Product Description
Novel Hydrogenation Catalyst
Advanced Catalytic Solution for Organic Sulfur & Olefin Conversion
1. Product Overview
Our Novel Hydrogenation Catalyst represents a breakthrough in catalytic hydroprocessing technology, specifically engineered to deliver exceptional conversion performance for both organic sulfides and olefins in diverse industrial feedstocks. Developed through years of R&D and field validation, this catalyst addresses the growing demand for efficient, reliable, and cost-effective gas purification solutions across the petroleum refining, petrochemical, and natural gas industries.
At its core, the catalyst leverages an optimized formulation of transition metal active components supported on a high-surface-area alumina substrate, enhanced with proprietary promoters that synergistically boost both activity and stability. The result is a catalyst that achieves superior hydrogenation conversion rates under moderate operating conditions, enabling operators to meet increasingly stringent product quality and environmental compliance requirements.
This hydrogenation catalyst is particularly well-suited for refinery dry gas (with olefin content <8%), petroleum fractions, refinery gas, natural gas, oil field gas, and water gas applications. Its versatile performance profile makes it an ideal choice for both new installations and catalyst replacement projects aiming to upgrade existing hydrotreatment units.
2. Key Features & Performance Advantages
2.1 Exceptional Hydrogenation Activity
The catalyst demonstrates outstanding conversion capacity for both organic sulfides and olefins in feed gases. Its optimized active phase architecture—featuring well-dispersed metal sulfide sites with precisely tuned electronic properties—enables efficient hydrogen activation and substrate adsorption. Organic sulfur compounds including mercaptans, sulfides, disulfides, thiophenes, and carbonyl sulfide (COS) are effectively converted to hydrogen sulfide (H₂S), while olefins are selectively hydrogenated to corresponding paraffins.
Under typical operating conditions, the catalyst achieves organic sulfur conversion rates exceeding 95%, with the capability to reach 99%+ under optimized parameters. Olefin saturation performance is equally impressive, ensuring compliance with downstream processing requirements and product quality specifications.
2.2 Broad Feedstock Compatibility
One of the standout features of this novel catalyst is its versatility across diverse feedstock compositions. Unlike many competing catalysts that perform optimally only with specific feed types, our hydrogenation catalyst consistently delivers strong results across:
• Refinery dry gas (olefin content <8%)
• Petroleum distillates and fractions
• Refinery off-gases
• Natural gas and associated gas
• Oil field gas
• Water gas and coke oven gas
This broad applicability reduces the need for specialized catalysts for different units, simplifying inventory management and reducing operational complexity for facilities with multiple hydroprocessing trains.
2.3 Robust Stability & Long Service Life
Engineered for industrial durability, the catalyst features a mechanically robust alumina support with optimized pore structure that resists thermal degradation and coking. The active metal components are firmly anchored to the support surface through advanced impregnation and calcination techniques, minimizing metal sintering and leaching under prolonged high-temperature operation.
Field trials demonstrate that the catalyst maintains over 90% of its initial activity after 24+ months of continuous operation under typical conditions, significantly reducing replacement frequency and associated downtime costs. Its resistance to common catalyst poisons—including trace heavy metals and nitrogen compounds—further contributes to its impressive operational longevity.
2.4 Flexible Operating Window
The catalyst operates effectively across a wide range of temperatures, pressures, and space velocities, providing operators with substantial process flexibility. This broad operating window is particularly valuable for facilities with variable feed compositions or fluctuating production demands, as the catalyst maintains consistent performance without requiring frequent parameter adjustments.
Whether deployed in isothermal or adiabatic hydrogenation processes, the catalyst adapts seamlessly to different reactor configurations and process designs, making it suitable for both grassroots units and retrofitting existing equipment.
2.5 Energy & Cost Efficiency
By achieving high conversion rates at moderate temperatures and pressures, the catalyst helps reduce energy consumption compared to conventional alternatives requiring more severe operating conditions. Lower operating temperatures also translate to reduced thermal stress on reactor vessels and associated equipment, extending asset life and reducing maintenance costs.
Furthermore, the catalyst's high activity allows for higher space velocities, enabling increased throughput within existing reactor volumes. This capacity uplift can deliver significant returns on investment without requiring capital-intensive equipment upgrades.
