Headwaters Technology Innovation, LLC

Wilmington Trust Fsb

Zhenhua Zhou

Bing Zhou

Zhihua Wu

Changkun Liu

Sukesh Parasher

Horacio Trevino

Michael A Rueter

Cheng Zhang

Yijun Lu

Horacio Treviño

Hydrocarbon-soluble molybdenum catalyst precursors include a plurality of molybdenum cations that are each bonded with a plurality of organic anions to form an oil soluble molybdenum salt. A portion of the molybdenum atoms are in the 3+ oxidation state such that the plurality of molybdenum atoms has an average oxidation state of less than 4+, e.g., less than about 3.8+, especially less than about 3.5+. The catalyst precursors can form a hydroprocessing molybdenum sulfide catalyst in heavy oil feedstocks. The oil soluble molybdenum salts are manufactured in the presence of a reducing agent, such as hydrogen gas, to obtain the molybdenum in the desired oxidation state. Preferably the reaction is performed with hydrogen or an organic reducing agent and at a temperature such that the molybdenum atoms are reduced to eliminate substantially all molybdenum oxide species.

Hydrocarbon-soluble molybdenum catalyst precursors and methods for making same

Hydrocarbons containing polynuclear aromatics, such as cycle oil and pyrolysis fuel oil (PFO), are upgraded using an catalyst complex that selectively cracks the polynuclear aromatic compounds to form higher value mono-aromatic compounds, such as benzene toluene, xylenes and ethyl benzene (i.e., BTX). The catalyst complexes include a catalytic metal center and a plurality of organic ligands. During the hydrocracking procedure, the organic ligand preserves one of the aromatic rings of the polynuclear aromatic compounds while the catalytic metal breaks the other aromatic rings thereby yielding a monoaromatic compound.

Process for increasing the mono-aromatic content of polynuclear-aromatic-containing feedstocks

Oil soluble catalysts are used in a process to hydrodesulfurize petroleum feedstock having a high concentration of sulfur-containing compounds and convert the feedstock to a higher value product. The catalyst complex includes at least one attractor species and at least one catalytic metal that are bonded to a plurality of organic ligands that make the catalyst complex oil-soluble. The attractor species selectively attracts the catalyst to sulfur sites in sulfur-containing compounds in the feedstock where the catalytic metal can catalyze the removal of sulfur. Because the attractor species selectively attracts the catalysts to sulfur sites, non-productive, hydrogen consuming side reactions are reduced and greater rates of hydrodesulfurization are achieved while consuming less hydrogen per unit sulfur removed.

Catalyst and method for hydrodesulfurization of hydrocarbons

Oil soluble catalysts are used to convert polynuclear aromatic compounds in a hydrocarbon feedstock to higher value mono-aromatic compounds. The catalyst complex includes a catalytic metal center that is bonded to a plurality of organic ligands that make the catalyst complex oil-soluble. The ligands include an aromatic ring and a ligand spacer group. The ligand spacer group provides spacing of 2-6 atoms between the metal center and the aromatic ring. The spacing between the aromatic group and the catalytic metal center advantageously allows the catalyst to selectively crack polynuclear aromatic rings while preserving one of the aromatic rings, thereby increasing the content of mono-aromatic compounds in the hydrocarbon feedstock.

Catalyst for hydrocracking hydrocarbons containing polynuclear aromatic compounds

Nanoparticle catalysts are manufactured by first preparing a solution of a solvent and a plurality of complexed and caged catalyst atoms. Each of the complexed and caged catalyst atoms has at least three organic ligands forming a cage around the catalyst atom. The complexed and caged catalyst atoms are reduced to form a plurality of nanoparticles. During formation of the nanoparticles, the organic ligands provide spacing between the catalyst atoms via steric hindrances and/or provide interactions with a support material. The spacing and interactions with the support material allow formation of small, stable, and uniform nanoparticles.

Supported nanoparticle catalysts manufactured using caged catalyst atoms

Nanoparticle catalysts are manufactured by first preparing a solution of a solvent and a plurality of complexed catalyst atoms. Each of the complexed catalyst atoms has at least three organic ligands. The complexed catalyst atoms are reduced to form a plurality of nanoparticles. During formation of the nanoparticles, the organic ligands provide spacing between the catalyst atoms via steric hindrances and/or provide interactions with a support material. The spacing and interactions with the support material allow formation of small, stable, and uniform nanoparticles. The supported nanoparticle catalyst is then incorporated into a fuel cell electrode.

Methods of manufacturing fuel cell electrodes incorporating highly dispersed nanoparticle catalysts

Bimetallic catalyst precursors are manufactured from a plurality of molybdenum atoms and a plurality of atoms of a secondary transition metal (e.g., one or more of cobalt, iron, or nickel). The molybdenum atoms and the secondary transition metal atoms are each bonded with a plurality of organic anions (e.g., 2-ethyl hexanoate) to form a mixture of an oil-soluble molybdenum salt and an oil-soluble secondary transition metal salt. The molybdenum and/or the secondary transition metals are preferably reacted with the organic agent in the presence of a strong reducing agent such as hydrogen. To obtain this mixture of metal salts, an organic agent is reacted with the molybdenum at a temperature between about 100&#xb0; C. and about 350&#xb0; C. The secondary transition metal is reacted with the organic agent at a different temperature, preferably between 50&#xb0; C. and 200&#xb0; C. The metal salts are capable of forming a hydroprocessing metal sulfide catalyst in heavy oil feedstocks.

