Synthesis and performance evaluation of hydrocracking catalysts: A review

Recovery technology of spent hydrogenation catalysts -A review

Spent hydrogenation catalysts (HDCs) contain many Mo, V, Co, Ni, and Al2O3 carriers, which are valuable secondary resources. However, improper disposal can also lead to environmental pollution risks. In the past decade, research reviews on the recovery of valuable metals from spent HDCs have been somewhat reported, mainly summarizing basic technical processes. Based on previous work, this article reviews the emerging recycling technologies of spent HDCs in recent years. The research trend of furnace optimization in the pyrometallurgical process was innovatively proposed, and the importance of developing new mild leaching agents for the high-quality recycling of Al2O3 carriers in the hydrometallurgical process was clarified.

Impact of lanthanum ion exchange and steaming dealumination on middle distillate production using nanosized Y zeolite catalysts in hydrocracking reactions

In the field of hydrocracking reactions, achieving optimal middle distillate yields remains a persistent challenge with commercially available zeolite Y catalysts. This limitation is attributed to challenges related to diffusion constraints within the catalyst. In response, we present a promising solution not only to these problems but also to the challenges encountered in nanosized Y zeolites when attempting to generate acidic sites within their structure and when analyzing their performance in vacuum gas oil hydrocracking. NiMo catalysts based on nanosized Y zeolites with different crystal sizes exchanged with lanthanum, effectively address diffusion issues and significantly enhance catalyst performance compared to dealuminated nanosized and commercial Y zeolite under the same reaction conditions. The catalysts were characterized by TGA, ICP-OES, XPS, N2 physisorption, FT-IR for pyridine acidity, TEM-mapping, and the 3-methyl thiophene reaction to test the hydrogenating capacity. Surface analysis and microscopy showed greater porosity in the catalysts with smaller zeolites and different arrangements of their components. The catalysts based on steamed protonated nanosized Y zeolites with a larger size and lanthanide nanosized Y zeolite with a smaller size yielded more middle distillates. Research provides a comprehensive analysis, providing a correlation between the catalytic performance and the size of the nanosized Y zeolite.

New insights into the bioremediation of petroleum contaminants: A systematic review

Petroleum product is an essential resource for energy, that has been exploited by wide range of industries and regular life. A carbonaceous contamination of marine and terrestrial environments caused by errant runoffs of consequential petroleum-derived contaminants. Additionally, petroleum hydrocarbons can have adverse effects on human health and global ecosystems and also have negative demographic consequences in petroleum industries. Key contaminants of petroleum products, primarily includes aliphatic hydrocarbons, benzene, toluene, ethylbenzene, and xylene (BTEX), polycyclic aromatic hydrocarbons (PAHs), resins, and asphaltenes. On environmental interaction, these pollutants result in ecotoxicity as well as human toxicity. Oxidative stress, mitochondrial damage, DNA mutations, and protein dysfunction are a few key causative mechanisms behind the toxic impacts. Henceforth, it becomes very evident to have certain remedial strategies which could help on eliminating these xenobiotics from the environment. This brings the efficacious application of bioremediation to remove or degrade pollutants from the ecosystems. In the recent scenario, extensive research and experimentation have been implemented towards bio-benign remediation of these petroleum-based pollutants, aiming to reduce the load of these toxic molecules in the environment. This review gives a detailed overview of petroleum pollutants, and their toxicity. Methods used for degrading them in the environment using microbes, periphytes, phyto-microbial interactions, genetically modified organisms, and nano-microbial remediation. All of these methods could have a significant impact on environmental management.

Waste cooking oil processing over cobalt aluminate nanoparticles for liquid biofuel hydrocarbons production