3. Technical Specifications
3.1 Physical Properties
Specification
Appearance : Extrudates, blue-gray
Active Components : Co, Mo, Ni (supported on γ-Al₂O₃)
Promoters: Rare earth and proprietary additives
Diameter: Φ 2.0 – 3.0 mm
Length: 3 – 15 mm
Bulk Density: 0.60 – 0.70 kg/L
Crushing Strength: ≥ 120 N/cm
Specific Surface Area: ≥ 180 m²/g
Pore Volume: ≥ 0.35 mL/g
3.2 Performance Indicators
Parameter
Typical Value
Organic Sulfur Conversion ≥ 95.0%
Olefin Hydrogenation Rate ≥ 90.0%
Operating Temperature 200 – 400°C
Operating Pressure 0.1 – 4.0 MPa
Liquid Space Velocity 1 – 6 h⁻¹ (liquid)
Gas Space Velocity 500 – 3000 h⁻¹ (gas)
H₂/Oil Volume Ratio ≥ 100
Service Life ≥ 24 months
Note: Specific performance targets may vary depending on feedstock composition, operating conditions, and process configuration. Our technical team provides customized performance projections based on detailed process simulations.
4. Reaction Mechanism
The hydrogenation process catalyzed by our product involves multiple coordinated reaction pathways, each targeting specific contaminant classes:
4.1 Organic Sulfur Hydroconversion
Organic sulfur compounds undergo hydrogenolysis reactions that cleave carbon-sulfur bonds and produce H₂S:
• Mercaptans: R-SH + H₂ → R-H + H₂S
• Sulfides: R-S-R' + 2H₂ → R-H + R'-H + H₂S
• Disulfides: R-S-S-R' + 3H₂ → R-H + R'-H + 2H₂S
• Carbonyl Sulfide: COS + H₂ → CO + H₂S
• Carbon Disulfide: CS₂ + 4H₂ → CH₄ + 2H₂S
• Thiophenes: C₄H₄S + 4H₂ → C₄H₁₀ + H₂S
The catalyst's active metal sulfide sites facilitate both hydrogen activation and sulfur-carbon bond scission through a mechanism involving heterolytic H₂ dissociation at coordinatively unsaturated metal centers, followed by hydrogen transfer to adsorbed substrate molecules.
4.2 Olefin Hydrogenation
Olefins (alkenes) are saturated to corresponding paraffins (alkanes) via addition of hydrogen across the carbon-carbon double bond:
CₙH₂ₙ + H₂ → CₙH₂ₙ₊₂
The reaction proceeds through adsorption of the olefin on the catalyst surface via π-electron interaction with metal centers, followed by sequential hydrogen atom addition. Our catalyst's optimized surface acidity and metal dispersion ensure high olefin conversion while minimizing undesirable side reactions such as cracking or polymerization.
4.3 Oxygen Removal
Trace oxygen in feedstocks is also effectively removed:
O₂ + 2H₂ → 2H₂O
This comprehensive reactivity profile means a single catalyst bed can address multiple contaminant types simultaneously, simplifying process design and reducing equipment footprint.
5. Application Areas
5.1 Refinery Dry Gas Hydrogenation
Refinery dry gas—typically containing ethylene, propylene, and other light olefins along with organic sulfur compounds—requires purification before use as fuel or chemical feedstock. Our catalyst excels in this application, particularly when olefin content is below 8%, efficiently saturating olefins and converting organic sulfur to H₂S for subsequent removal by amine scrubbing or ZnO adsorption.
The catalyst's moderate temperature requirement makes it well-suited for integration with existing refinery gas treatment trains, enabling operators to upgrade gas quality without major process modifications.
5.2 Petroleum Fraction Hydrotreating
For naphtha, kerosene, and diesel fractions, the catalyst provides effective hydrodesulfurization and olefin saturation. It is particularly valuable for treating cracked naphtha streams containing high olefin and sulfur content, where selective hydrogenation of dienes and reactive sulfur species helps improve product stability and reduce downstream processing challenges.
5.3 Natural Gas & Associated Gas Treatment
Natural gas and associated gas from oil production often contain variable levels of organic sulfur compounds—including mercaptans, sulfides, and COS—that must be removed to meet pipeline specifications and protect downstream processing equipment. Our hydrogenation catalyst converts these organic sulfur species to H₂S, which can then be efficiently removed using conventional gas sweetening processes.
5.4 Oil Field Gas Processing
Oil field gas frequently contains heavy hydrocarbons, olefins, and sulfur compounds that complicate its utilization as fuel or feedstock. The catalyst's robust performance across variable compositions makes it an excellent choice for oil field gas upgrading, enabling reliable operation even with fluctuating feed quality.
