Effects of dispersed MoS2 catalysts and reaction conditions on slurry phase hydrocracking of vacuum residue

Recovery of valuable metals from spent hydrodesulfurization (HDS) catalysts: A comprehensive research review and specific industrial cases

Spent hydrodesulfurization (HDS) catalysts, produced in the petroleum refining process, are usually classified in hazardous solid waste. Recovery of valuable metals from spent HDS catalyst not only reduce substantially environmental risk but is an important way to alleviate global resource shortages for high-valuable metals. This study reviews numerous references regarding to recovery valuable metals from spent HDS catalyst in last decades, and divided current methods into three processes: pretreatment, oxidation-leaching, and separation-purification processes. Roasting and solvent washing usually emerge as primary methods in the pretreatment process, and effectively eliminate the surface oily substances and sulfur. Sodium salt roasting-leaching are considered as higher efficient among all leaching methods. The application of organic acid in the leaching can separate valuable metals selectively and simplify subsequent purification steps. In separation-purification processes, solvent extraction is still a standout method to isolate challenging metals such as Mo, W and V. However, the burgeoning field of ion imprinting technology exhibits the promising potential. Additionally, Random Forest and XGBoost model are used to analyze reported methods to recovery Mo and Ni and predict the key factor to regulate recovery efficiency. The results show that Mo recovery process is depended on the spent HDS characteristics and solid-liquid ratio in leaching process, while Ni recovery processes is depended on the roasting time and roasting temperature. Finally, serval specific industrial cases on recycling valuable metals from spent HDS were given, and found that sodium salt roasting-water leaching process was still frequent used in practical application due to its characteristics of high efficiency and low cost.

Stability of MoS2 Nanocatalysts for the Slurry-Phase Catalytic Hydrogenation of Anthracene

The stability of both the structure and activity of MoS2 nanocatalysts is crucial for minimizing the catalyst cost of the slurry-phase (SP) catalytic hydrogenation. MoS2-GP and MoS2-SP catalysts were, respectively, obtained by gas-phase (denoted as GP) and SP aging of fresh MoS2 catalysts. The MoS2-SP catalyst demonstrated a comparable catalytic hydrogenation activity to that of the fresh MoS2 catalyst, which is about 1.7 times of that for the MoS2-GP catalyst. After 12 cycles of the MoS2-SP catalyst, the obtained Cy12 catalyst demonstrates a retention of 92.0% of its initial catalytic activity. The MoS2-SP catalyst exhibits an impressive stability of catalytic hydrogenation. The MoS2-SP catalyst exhibits average stacking layers of 3.3 and an average slab of 5.2 nm and exposes 14.0% of active sites. The MoS2-SP catalyst can serve as a highly active and stable catalyst for catalytic hydrogenation. This finding can offer valuable insights into the stability of the hydrogenation catalyst in SP hydrogenation technology.

High-efficiency recycling of Mo and Ni from spent HDS catalysts: Enhanced oxidation with O2-rich roasting and selective separation with organic acid leaching- complexation extraction

Spent petroleum refining catalyst is regarded as the important secondary resource for valuable metals. However, common recycling strategies, including soda roasting, acid and alkaline solutions leaching and chemically precipitation, produced large quantities of high salinity wastewater. This study proposed an efficient method to recovery of Mo and Ni from the spent hydrodesulfurization (HDS) catalyst via O2-rich roasting and organic acid leaching with the advantage of less salinity wastewater production. The transformation of Mo(IV) into soluble Mo(VI) was enhanced by O2-rich atmosphere roasting, and 98.64% of Mo(IV) was oxidized at 650 ℃ for 2 h in atmosphere containing 30% of O2. The oxidation process of Mo(IV) was agreed with the shrinkage pore model, and regulated by surface reaction and internal diffusion. 97.97% of Mo(VI) was leached from roasted product by oxalic acid, separated with complexation extraction agent of Ala-TBP and recovered as (NH4)8Mo10O34 and (NH4)2Mo3O10 by evaporative crystallization. Ni was leached out from spent catalyst with 1 mol/L acetic acid, and precipitated as NiC2O4 with oxalic acid. 95.92% of Mo and 96.77% of Ni were recovered from spent HDS catalyst with this recycling route. This study provided a high-efficient and eco-friendly method to recovery of valuable metals from spent catalyst.