The catalytic conversion of waste cooking oil (WCO) was carried out over a synthetic nano catalyst of cobalt aluminate (CoAl₂O₄) to produce biofuel range fractions. A precipitation method was used to create a nanoparticle catalyst, which was then examined using field-emission scanning electron microscopy, X-ray diffraction, energy dispersive X-ray, nitrogen adsorption measurements, high-resolution transmission electron Microscopy (HRTEM), infrared spectroscopy, while a gas chromatography-mass spectrometer (GC-MS) was used to analyze the chemical construction of the liquid biofuel. A range of experimental temperatures was looked at including 350, 375, 400, 425, and 450 °C; hydrogen pressure of 50, 2.5, and 5.0 MPa; and liquid hour space velocity (LHSV) of 1, 2.5, and 5 h^-1. As temperature, pressure, and liquid hourly space velocity increased, the amount of bio-jet and biodiesel fractional products decreased, while liquid light fraction hydrocarbons increased. 93% optimum conversion of waste cooking oil over CoAl₂O₄ nano-particles was achieved at 400 °C, 50 bar, and 1 h^-1 (LHSV) as 20% yield of bio-jet range,16% gasoline, and 53% biodiesel. According to the product analysis, catalytic hydrocracking of WCO resulted in fuels with chemical and physical characteristics that were on par with those required for fuels derived from petroleum. The study's findings demonstrated the nano cobalt aluminate catalyst's high performance in a catalytic cracking process, which resulted in a WCO to biofuel conversion ratio that was greater than 90%. In this study, we looked at cobalt aluminate nanoparticles as a less complex and expensive alternative to traditional zeolite catalysts for the catalytic cracking process used to produce biofuel and thus can be manufactured locally, which saves the cost of imports for us as a developing country.

Highly Selective Bio-hydrocarbon Production using Sidoarjo Mud Based-Catalysts in the Hydrocracking of Waste Palm Cooking Oil

In this work, Lapindo mud (LM) was used as catalyst support. This is because the Lapindo mud has a high SiO2 content of 45.33 %. This research aims to produce a hydrocracking catalyst based on Lapindo mud through impregnation of Ni and Pt metals as well as grafting amine groups. Ni and Pt metals impregnation using wet impregnation method followed by amine group grafting. The best catalyst in this study was NiPt-NH2/LM which contained Ni and Pt metals, surface area, and pore diameters of 1.68 wt.% and 0.4 wt.%, 6.59 m2/g, 15.51 nm, respectively. The effectiveness of the catalyst was tested against temperature and catalyst: feed ratio. The catalyst with the best activity and selectivity was tested for reusability 3 times through hydrocracking process. The yield of liquid products obtained in the hydrocracking process of WPO using NiPt-NH2/LM catalyst with the optimum temperature and the weight ratio of catalyst:feed at 550 oC was 79.4 wt. % which consists of hydrocarbon compound of 55.9 wt.%. The yield of liquid products obtained in the hydrocracking WPO using the used NiPt-BH2/LM catalyst was 28.4 wt.% which consists of hydrocarbon compound of 23.6 wt.%. Copyright © 2022 by Authors, Published by BCREC Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0). 

Carbon Nanostructure/Zeolite Y Composites as Supports for Monometallic and Bimetallic Hydrocracking Catalysts

In this study, we examine the effect of integrating different carbon nanostructures (carbon nanotubes, CNTs, graphene nanoplatelets, GNPs) into Ni- and Ni-W-based bi-functional catalysts for hydrocracking of heptane performed at 400 °C. The effect of varying the SiO2/Al2O3 ratio of the zeolite Y support (between 5 and 30) on the heptane conversion is also studied. The results show that the activity, in terms of heptane conversion, followed the order CNT/Ni-ZY5 (92%) > GNP/Ni-ZY5 (89%) > CNT/Ni-W-ZY30 (86%) > GNP/Ni-W-ZY30 (85%) > CNT/Ni-ZY30 (84%) > GNP/Ni-ZY30 (83%). Thus, the CNT-based catalysts exhibited slightly higher heptane conversion as compared to the GNP-based ones. Furthermore, bimetallic (Ni-W) catalysts possessed higher BET surface areas (725 m2/g for CNT/Ni-W-ZY30 and 612 m2/g for CNT/Ni-ZY30) and exhibited enhanced hydrocracking activity as compared to the monometallic (Ni) catalyst with the same zeolite support and type of carbon structure. It was also shown that CNT-based catalysts possessed higher regeneration capability than their GNP-based counterparts due to the slightly higher thermal stability of the CVD-grown CNTs.