5.5 Water Gas & Coke Oven Gas Purification
Water gas and coke oven gas are valuable industrial gases but contain various impurities including organic sulfur, olefins, and oxygen. Our hydrogenation catalyst provides an effective pre-treatment step, converting these contaminants into forms that can be readily removed in subsequent purification stages. This is critical for protecting sensitive downstream catalysts—such as those used in methanol synthesis or methanation—from sulfur poisoning and degradation.
6. Operating Guidelines
6.1 Catalyst Loading
Proper catalyst loading is essential for optimal performance and uniform flow distribution. We recommend:
• Ensure reactor internals are clean and free of debris before loading
• Use appropriate loading equipment to prevent catalyst attrition
• Maintain uniform bed density to avoid channeling
• Install proper support media and grading layers as specified
• Follow recommended loading procedures for radial or axial flow reactors
Our technical service team provides on-site supervision for critical loading operations to ensure optimal catalyst placement and bed configuration.
6.2 Activation / Sulfidation
The catalyst is typically supplied in oxide form and requires sulfidation before operation. The sulfidation process transforms metal oxides into the catalytically active sulfide phases. We recommend:
• Use appropriate sulfiding agent (DMDS, CS₂, or other suitable agents)
• Follow carefully controlled temperature ramp profiles
• Monitor H₂S breakthrough to confirm complete sulfidation
• Maintain sufficient H₂ partial pressure throughout activation
Improper sulfidation can significantly reduce catalyst activity and lifespan. Our technical team provides detailed activation procedures and can supervise the commissioning process.
6.3 Normal Operation
For optimal performance and catalyst longevity, maintain operating parameters within recommended ranges:
• Gradual temperature and pressure changes during startup and shutdown
• Avoid rapid feed composition swings when possible
• Monitor pressure drop across the bed as an indicator of fouling
• Regularly sample and analyze feed and product compositions
• Maintain proper H₂ circulation rate and purity
6.4 Regeneration
After extended operation, the catalyst may experience gradual deactivation due to coke deposition. In-situ or ex-situ regeneration can effectively restore activity by controlled burning of carbonaceous deposits. Our technical team can provide regeneration procedures and performance recovery assessments to help operators maximize catalyst value.
7. Packaging, Storage & Safety
7.1 Packaging
The catalyst is supplied in durable, moisture-resistant steel drums or flexible intermediate bulk containers (FIBCs) with polyethylene inner liners to protect against moisture contamination during transport and storage. Each shipment includes a Certificate of Analysis confirming compliance with specifications.
7.2 Storage
• Store in a cool, dry, well-ventilated area
• Keep containers tightly sealed when not in use
• Protect from direct sunlight and extreme temperatures
• Avoid contact with acids, bases, and reactive chemicals
• Follow proper material handling procedures, including appropriate personal protective equipment
7.3 Safety Considerations
• Avoid inhalation of catalyst dust; use respiratory protection when handling
• Avoid skin and eye contact; wear gloves and safety glasses
• Wash thoroughly with soap and water after handling
• In case of eye contact, flush with water for 15 minutes and seek medical attention
• Spent catalyst may contain adsorbed hazardous substances; handle and dispose of according to local regulations
• Sulfided catalyst may release toxic H₂S if exposed to air or moisture—follow proper handling protocols for reduced catalysts
8. Technical Support & Services
We are committed to ensuring our customers achieve maximum value from our catalysts through comprehensive technical support:
Catalyst Selection & Testing: Our technical team evaluates specific process conditions and performance targets to recommend the optimal catalyst formulation and loading scheme. We offer laboratory-scale testing and pilot plant validation to confirm performance expectations.
Process Simulation & Optimization: Using advanced process simulation tools, we model reactor performance under various operating scenarios, helping customers optimize conditions for maximum efficiency and product quality.
On-Site Technical Service: Experienced technical specialists provide on-site support for catalyst loading, activation/commissioning, performance audits, and troubleshooting.
Regular Performance Monitoring: We offer ongoing performance analysis and optimization recommendations to maintain peak catalyst efficiency throughout its service life.
Regeneration & Recycling Services: For spent catalysts, we provide regeneration assessment and can coordinate catalyst recycling programs to recover valuable metals, reducing environmental impact and overall lifecycle costs.
For more information about our Novel Hydrogenation Catalyst, including detailed product data sheets, safety information, or technical consultation, please contact our sales and technical support team. We work closely with each customer to develop tailored solutions that meet specific operational requirements and deliver measurable economic value.
