃ with boehmite in different proportions. All prepared catalysts were characterized by chemical analysis and by surface area, pore volume, pore size and crushing strength measurements. The hydrodesulfurization (HDS) and hydrodemetallization (HDM) activities of the catalysts were evaluated by testing in a high pressure fixed-bed microreactor unit using Kuwait atmospheric residue as feed. A commercial HDM catalyst was also tested under similar operating conditions and their HDS and HDM activities were compared with that of the prepared catalysts. The results revealed that catalyst prepared with addition of up to 40 wt% spent catalyst to boehmite had fairly high surface area and pore volume together with large pores. The catalyst prepared by mixing and extruding about 40 wt% spent catalyst with boehmite was relatively more active for promoting HDM and HDS reactions than a reference commercial HDM catalyst. The formation of some kind of new active sites from the metals (V, Mo and Ni) present in the spent catalyst is suggested to be responsible for the high HDM activity of the prepared catalyst.     

Ni2P催化剂的制备及其在加氢脱硫的研究进展

现在油品重质化越来越严重,为了满足环境保护局和人们的要求,对油品加氢脱硫已是一项急迫的任务。过渡金属磷化物具有优异的加氢脱硫活性和稳定性,尤其是Ni2P催化剂,将成为催化材料领域研究的热点。本文综述了Ni2P催化剂制备方法和加氢脱硫活性。Ni2P催化剂有望成为继硫化物、碳化物催化剂之后的又一代深度加氢脱硫催化剂。     

低温费托合成蜡油加氢裂化精制技术的研究进展

低温费托合成技术因具有产品质量性好、反应耗能低、生产能力大且催化剂种类广泛等优点在煤化工领域备受关注,低温费托合成的蜡油产品可通过加氢裂化精制获取高品质清洁油品,具有巨大的应用价值。本文首先阐述了费托合成的产物特性,分析了加氢裂化过程的反应特点、双功能催化剂的碳正离子反应机理及蜡油主要反应历程。在此基础上,着重综述了蜡油加氢裂化双功能催化剂的研究进展,讨论了活性金属组分、载体以及助剂对加氢裂化过程的影响,分析表明活性金属的负载量、载体的酸量和孔道结构对催化性能有极大影响,合理优化和平衡加氢金属活性位和裂解酸性位是确保蜡油加氢裂化催化剂活性的关键。更为重要的是,基于分子筛载体的择形效应,实现载体多级孔结构和活性位的理性集成无疑会促进蜡油加氢产物的合理分布。