Competitive and sequence reactions of typical hydrocarbon molecules in diesel fraction hydrocracking - a theoretical study by DFT calculations

The molecular structures of hydrocarbon molecules determine the competitive and sequence reactions in the diesel hydrocracking process. In this study, the hydrocracking reactions of typical hydrocarbons with various saturation degrees and molecular weights in diesel fractions synergistically catalyzed by the Ni–Mo–S nanocluster and Al–Si FAU zeolite are investigated. The results show that the two major rate-controlling steps in saturated hydrocarbon hydrocracking are dehydrogenation on the Ni–Mo–S active sites and the cracking of the C–C bonds on the FAU zeolite acid center. Moreover, the major rate-controlling step in cracking the cycloalkyl aromatic hydrocarbons is the protonation of the aromatic ring. Moreover, the aromatic hydrocarbons presented an apparent advantage in competitive adsorption on the Ni–Mo–S active sites, whereas hydrocarbons with higher molecular weights demonstrated a moderate adsorption advantage on both Ni–Mo–S active sites and FAU zeolite acid centers.

The molecular structures of hydrocarbon molecules determine the competitive and sequence reactions in the diesel hydrocracking process.

Synthesis of Mesoporous Carbon from Merbau Sawdust as a Nickel Metal Catalyst Support for Castor Oil Hydrocracking

Synthesis of mesoporous carbon from merbau sawdust with H2O2 as activator using reflux method followed by carbonization at 800 °C (RC800) had been carried out. This research is aiming to produce effective pathway to synthesize effective nickel-mesoporous carbon catalyst. The nickel metal was impregnated on the mesoporous carbon by wet impregnation using the salt precursor of Ni(NO3)2∙6H2O. The results showed that carbon RC800 and C800 had a specific surface area of 135.18 and 182.48 m2/g. Specific surface area of Ni/RC800 and Ni/C800 catalyst were 41.31 and 7.15 m2/g, respectively. The metal content in Ni/RC800 and Ni/C800 catalyst were 0.83 and 0.92 wt%, respectively. Ni/RC800 catalyst had the highest acidity (7.64 mmol/g) compared to Ni/C800 catalyst (6.99 mmol/g), RC800 (97.43 mmol/g), and C800 (6.17 mmol/g). The Ni/RC800 catalyst has the highest activity with the liquid product conversion of 66.01 wt%. Its selectivity towards gasoline fraction, diesel fraction, alcohol, and organic was 8.06, 1.17, 2.61, and 54.13%, respectively. Copyright © 2022 by Authors, Published by BCREC Group. This is an open access article under the CC BY-SA License (https://creativecommons.org/licenses/by-sa/4.0).

Hydrocracking optimization of palm oil to bio-gasoline and bio-aviation fuels using molybdenum nitride-bentonite catalyst

In this study, molybdenum nitride-bentonite was successfully employed for the reaction of hydrocracking of palm oil to produce a bio-gasoline and bio-aviation fuel. The prepared catalyst was characterized using XRD, FT-IR, and SEM-EDX. The acidity of the catalyst was determined using the pyridine gravimetric method. The result showed that the acidity of bentonite was increased after modification using molybdenum nitride. The hydrocracking study showed that the highest conversion and product fraction of bio-gasoline and bio-aviation fuel were exhibited by molybdenum nitride-bentonite 8 mEq g⁻¹. The catalyst was later used to optimize the hydrocracking process using RSM-CCD. The effects of the process variables such as temperature, contact time, and catalyst to feed ratio, on the response variables, such as conversion, oil, gas, and coke yield, were investigated. The analysis of variance showed that the proposed quadratic model was statistically significant with adequate precision to estimate the responses. The optimum conditions in the hydrocracking process were achieved at a temperature of 731.94 K, contact time of 0.12 h, and a catalyst to feed ratio of 0.12 w/v with a conversion of 78.33%, an oil yield of 50.32%, gas yield of 44.00% and coke yield of 5.73%. The RSM-CCD was demonstrated as a suitable method for estimating the hydrocracking process of palm oil using a MoN-bentonite catalyst due to its closeness to the optimal value of the expected yield. This study provided a potential catalyst of based on bentonite modified using molybdenum nitride for the hydrocracking of palm oil.

In this study, molybdenum nitride-bentonite was successfully employed for the reaction of hydrocracking of palm oil to produce a bio-gasoline and bio-aviation fuel.

Effect of two-component amorphous silica-alumina (ASA) with different Si/Al molar ratios on hydrocracking reactions for increasing naphtha over NiW/USY-ASA

The combination of ASA-0.4 and ASA-2 produces new acidic OH groups by increasing the contact points between silicon and aluminum. These OH groups improve the density of acid sites and increases the area of the active adsorption area of the support.

