# US 11,992,829 B2 · Peptization agent and solid catalyst manufacturing method

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- Number: US 11,992,829 B2
- Document ID: US11992829B2
- Status: Granted
- Kind: B2
- Application number: 17/689,009
- Filed: 2022-03-08
- Published: 2023-09-14
- Granted: 2024-05-28
- Earliest claimed: 2022-03-08
- Assignees: Saudi Arabian Oil Company
- Applicants: Saudi Arabian Oil Company
- Inventors: Guanghui Zhu; Omer Refa Koseoglu
- Web page: https://patentgrep.com/patent/US11992829B2

## CPC

- B01J 37/0072: {Preparation of particles, e.g. dispersion of droplets in an oil bath}
- B01J 37/0207: {Pretreatment of the support}
- B01J 21/04: Alumina
- B01J 21/08: Silica
- B01J 21/12: Silica and alumina
- B01J 29/06: Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
- B01J 29/084: {Y-type faujasite}
- B01J 35/37: Crush or impact strength
- B01J 35/615: {100-500 m2/g}
- B01J 35/633: {less than 0.5 ml/g}
- B01J 35/635: {0.5-1.0 ml/g}
- B01J 35/647: {2-50 nm}
- B01J 37/0009: {Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst}
- B01J 37/031: {Precipitation}
- B01J 37/04: Mixing {(B01J37/0009, B01J37/0018 take precedence)}
- B01J 2229/42: Addition of matrix or binder particles
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS

## Abstract

Methods of solid catalyst manufacture using a peptization agent, and formed solid catalyst materials having improved structural properties are provided. The peptization agent includes one or more oxidized disulfide oil (“ODSO”) compounds. These ODSO compounds peptization agents serve to improve the adhesion characteristics of the binder material, and as a result increase the particle strength of the final catalyst particles.

## Claims

### Claim 1

A method for manufacture of solid catalyst particles and/or solid catalyst support particles comprising:
providing a first intermediate composition comprising one or more base catalyst materials and/or one or more base catalyst support materials;
providing a second intermediate composition comprising one or more inorganic oxide materials;
contacting the second intermediate composition with an effective quantity of a peptization agent to form a peptized binder composition,
wherein the peptization agent includes one or more oxidized disulfide oil (ODSO) compounds;
mixing the first intermediate composition and the peptized binder composition to form a composite;
forming solid catalyst particles and/or solid catalyst support particles from the composite.

### Claim 2 (depends on 1)

The method as in claim 1, further comprising thermally treating the catalyst particles.

### Claim 3 (depends on 1)

The method as in claim 1, wherein the first intermediate composition comprises zeolite, amorphous alumina silicate, silica, metal salts, or a mixture comprising two or more of zeolite, amorphous silica alumina, silica or metal salts.

### Claim 4 (depends on 3)

The method as in claim 3, wherein the first intermediate composition comprises a mixture of zeolite and amorphous silica alumina.

### Claim 5 (depends on 1)

The method as in claim 1, wherein the inorganic oxide as the second intermediate composition forms the peptized binder composition as a binder when mixed with the peptization agent, wherein the peptized binder composition increases adhesion within the first intermediate composition in the solid catalyst particles and/or solid catalyst support particles.

### Claim 6 (depends on 1)

The method as in claim 1, wherein the inorganic oxide material comprises alumina.

### Claim 7 (depends on 1)

The method as in claim 1, wherein mixing of the first catalyst intermediate composition and the peptized binder composition comprises mulling or kneading, wherein deionized water is added during mulling or kneading to increase extrudability of the composite.

### Claim 8 (depends on 1)

The method as in claim 1, wherein the ratio of a quantity of ODSO in the peptization agent to a quantity of the second intermediate composition is in the range of about 1:1 to about 1:1000.

### Claim 9 (depends on 1)

Solid catalyst particles and/or solid catalyst support particles formed according to the method as in claim 1, containing sulfur from the ODSO within the particles.

### Claim 10 (depends on 8)

The method as in claim 8, wherein the ratio of the quantity of ODSO in the peptization agent to the quantity of the second intermediate composition is in the range of about 1:1 to about 1:20.

### Claim 11 (depends on 9)

Solid catalyst particles and/or solid catalyst support particles as in claim 9, which exhibit higher crush strength compared to analogous solid catalyst particles and/or solid catalyst support particles formed with equivalent mass or molar amounts of nitric acid as a peptization agents.

### Claim 12 (depends on 9)

Solid catalyst particles and/or solid catalyst support particles as in claim 9, which exhibit crush strength in the range of about 20-50 Newtons (N) per millimeter.

### Claim 13 (depends on 1)

The method as in claim 1, wherein the one or more ODSO compounds is selected from the group consisting of compounds having the general formula (R—SO—S—R′), (R—SOO—S—R′), (R—SOO—SO—R′), (R—SOO—SOO—R′), (R—SO—SO—R′), (R—SO—SOO—OH), (R—SOO—SOO—OH), (R—SO—SO—OH), (R—SOO—SO—OH), (R—SO—SO—OR′), (R—SOO—SO—OR′), (R—SO—SOO—OR′) and (R—SOO—SOO—OR′) wherein R and R′ can be the same or different C1-C10 alkyl or C6-C10 aryl.

### Claim 14 (depends on 1)

The method as in claim 1, wherein the one or more ODSO compounds is selected from the group consisting of water-soluble ODSO compounds having the general formula (R—SOO—SO—R′), (R—SOO—SOO—R′), (R—SO—SOO—OH), (R—SOO—SOO—OH), (R—SOO—SO—OH), (R—SO—SO—OR′), (R—SOO—SO—OR′), (R—SO—SOO—OR′) and (R—SOO—SOO—OR′) wherein R and R′ can be the same or different C1-C10 alkyl or C6-C10 aryl.

### Claim 15 (depends on 1)

The method as in claim 1, wherein the peptization agent comprises a mixture of two or more types of ODSO compounds selected from the group consisting of compounds having the general formula (R—SO—S—R′), (R—SOO—S—R′), (R—SOO—SO—R′), (R—SOO—SOO—R′), (R—SO—SO—R′), (R—SO—SOO—OH), (R—SOO—SOO—OH), (R—SO—SO—OH), (R—SOO—SO—OH), (R—SO—SO—OR′), (R—SOO—SO—OR′), (R—SO—SOO—OR′) and (R—SOO—SOO—OR′) wherein R and R′ can be the same or different C1-C10 alkyl or C6-C10 aryl.

### Claim 16 (depends on 1)

The method as in claim 1, wherein the peptization agent comprises a mixture of two or more types of water-soluble ODSO compounds selected from the group consisting of compounds having the general formula (R—SOO—SO—R′), (R—SOO—SOO—R′), (R—SO—SOO—OH), (R—SOO—SOO—OH), (R—SOO—SO—OH), (R—SO—SO—OR′), (R—SOO—SO—OR′), (R—SO—SOO—OR′) and (R—SOO—SOO—OR′) wherein R and R′ can be the same or different C1-C10 alkyl or C6-C10 aryl.

### Claim 17 (depends on 15)

The method as in claim 15, wherein the mixture of two or more types of ODSO compounds corresponds to oxidized disulfide oils present in an effluent refinery hydrocarbon stream recovered following catalytic oxidation of mercaptans present in the effluent refinery hydrocarbon stream.

### Claim 18 (depends on 16)

The method as in claim 16, wherein the mixture of two or more types of ODSO compounds corresponds to oxidized disulfide oils present in an effluent refinery hydrocarbon stream recovered following catalytic oxidation of mercaptans present in the effluent refinery hydrocarbon stream.