Slurry-Phase Hydrogenation of Different Asphaltenes to Liquid Fuels on Dispersed MoS2 Nanocatalysts

Asphaltene, the most complex and recalcitrant fraction of heavy oil, was investigated in this study to gain new insights into its structure and reactivity. Two types of asphaltenes, ECT-As and COB-As, were extracted from ethylene cracking tar (ECT) and Canada's oil sands bitumen (COB), respectively, and used as reactants for slurry-phase hydrogenation. Characterization of ECT-As and COB-As was carried out by a combination of techniques, including XRD, elemental analysis, simulated distillation, SEM, TEM, NMR, and FT-IR, to gain insights into their composition and structure. A dispersed MoS₂ nanocatalyst was used to study the reactivity of ECT-As and COB-As under hydrogenation conditions. The results showed that under optimal catalytic conditions, the vacuum residue content of hydrogenation products could be reduced to less than 20%, and the products contained over 50% light components (gasoline and diesel oil), indicating that ECT-As and COB-As were effectively upgraded. The characterization results indicated that ECT-As contained a higher aromatic carbon content, shorter alkyl side chains, fewer heteroatoms, and less highly condensed aromatics than COB-As. The light components (gasoline and diesel oil) of ECT-As hydrogenation products mainly consisted of aromatic compounds with 1-4 rings, with the alkyl chains mainly composed of C1-C2, while light components of COB-As hydrogenation products were mainly composed of aromatic compounds with 1-2 rings and C11-C22 paraffins. The characterization of ECT-As and COB-As and their hydrogenation products revealed that ECT-As was an "archipelago type" asphaltene, composed of multiple small aromatic nuclei interconnected through short alkyl chains, while COB-As was an "island type" asphaltene, with long alkyl chains connected to aromatic nuclei. It is suggested that the structure of asphaltene has a significant impact on both its reactivity and product distribution.

Single-Atom Catalysts for Hydrogen Activation

Selective hydrogenation is one of the most important reactions in fine chemical industry, and the activation of H₂ is the key step for hydrogenation. Catalysts play a critical role in selective hydrogenation, and some single-atom catalysts (SACs) are highly capable of activating H₂ in selective hydrogenation by virtue of the maximized atom utilization and the highly uniform active sites. Therefore, more research efforts are needed for the rational design of SACs with superior H₂ -activating capabilities. Herein, the research progress on H₂ activation in typical hydrogenation systems (such as alkyne hydrogenation, hydroformylation, hydrodechlorination, hydrodeoxygenation, nitroaromatics hydrogenation, and polycyclic aromatics hydrogenation) is reviewed, the mechanisms of SACs for H₂ activation are summarized, and the structural regulation strategies for SACs are proposed to promote H₂ activation and provide schemes for the design of high-selectivity hydrogenation catalysts from the atomic scale. At the end of this review, an outlook on the opportunities and challenges for SACs to be developed for selective hydrogenation is presented.

Atomic coordination structural dynamic evolution of single-atom Mo catalyst for promoting H2 activation in slurry phase hydrocracking

Development of efficient catalysts with high atomic utilization and turnover frequency (TOF) for H₂ activation in slurry phase hydrocracking (SPHC) is crucial for the conversion of vacuum residue (VR). Herein, for the first time, we reported a robust and stable single atoms (SAs) Mo catalyst through a polymerization-pyrolysis-in situ sulfurization strategy for activating H₂ in SPHC of VR. An interesting atomic coordination structural dynamic evolution of Mo active sites was discovered. During hydrocracking of VR, the O atoms that coordinated with Mo were gradually replaced by S atoms, which led to the O/S exchange process. The coordination structure of the Mo SAs changed from pre-reaction Mo-O₃S₁ to post-reaction Mo-O₁S₃ coordination configurations, promoting the efficient homolytic cleavage activation of H₂ into H radical species effectively. The evolved Mo SAs catalyst exhibited robust catalytic hydrogenation activity with the per pass conversion of VR of 65 wt%, product yield of liquid oils of 93 wt%, coke content of only 0.63 wt%, TOF calculated for total metals up to 0.35 s^-1, and good cyclic stability. Theoretical calculation reveals that the significant variation of occupied Mo 4d states before and after H₂ interaction has a direct bearing on the dynamic evolution of Mo SAs catalyst structure. The lower d-band center of Mo-O₁S₃ site indicates that atomic H diffusion is easy, which is conducive to catalytic hydrogenation. The finding of this study is of great significance to the development of high atom economy catalysts for the industrial application of heavy oil upgrading technology.

