Hydroprocessing catalysts

Catalytic hydroprocessing of liquid biomass is a technology currently under developed and there is a lot of room for optimization. For example there are not many commercial catalysts specifically designed and developed for such applications, while conventional commercial cat­alysts, employed for catalytic hydroprocessing of refinery streams, are used instead. Common
hydrotreating catalysts employed contain active metals on alumina substrate with increased surface area. The most known commercial catalysts employ Cobalt and Molybdenum (CoMo) or Nikel and Molybdenum (NiMo) in alumina substrate (Al2O3) as shown in Figure 4.

Подпись: Figure 4. Typical hydrotreating catalysts (a) before use and (b) after use
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(b)

Hydrotreating catalysts are dual action catalytic material, triggering both hydrogenation and cracking/isomerization reactions. On one hand hydrogenation takes place on the active metals (Mo, Ni, Co, Pd, Pt) which catalyze the feedstock molecules rendering them more ac­tive when subject to cracking and heteroatom removal, while limiting coke formation on the catalyst. Furthermore hydrogenation supports cracking by forming an active olefinic inter­mediate molecule via dehydrogenation. On the other hand both cracking and isomerization reactions take place in acidic environment such as amorphous oxides (SiO2 — Al2O3) or crys­talline zeolites (mainly z-zeolites) or mixtures of zeolites with amorphous oxides.

During the first contact of the feedstock molecules with the catalyst, a temperature increase is likely to develop due to the exothermic reactions that occur. However, during the continu­ous utilization of the catalyst and coke deposition, the catalyst activity eventually reduces from 1/3 to 1/2 of its initial one. The catalyst deactivation rate mainly depends on tempera­ture and hydrogen partial pressure. Increased temperatures accelerate catalyst deactivation while high hydrogen partial pressure tends to mitigate catalyst deactivation rate. Most of the catalyst activity can be recovered by catalyst regeneration.

The selection of a suitable hydroprocessing catalyst is a critical step defining the hydro­processing product yield and quality as well as the operating cycle time of the process in petroleum industry [5]. However the hydrotreating catalyst selection for biomass applica­tions is particularly crucial and challenging for two reasons: a) catalyst activity varies sig­nificantly, as commercial catalysts are designed for different feedstocks, i. e. feedstocks with high sulfur concentration, heavy feedstocks (containing large molecules), feedstocks with high oxygen concentration etc, and b) there are currently no commercial hydropro­cessing catalysts available for lipid feedstocks and other intermediate products of biomass conversion processes (e. g. pyrolysis biooil), and thus commercial hydrotreating catalysts need to be explored and evaluated as different catalyst have different yields (Figure 5) and different degradation rate [8]. Nevertheless, significant efforts have been directed to-

wards developing special hydrotreating catalysts for converting/upgrading liquid biomass to biofuels [912].

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Gasoline Diesel

Figure 5. Catalyst comparison based on gasoline and diesel yields for WCO hydrotreating [8]. (Reprinted from Fuel, 93, S. Bezergianni, A. Kalogianni, A. Dimitriadis, Catalyst evaluation for waste cooking oil hydroprocessing, 638-641, 2012, with permission from Elsevier).