(214d) - Accelerated Deployment of Nanostructured Hydrotreating Catalysts

Argonne invented methods for preparing nanostructured catalysts that exhibit superior performance in bench-scale testing. In this project, we will demonstrate that these new nanomanufacturing techniques, atomic layer deposition, allow us to rapidly develop, evaluate, and deploy catalysts for industrial utilization. As a pioneer test of this capability, we will design, screen, and manufacture hydrotreating catalysts for the re-refining of used oil. We will work in partnership with Universal Lubricants Inc. to develop these catalysts and integrate them into their re-refining facility. In addition to the energy, environmental, and economic benefits associated with oil recycling, the successful completion of this project will demonstrate the capability of this nanomanufacturing technology to rapidly impact industrial catalysts in a broad range of energy intensive, large carbon footprint applications

A recent study of the potential energy savings from the implementation of improved catalyst selectivity in the entire US chemical industries estimate energy savings of 280-600 TBtu/yr assuming that the remaining theoretical margin for catalyst improvement is cut in half. These projections are based on the replacement of catalysts in existing processes. In order to realize some of this potential using ALD catalyst requires broad adoption in industry of the development function.

The potential reduction of CO2 emissions in oil re-refining will come primarily from avoided consumption of virgin oils for base lube stock. In addition, use of waste oils as low-grade boiler fuel presents potential environmental hazards if independent or wildcat operations purchase the materials. The value-add market of waste oil re-refining will provide a market pull for collection of waste materials for the developed process.

Demonstration of a nanocatalyst design and commercialization in a 3-5 year time frame should open ALD to new catalyst opportunities and expand its impact to other energy intensive processes.