Recent Advances in Catalysis Based on Transition Metals Supported on Zeolites

This article reviews the current state and development of thermal catalytic processes using transition metals (TM) supported on zeolites (TM/Z), as well as the contribution of theoretical studies to understand the details of the catalytic processes. Structural features inherent to zeolites, and their corresponding properties such as ion exchange capacity, stable and very regular microporosity, the ability to create additional mesoporosity, as well as the potential chemical modification of their properties by isomorphic substitution of tetrahedral atoms in the crystal framework, make them unique catalyst carriers. New methods that modify zeolites, including sequential ion exchange, multiple isomorphic substitution, and the creation of hierarchically porous structures both during synthesis and in subsequent stages of post-synthetic processing, continue to be discovered. TM/Z catalysts can be applied to new processes such as CO₂ capture/conversion, methane activation/conversion, selective catalytic NO_x reduction (SCR-deNO_x), catalytic depolymerization, biomass conversion and H₂ production/storage.

Detailed nature of tire pyrolysis oil blended with light cycle oil and its hydroprocessed products using a NiW/HY catalyst

The pyrolysis of scrap tires is a very attractive strategy to valorize chemically these end-of-life wastes. The products of this step and any additional one, such as hydrotreating, are relatively complex in nature entangling the understanding and limiting the viability. In this work, we have investigated in detail the composition of a tire pyrolysis oil blended with light cycle oil (from a refinery) and its hydrotreated products using a bifunctional NiW/HY catalyst at 320-400 °C. We have applied a set of analytical techniques to assess the composition, namely simulated distillation, ICP, GC/FID-PFPD, GC × GC/MS, and APPI FT-ICR/MS. Our results show the strength of our analytical workflow to highlight the compositional similarities of this pyrolysis oil with the standard refinery streams. The main differences arise from the higher boiling point species (originated during the pyrolysis of tires) and relatively high concentration of oxygenates. These effects can be minimized by hydrotreating the feed which effectively removes heteroatomic compounds from the feed while boosting the quantity and quality of gasoline and diesel fractions.

Waste Refinery: The Valorization of Waste Plastics and End-of-Life Tires in Refinery Units. A Review

This review collects a wide range of initiatives and results that expose the potential of the refineries to be converted into waste refineries. Thus, they will use their current units for the valorization of consumer society wastes (waste plastics and end-of-life tires in particular) that are manufactured with petroleum derivatives. The capacity, technological development, and versatility of fluid catalytic cracking (FCC) and hydroprocessing units make them appropriate for achieving this goal. Polyolefinic plastics (polyethylene and polypropylene), the waxes obtained in their fast pyrolysis, and the tire pyrolysis oils can be cofed together with the current streams of the industrial units. Conventional refineries have the opportunity of operating as waste refineries cofeeding these alternative feeds and tailoring the properties of the fuels and raw materials produced to be adapted to commercial requirements within the oil economy frame. This strategy will contribute in a centralized and rational way to the recycling of the consumer society wastes on a large scale. Furthermore, the use of already existing and, especially, depreciated units for the production of fuels and raw materials (such as light olefins and aromatics) promotes the economy of the recycling process.

Effect of the catalyst in the BTX production by hydrocracking of light cycle oil

Catalysts to produce the important petrochemicals like benzene, toluene, and xylene (BTX) from refinery feedstocks, like light cycle oil (LCO) are reviewed here by covering published papers using model mixtures and real feeds. Model compounds experiments like tetralin and naphthalene derivatives provided a 53–55% total BTX yield. Higher yields were never attained due to the inevitable gas formation and other C9+-alkylbenzenes formed. For tetralin, the best catalysts are those conformed by Ni, CoMo, NiMo, or NiSn over zeolite H-Beta. For naphthalene derivatives, the best catalysts were those conformed by W and NiW over zeolite H-Beta silylated. Real feeds produced a total BTX yield of up to 35% at the best experimental conditions. Higher yields were never reached due to the presence of other types of hydrocarbons in the feed which can compete for the catalytic sites. The best catalysts were those conformed by Mo, CoMo, or NiMo over zeolite H-Beta. Some improvements were obtained by adding ZSM-5 to the support or in mixtures with other catalysts.