Octahedral Cluster Complex of Molybdenum as Oil-Soluble Catalyst for Improving In Situ Upgrading of Heavy Crude Oil: Synthesis and Application

Heavy oil resources are attracting considerable interest in terms of sustaining energy demand. However, the exploitation of such resources requires deeper understanding of the processes occurring during their development. Promising methods currently used for enhancing heavy oil recovery are steam injection methods, which are based on aquathermolysis of heavy oil at higher temperatures. Regardless of its efficiency in the field of in situ upgrading of heavy oil, this technique still suffers from energy consumption and inefficient heat transfer for deeper reservoirs. During this study, we have developed a molybdenum-based catalyst for improving the process of heavy oil upgrading at higher temperature in the presence of water. The obtained catalyst has been characterized by a set of physico-chemical methods and was then applied for heavy oil hydrothermal processing in a high-pressure reactor at 200, 250 and 300 °C. The comparative study between heavy oil hydrothermal upgrading in the presence and absence of the obtained molybdenum-based oil soluble catalysts has pointed toward its potential application for heavy oil in situ upgrading techniques. In other words, the used catalyst was able to reduce heavy oil viscosity by more than 63% at 300 °C. Moreover, our results have demonstrated the efficiency of a molybdenum-based catalyst in improving saturates and light hydrocarbon content in the upgraded oil compared to the same quantity of these fractions in the initial oil and in the non-catalytically upgraded oil at similar temperatures. This has been explained by the significant role played by the used catalyst in destructing asphaltenes and resins as shown by XRD, elemental analysis, and gas chromatography, which confirmed the presence of molybdenum sulfur particles in the reaction medium at higher temperatures, especially at 300 °C. These particles contributed to stimulating hydrodesulphurization, cracking and hydrogenation reactions by breaking down the C-heteroatom bonds and consequently by destructing sphaltenes and resins into smaller fractions, leading to higher mobility and quality of the upgraded oil. Our results add to the growing body of literature on the catalytic upgrading of heavy oil in the presence of transition metal particles.

New Insight into Desodiation/Sodiation Mechanism of MoS2: Sodium Insertion in Amorphous Mo-S Clusters

Molybdenum disulfide (MoS₂) is a promising anode material for sodium batteries due to its high theoretical capacity. While significantly improved electrochemical performance has been achieved, the reaction mechanism is still equivocal. Herein, we applied electron pair distribution function and X-ray absorption spectroscopy to investigate the desodiation/sodiation mechanism of MoS₂ electrodes. The results reveal that Mo-S bonds are well preserved and dominant in the sodiation product matrix but do not convert to metallic Mo and Na₂S even at deep sodiation. The MoS₂ multilayer sheets break into disordered MoS_x clusters with modified octahedral symmetry during discharging. The long-range order was not rebuilt during subsequent charging but with partial recovery of the Mo-S coordination symmetry. The mechanism of the reaction is independent of the carbon matrix, although it prevents the MoS_x clusters from leaching into the electrolyte and thus contributes to an extended cycle life. This work refreshes the fundamental understanding of the desodiation/sodiation mechanism of MoS₂ materials.

The Effect of MoS2 Active Site Dispersion on Suppression of Polycondensation Reactions during Heavy Oil Hydroconversion

In this work, the composition, structural and morphological features, and particle size of the active phase of the catalyst (MoS2), synthesized in-situ during the heavy oil hydroconversion performed in continuous flow reactor on lab-scale pilot flow unit at T = 450 °C, P = 6.0–9.0 MPa, V = 1.0 h−1, H2/feed = 1000 nL/L, catalyst concentration C (Mo) = 0.01–0.08%wt have been studied. It has been shown that MoS2 formed during hydroconversion is represented by nanosized particles stabilized by polycondensation products as a result of strong adsorption and aggregation with the components of the hydroconversion reaction medium. The influence of morphological characteristics of catalyst nanoparticles on the feed conversion, the yield of gaseous and liquid products, and the quality of distillate fractions, as well as the yield of polycondensation products, have been studied. It has been established that an increase in MoS2 active site dispersion, both due to a decreased plate length and lower stacking numbers in MoS2 cluster, enhances hydroconversion effectivity, particularly, in suppressing polycondensation reactions.

