Headwaters Technology Innovation, LLC

Wilmington Trust Fsb

Zhihua Wu

Bing Zhou

Zhenhua Zhou

Sukesh Parasher

Michael A Rueter

Horacio Trevino

Changkun Liu

Cheng Zhang

Martin Fransson

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

Tobacco products and articles are disclosed that include a nanoparticle catalyst. The nanoparticles are capable of degrading undesirable small molecules in tobacco smoke. The nanoparticle catalyst includes a dispersing agent that inhibits the deactivation of the nanoparticle catalyst. One embodiment disclosed has a dispersing agent that anchors the nanoparticles to a support material thereby preventing agglomeration of the nanoparticles. The dispersed nanoparticles exhibit higher activity and reduce the required loading in the tobacco material.

Tobacco catalyst and methods for reducing the amount of undesirable small molecules in tobacco smoke

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

Organically complexed nanocatalyst compositions are applied to or mixed with a carbon-containing fuel (e.g., tobacco, coal, briquetted charcoal, biomass, or a liquid hydrocarbon like fuel oils or gasoline) in order to enhance combustion properties of the fuel. Nanocatalyst compositions can be applied to or mixed with a solid fuel substrate in order to reduce the amount of CO, hydrocarbons and soot produced by the fuel during combustion. In addition, coal can be treated with inventive nanocatalyst compositions to reduce the amount of NOproduced during combustion (e.g., by removing coal nitrogen in a low oxygen pre-combustion zone of a low NOx burner). The nanocatalyst compositions include nanocatalyst particles made using a dispersing agent. They can be formed as a stable suspension to facilitate storage, transportation and application of the catalyst nanoparticles to a fuel substrate.

Organically complexed nanocatalysts for improving combustion properties of fuels and fuel compositions incorporating such catalysts

Organically complexed nanocatalyst compositions are applied to or mixed with a carbon-containing fuel (e.g., tobacco, coal, briquetted charcoal, biomass, or a liquid hydrocarbon like fuel oils or gasoline) in order to enhance combustion properties of the fuel. Nanocatalyst compositions can be applied to or mixed with a solid fuel substrate in order to reduce the amount of CO, hydrocarbons, and soot produced by the fuel during combustion. In addition, coal can be treated with inventive nanocatalyst compositions to reduce the amount of NOproduced during combustion (e.g., by removing coal nitrogen in a low oxygen pre-combustion zone of a low NOx burner). The nanocatalyst compositions include nanocatalyst particles made using a dispersing agent. At least a portion of the nanoparticles is crystalline with a spacing between crystal planes greater than about 0.28 nm. The nanocatalyst particles can be activated by heating to a temperature greater than about 75&#xb0; C., more preferably greater than about 150&#xb0; C. and most preferably greater than about 250&#xb0; C.

Crystalline nanocatalysts for improving combustion properties of fuels and fuel compositions incorporating such catalysts

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

The reforming catalysts include a halogen promoter and a plurality of nanocatalyst particles supported on a support material. The nanocatalyst particles have a controlled crystal face exposure of predominately (110). The controlled coordination structure is manufactured by reacting a plurality of catalyst atoms with a control agent such as polyacrylic acid and causing or allowing the catalyst atoms to form nanocatalyst particles. The catalysts are used in a reforming reaction to improve the octane number of gasoline feedstock. The reforming catalysts show improved Chydrocarbon production and improved octane barrel number increases as compared to commercially available reforming catalysts.

Reforming catalysts having a controlled coordination structure and methods for preparing such compositions

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.

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Lawrenceville, NJ, United States of America

Zhihua Wu