Hierarchical Hybrid Supports and Synthesis Strategies for Hydrodesulfurization of Recalcitrance Organosulfur Compounds

It is undisputed that there is a paradigm shift in the global trend of crude oil towards being more sour and heavier than usual light sources. Consequently, the hydrotreating activity becomes a bottleneck with high content of S, N, metals and other impurities than expected. On the other hand, the price of petroleum products lately witnessed instability and fell to the lowest average price (<USD 20) in recent times. In the same vein, the regulation to control the emission of toxic compounds in the atmosphere become stricter as promulgated by various policymakers. In this sense, robust hydrotreating catalysts with characteristics efficient catalytic activity, selectivity and stability are highly desirable. Recently, different approaches have been used to improve and cushion the unprecedented effect emanated from economic, social and environmental challenges posed by heavy and sour crude sources, price instability of the refined products and regulation to lower the sulfur to minimum level or zero parts per millions (ppm). Importantly, the role of support in catalysis cannot be over emphasized, whilst the surface area and porosity, mechanical and thermal stability, dispersion of active metals, acidity/basicity have been greatly improved, the increased activity, stability and selectivity has been observed significantly. In this review, hybrid supports based on aluminosilicates (zeolitic types) and other notable supports from recent literatures were explored and discussed for Ni(Co)Mo(W) supported catalysts for hydrodesulfurization (HDS) activity of heavy organosulfur molecules. The emphasis on the hybrid supports' varied characteristics for HDS of organosulfur molecules, where there are necessities for fast diffusion of reactants and products, better dispersion of MoS₂ crystallites, high surface area and pore volume, and increased acidity of the catalysts are greatly emphasized. Furthermore, the progress made so far on different HDS active phases viz. noble metals, metal phosphides, intermetallic silicides, carbides and iron-zinc are highlighted in this write-up, irrespective of the support composition in the supported catalysts formulations. The need for application of predictive tools, like machine learning (ML) in the design and development of HDS catalysts, and performance evaluation of HDS activity towards achieving better catalytic operation was briefly highlighted. Finally, the review will serve as a summary of scientific efforts in this regards and bridge a gap for the newcomers to investigate the topic in a better way through proper selection and efficient catalysts design.

The enzyme-induced formation of iron hybrid nanostructures with different morphologies

A new synthesis method for tailor-made iron-hybrid nanoparticles has been carried out for the first time using enzymes, which directly induce the formation of inorganic iron species. The role of the protein was critical for the formation and morphology of the iron nanostructures and, depending on the enzyme, by simple mixing with ammonium iron(ii) sulfate at room temperature and under air, it was possible to obtain, for the first time, well stabilized superparamagnetic iron and iron oxide nanorods, nanosheets and nanorings or even completely amorphous non-magnetic iron structures in the protein network. These iron nanostructure-enzyme hybrids showed excellent results as heterogeneous catalysts in organic chemistry (chemoselective hydrogenation and C-C bonding formation) and environmental remediation processes.

Strong metal–support interactions between palladium nanoclusters and hematite toward enhanced acetylene dicarbonylation at low temperature

A four-fold increase in palladium-based acetylene dicarbonylation activity was obtained at low temperature due to the strong metal–support interaction between Pd and the earth-abundant α-Fe₂O₃ material.

Synthesis of ZSM-5/KIT-6 with a tunable pore structure and its catalytic application in the hydrodesulfurization of dibenzothiophene and diesel oil

Porous support materials were prepared by assembling primary and secondary ZSM-5 structural units into a well-ordered mesoporous framework. The materials possessed both ZSM-5 microporous building units and mesoporous structure were used as supports for the preparation of hydrodesulfurization (HDS) catalysts. The materials and their corresponding catalysts were characterized by XRD, FTIR, ²⁷Al MAS NMR, TEM, N₂ adsorption–desorption, Py-FTIR, H₂-TPR, Raman, and HRTEM techniques. The pore structures of the composite materials were modulated by adjusting the molar ratio of butanol/P123 (BuOH/P123) and then, the influences of BuOH/P123 on the catalytic performance in the HDS of dibenzothiophene (DBT) and diesel oil were systematically studied. The results showed that butanol has a big influence on the structure of the micro–mesoporous material, whereby different micro–mesoporous structures, such as the p6mm hexagonal structure or Ia3̄d cubic structure, were formed with different butanol addition amounts. The composite ZK-3 (BuOH/P123 = 100) possessed the best surface area and pore structure. Therefore, the NiMo/ZK-3 catalyst showed the highest catalytic activity in the HDS of DBT with a BP selectivity of 72.1% due to its excellent textural property, moderate MSI, relatively high B/L ratios, and highly dispersed NiMoS active phases. Moreover, the NiMo/AZK-3 catalyst exhibited excellent catalytic performance in the HDS of diesel oil.

Porous material with tunable pore structure ZSM-5/KIT-6 was prepared by adjusting the addition amount of n-butanol. NiMo/ZK-3 and NiMo/AZK-3 catalysts exhibit good catalytic performances in the HDS of DBT and diesel oil, respectively.