Insight into the Microstructure and Deactivation Effects on Commercial NiMo/γ-Al2O3 Catalyst through Aberration-Corrected Scanning Transmission Electron Microscopy

Atom-resolved microstructure variations and deactivation effects on the commercial NiMo/γ-Al2O3 catalysts were revealed by aberration-corrected scanning transmission electron microscope (Cs-STEM) equipped with enhanced energy dispersive X-ray spectroscopy (EDS). Structural information parallel to and vertical to the electron beam provides definitive insight toward an understanding of structure–activity relations. Under the mild to harsher reaction conditions, “fragment” structures (like metal single atoms, metal clusters, and nanoparticles) of commercial NiMo/γ-Al2O3 catalysts, gradually reduces, while MoS2 nanoslabs get longer and thinner. Such a result about active slabs leads to the reduction in the number of active sites, resulting in a significant decrease in activity. Likewise, the average atomic ratio of promoter Ni and Ni/(Mo + S) ratio of slabs decrease from 2.53% to 0.45% and from 0.0788 to 0.0326, respectively, by means of EDS under the same conditions stated above, reflecting the weakening of the promotional effect. XPS result confirms the existence of NixSy species in deactivated catalysts. This could be ascribed to the Ni segregation from active phase. Furthermore, statistical data give realistic coke behaviors associated with the active metals. With catalytic activity decreasing, the coke on the active metals regions tends to increase faster than that on the support regions. This highlights that the commercial NiMo/γ-Al2O3 catalyst during catalysis is prone to produce more coke on the active metal areas.

Hydrocracking of Athabasca Vacuum Residue Using Ni-Mo-Supported Drill Cuttings

Ni-Mo supported drill cuttings were used to catalyze the hydrocracking (HDC) of Athabasca vacuum residue (AVR) in an autoclave. Drill cuttings are a common waste product that are, depending on their origin, plentiful in acidic sites. The catalyst was prepared using the wet impregnation method. HDC was carried out at both low and high H2 pressure at 400 °C. Control thermal cracking (TC) and HDC runs with and without raw drill cuttings were performed to better examine the role of the supported drill cuttings catalyst. The quality in terms of viscosity and °API gravity, and the yield of various fractions making up the product oil were used to gauge the performance of the catalyst. Similar temperature and energy profiles between TC and HDC suggested strong overlap between the two different reactions, despite H2 presence. Nevertheless, supported drill cuttings runs at high H2 pressures promoted H2 consumption to a strong extent. Consequently, the liquid yield was the highest (~75 wt.%) and the coke yield was negligible. High temperature simulated distillation results revealed a residue conversion of ~55% for both low and high pressure HDC catalytic runs. The product oil quality with respect to viscosity and °API gravity was also found to be comparable between the low and high pressure HDC catalytic runs. Accordingly, no trade-off between liquid yield and quality was incurred at high H2 pressure. Effectively the supported drill cuttings drastically reduced coke formation, while maximizing the yield of the desired liquid product.

Effect of Additives on the Activity of Nickel–Tungsten Sulfide Hydroconversion Catalysts Prepared In Situ from Oil-Soluble Precursors

The nickel–tungsten sulfide catalysts for the hydroconversion of hydrocarbons were prepared from oil-soluble nickel and tungsten precursor compounds in situ with the use of silica, alumina, titania, zeolite Y, and amorphous aluminosilicate as additives in a vacuum gas oil medium. It was found that the catalytic activity in hydrocracking depends on the concentration of acid sites in the resulting catalyst. With the use of oxide additives, the dispersion and the promoter ratio of the in situ formed sulfide particles increased in the order SiO2–Al2O3–TiO2. It was noted that the promoter ratio of sulfide particles obtained with the use of aluminosilicate additives depended on their porous structure peculiarities. The use of titanium dioxide as a catalytic system component made it possible to reach high activity in hydrocracking, hydrodearomatization, and hydrodesulfurization, which was comparable to that of a system based on zeolite Y, a highly acidic component.