Dewaxing Catalyst with Hydrothermally Stable Binder
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Solution Overview
Problem
Conventional dewaxing catalysts face challenges with hydrothermal stability, catalyst poisoning, and mechanical strength when processing waxy feedstocks, particularly those with high oxygen content, leading to deactivation and reduced activity.
Innovation Solution
A dewaxing catalyst comprising a zeolite component (ZSM-48 or ZSM-23) combined with a hydrogenation component (Pt or Ni) and a hydrothermally stable binder (nickel molybdenum tungsten oxides, nickel molybdenum tungsten sulfide, WO3, La2O3, CeO2, or Nb2O5), optimized with specific weight ratios to enhance stability and activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional dewaxing catalysts are used to maximize dewaxing activity, then catalytic activity is improved, but hydrothermal stability deteriorates due to deactivation by steam causing dealumination of zeolite catalyst and degradation of oxide support/binder
Solution Approach 1:
The patent uses a composite catalyst system combining zeolite (ZSM-48 or ZSM-23) with specific binder materials (nickel molybdenum tungsten oxides, nickel molybdenum tungsten sulfide, WO3, La2O3, CeO2, or Nb2O5) to achieve both high dewaxing activity and hydrothermal stability. The composite structure allows the zeolite to provide catalytic activity while the specialized binder provides hydrothermal stability and prevents dealumination under steam exposure conditions.
2Strength
If zeolite catalysts are combined with inorganic oxide binder to ensure mechanical strength, then mechanical strength is improved, but hydrothermal stability deteriorates due to agglomeration of metal under steam conditions
Solution Approach 1:
The patent changes the chemical composition parameters of the binder material, selecting specific compounds (nickel molybdenum tungsten oxides, nickel molybdenum tungsten sulfide, WO3, La2O3, CeO2, or Nb2O5) that maintain mechanical strength while providing enhanced hydrothermal stability. These binder materials resist agglomeration under steam conditions better than conventional inorganic oxide binders.
3Productivity
If catalyst is exposed to steam generated from water conversion, then hydrogenation reaction is facilitated, but catalyst deactivation occurs due to dealuminating zeolite catalyst and degrading oxide support/binder
Solution Approach 1:
The patent converts the harmful effect of steam (which normally causes dealumination and deactivation) into a beneficial condition by using steam-tolerant binder materials that can withstand steam exposure. The specialized binders (nickel molybdenum tungsten oxides, nickel molybdenum tungsten sulfide, WO3, La2O3, CeO2, or Nb2O5) are specifically selected for their ability to maintain catalyst structure and activity in the presence of steam, allowing the hydrogenation reaction to proceed efficiently without deactivation.
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 catalysts demonstrate improved hydrothermal stability, reduced metal agglomeration, and increased catalytic selectivity and activity, effectively dewaxing oxygenated feeds without significant cracking, even in the presence of water and CO2.
Implementation Method 1
Catalysts that isomerize do not normally result in significant boiling point conversion. Catalysts that dewax primarily by isomerization are exemplified by the zeolites ZSM-22, ZSM-23, SSZ-32, ZSM-35, ZSM-48 and ZSM-50.
Implementation Method 2
a hydrogenation component selected from Pt, Ni, and a mixture thereof
Implementation Method 3
Catalytic dewaxing may be accomplished using catalysts that function primarily by cracking waxes to lower boiling products
Data Source
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AI summary
Provided are catalysts including: a zeolite component selected from zeolites having 10-member ring pores, zeolites having 12-member ring pores and a combination thereof, 0.1 to 5 weight % of a hydrogenation component selected from Pt, Pd, Ag, Ni, Co, Mo, W, Rh, Re, Ru, Ir and a mixture thereof, and a hydrothermally stable binder component selected from tantalum oxide, tungsten oxide, molybdenum oxide, vanadium oxide, magnesium oxide, calcium oxide, yttrium oxide, lanthanum oxide, cerium oxide, niobium oxide, tungstated zirconia, cobalt molybdenum oxide, cobalt molybdenum sulfide, nickel molybdenum oxide, nickel molybdenum sulfide, nickel tungsten oxide, nickel tungsten sulfide, cobalt tungsten oxide, cobalt tungsten sulfide, nickel molybdenum tungsten oxide and nickel molybdenum tungsten sulfide, cobalt molybdenum tungsten oxide and cobalt molybdenum tungsten sulfide, wherein the weight ratio of the zeolite to the hydrothermally stable binder is 85:15 to 25:75.