Amorphous Silica-Alumina Catalyst Preparation
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Solution Overview
Problem
Existing amorphous silica-alumina (ASA) catalysts used in hydrocracking processes have low surface area and pore volume, leading to reduced yield and selectivity for cracking bulky molecules.
Innovation Solution
A process involving reacting a zeolite with an oxidizing agent and a structure-directing agent, followed by calcination, to produce an amorphous silica-alumina catalyst with increased surface area and pore volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional ASA preparation methods (cogelling, coprecipitation, impregnation) are used, then the catalyst can be produced with standard manufacturing processes, but the surface area and pore volume remain low
Solution Approach 1:
The zeolite is pre-treated with base and oxidizing agents to create a precursor structure before the main synthesis step. This preliminary treatment modifies the zeolite to facilitate subsequent formation of high-surface-area ASA with enhanced porosity, achieving superior catalyst performance through preparatory modifications.
Solution Approach 2:
The invention changes key chemical parameters by using oxidizing agents (H2O2, NaClO, NaClO3, KMnO4, NaNO2, or NaNO3) instead of conventional neutral pH treatments, and employs structure-directing agents (SDAs) to control pore formation. These parameter changes result in ASA with surface area ≥900 m2/g and pore volume ≥0.9 mL/g, significantly improving the catalyst properties.
2Productivity
If conventional ASA catalysts are used in hydrocracking, then the process can proceed with standard catalysts, but the yield and selectivity for cracking bulky molecules are reduced
Solution Approach 1:
The invention creates ASA with enhanced porosity by incorporating SDAs that direct the formation of mesopores during synthesis. The resulting catalyst has pore volume ≥0.9 mL/g and surface area ≥900 m2/g, which improves access to bulky molecules and enhances cracking yield and selectivity compared to conventional ASA catalysts.
3Area of stationary object
If zeolite is treated with base and oxidizing agents followed by SDA treatment, then high surface area and pore volume are achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The invention combines multiple treatment steps (base treatment, oxidizing agent treatment, and SDA treatment) into a integrated sequential process. By merging these steps in a specific sequence using readily available chemicals, the process achieves high surface area ASA production without requiring complex equipment or specialized manufacturing infrastructure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting ASA catalyst exhibits a surface area of at least 900 m2/g and a pore volume of at least 0.9 ml/g, enhancing the selectivity and yield of diesel through the hydrocracking process.
Implementation Method 1
reacting a zeolite with an oxidizing agent in a first solvent to form a first product
Implementation Method 2
reacting a structure-directing agent with the first product to form a second product
Implementation Method 3
calcining the second product resulting in the amorphous silica-alumina
Data Source
AI summary
This disclosure relates to an amorphous silica-alumina catalyst with a high surface area and a high pore volume useful for hydrocracking. This disclosure also relates to a process of preparing an amorphous silica-alumina catalyst with an increased surface area and an increased pore volume.