Hydrocarbon-soluble, bimetallic catalyst precursors and methods for making same

An improved skeletal iron catalyst is provided for use in Fischer-Tropsch synthesis reactions for converting CO and Hto hydrocarbon products. The skeletal iron catalyst is manufactured using iron and a removable non-ferrous component such as aluminum. The iron and removable non-ferrous component are mixed together to form a precursor catalyst and then a portion of the removable non-ferrous component is removed to leave a skeletal iron catalyst. One or more first promoter metals and optionally one or more second promoter metals are incorporated into the skeletal iron catalyst either by blending the promoter into the precursor catalyst during the formation thereof or by depositing the promoter on the skeletal iron. The first promoter metals comprises a metal selected from the group consisting of titanium, zirconium, vanadium, cobalt, molybdenum, tungsten, and platinum-group metals. The first promoter metal is selected to improve the yield of Chydrocarbons when the skeletal iron catalyst is used in a Fischer-Tropsch reaction.

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Magnesium hydroxide nanoparticles are made from a magnesium compound that is reacted with an organic dispersing agent (e.g., a hydroxy acid) to form an intermediate magnesium compound. Magnesium hydroxide nanoparticles are formed from hydrolysis of the intermediate compound. The bonding between the organic dispersing agent and the magnesium during hydrolysis influences the size of the magnesium hydroxide nanoparticles formed therefrom. The magnesium hydroxide nanoparticles can be treated with an aliphatic compound (e.g., a monofunctional alcohol) to prevent aggregation of the nanoparticles during drying and/or to make the nanoparticles hydrophobic such that they can be evenly dispersed in a polymeric material. The magnesium hydroxide nanoparticles exhibit superior fire retarding properties in polymeric materials compared to known magnesium hydroxide particles.

Magnesium hydroxide nanoparticles, methods of making same and compositions incorporating same

Supported catalysts are manufactured from a pretreated porous support material and a nanocatalyst solution of catalyst nanoparticles. The porous support material is pre-treated with a gaseous solvent (e.g., steam or alcohol) to protect the support material from cracking during impregnation of the nanocatalyst solution. The supported catalysts have more uniform size, lower attrition of metals during manufacturing and use, and improved distributions of metal loading compared to catalysts manufactured using known techniques. Hydrogen peroxide manufactured from such catalysts is less likely to be contaminated with catalyst metal.

Methods for manufacturing supported catalyst from a porous support and a nanocatalyst solution

Improved bi-metallic nanocatalysts are manufactured using a control agent to produce nanoparticles having a controlled crystal face exposure. The bi-metallic nanocatalyst particles are manufactured in a two-step process. In a first step, nanocatalyst particles are manufactured using the control agent and the primary metal atoms. The primary metal atoms and the control agent are reacted to form complexed metal atoms. The complexed metal atoms are then allowed or caused to form nanoparticles. The nanoparticles formed in the first step using the control agent have a desired crystal face exposure. In a second step, the secondary metal atoms are deposited on the surface of the primary metal nanoparticles. The secondary catalyst atoms maintain the same crystal face exposure as the primary metal nanoparticles.

Methods for manufacturing bi-metallic catalysts having a controlled crystal face exposure

Reforming nanocatalysts are formed using a dispersing agent to increase the activity, selectivity and longevity of the catalyst when used in a reforming process. The nanocatalyst particles are formed using a dispersing agent having at least one functional group selected from the group of a hydroxyl, a carboxyl, a carbonyl, an amide, an amine, a thiol, a sulfonic acid, sulfonyl halide, an acyl halide, an organometallic complex, and combinations of these. The dispersing agent is particularly useful for forming multicomponent catalysts comprising an alloy, combination, mixture, decoration, or interspersion of platinum and one or more of tin, rhenium or iridium. The formation of the nanoparticles may include a heat treating process performed in an inert or oxidative environment to maintain the catalyst atoms in a non-zero oxidation state to thereby maintain a stronger bond between the dispersing agent and the catalyst atoms. Multicomponent reforming catalysts having anchored nanocatalyst particles exhibit particularly good activity, selectivity and longevity when used in the reforming of naphtha and/or formation of BTX.

Reforming nanocatalysts and method of making and using such catalysts

Catalysts suitable for use in reforming hydrocarbons have a halogen promoter and a plurality of dispersed nanocatalyst particles supported on a solid support. The dispersed nanocatalyst particles are manufactured using a dispersing agent to control the size and/or crystal face exposure of the particles. The controlled size and dispersion of the nanocatalyst particles allows the reforming catalyst to be loaded with significantly less halogen promoter while still maintaining or increasing the catalyst's reforming performance. The catalysts of the present invention have shown improved Cproduction with the significantly reduced levels of halogen promoter.

Reforming nanocatalysts and methods of making and using such catalysts

Methods for manufacturing supported catalysts and the use of these catalysts in, e.g., the direct synthesis of hydrogen peroxide. The nanocatalyst particles are manufactured from catalyst atoms complexed with organic agent molecules (e.g., polyacrylic acid). The complexed catalyst atoms are heated to cause formation of the nanocatalyst particles. The temperature used to cause formation of the particles is typically greater than 30&#xb0; C., preferably greater than 50&#xb0; C, and more preferably greater than 70&#xb0; C.

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Lawrenceville, NJ, United States of America

Zhenhua Zhou