Drop-in mixed-oxide catalyst platform for zero-octane-loss HDS & ULSD cetane leap (TRL 4)

A drop-in, modular mixed-oxide catalyst support platform (NiFeAl, MgFeAl, CoFeAl, ZnFeAl) derived from layered double hydroxide pre-cursors, validated at TRL 4 under high-pressure, continuous-flow micro-pilot conditions (40 Bar). The architecture features an interchangeable active phase (CoMo, NiMo, or Noble Metals) designed to eliminate polyaromatic steric hindrance in heavy and opportunity feedstocks.

Key Validated Performance Metrics: • ULSD & Middle Distillates (NiFeAl & MgFeAl): The CoMo/NiFeAl system delivers a 13x increase in catalytic activity and multiplies selectivity toward high-cetane bicyclohexyl by 14.44x (absolute BCH/CHB ratio of 1.30 vs. 0.09 for commercial benchmarks), driven by a 3x higher Mo-edge site density. The CoMo/MgFeAl system achieves exceptional active phase dispersion (101% sulfidation degree), delivering a 2x increase in HYD activity and a 6x improvement in HYD/DDS selectivity for steady-state ultra-deep HDS (<1 ppm sulfur) with zero coking deactivation. • FCC Gasoline Post-Treatment (CoFeAl & ZnFeAl): The CoMo/CoFeAl system demonstrates an intrinsic activity nearly 4x higher than commercial benchmarks paired with an HDS/HYD selectivity ratio 6 to 8 times superior to standard alumina, allowing deep desulfurization without olefin saturation. The CoMo/ZnFeAl system achieves 100% DDS selectivity (strictly zero olefin hydrogenation), guaranteeing full octane preservation and massive H2 OPEX savings. • Advanced Biofuels (HDO): Tunable basicity prevents rapid coking deactivation, making the matrix highly efficient for Hydrodeoxygenation (HDO) in Sustainable Aviation Fuel (SAF) and HVO production.

Industrial Fit & Digitalization: Synthesized via standard low-temperature co-precipitation, the platform requires strictly zero new CAPEX for existing commercial toll-manufacturing assets. Seeking Joint Development Agreements (JDA) or Toll Manufacturing partners to transition to TRL 6 through 10–50 kg batch pilot scale-up.