Dual Hydrogenating Phase Catalyst for Middle Distillate Selectivity
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Solution Overview
Problem
Conventional hydrocracking catalysts face challenges in achieving high activity and selectivity for middle distillates, with existing catalysts either having low activity or poor selectivity due to imbalanced acid and hydrogenating functions, and limited improvement in yield and textural characteristics of zeolites.
Innovation Solution
A process using a dealuminated Y zeolite (USY) with specific textural characteristics and a dual hydrogenating phase, comprising nickel and another hydro-dehydogenic element, deposited on the zeolite and a porous mineral matrix, to enhance hydrocracking and hydrotreating of hydrocarbon feedstocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hydrocracking catalysts use amorphous silica-alumina supports, then good quality middle distillates are produced, but catalyst activity is low
Solution Approach 1:
The invention uses a composite catalyst system combining amorphous silica-alumina support with crystalline Y zeolite and dual hydrogenating phases (nickel and cobalt/molybdenum). This composite structure integrates the shape selectivity and stability of zeolite with the high activity of metallic phases, achieving both high middle distillate quality and high catalyst activity simultaneously
Solution Approach 2:
The catalyst design implements local quality differentiation by placing nickel (0.5-3% wt) specifically on the Y zeolite crystals while distributing cobalt-molybdenum phase (1-10% wt each) on the amorphous silica-alumina matrix. This spatial separation optimizes the local chemical environment for each metal phase, enhancing both selectivity and activity in different catalyst regions
2Productivity
If zeolite Y catalysts are used, then high catalytic activity is achieved, but selectivity for middle distillates decreases
Solution Approach 1:
The invention implements local quality by differentiating the chemical composition and metal distribution between the zeolite and matrix regions. The Y zeolite contains nickel for hydrodehydrogenation while the silica-alumina matrix contains cobalt-molybdenum for hydrocracking, creating functionally specialized zones that optimize both activity and selectivity
Solution Approach 2:
The invention modifies the catalyst parameters by controlling the Si/Al ratio of Y zeolite (2.5-10) and adjusting the metal loadings (nickel: 0.5-3% wt, cobalt: 1-10% wt, molybdenum: 1-10% wt). These parameter optimizations balance the acid strength and hydrogenating function, achieving high activity with improved middle distillate selectivity
3Reliability
If high metal content is used in hydrocracking catalysts, then hydrogenating function is enhanced, but cost and complexity increase
Solution Approach 1:
The invention reduces overall complexity by localizing metal functions: nickel (0.5-3% wt) is confined to the zeolite phase while cobalt-molybdenum (1-10% wt each) is localized on the matrix. This spatial differentiation allows each metal to operate in its optimal environment with lower overall loadings, reducing cost and simplifying the catalyst formulation
Solution Approach 2:
The catalyst is segmented into two functional domains: Y zeolite crystals for hydrodehydrogenation and silica-alumina matrix for hydrocracking. Each segment contains specifically designed metal phases, allowing independent optimization of each function while reducing the total metal content required compared to homogeneous high-metal catalysts
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 process achieves improved yield and selectivity of middle distillates while maintaining high activity, surpassing the performance of conventional catalysts by leveraging the unique textural characteristics of the dealuminated USY zeolite and the dual hydrogenating phase.
Implementation Method 1
The acid function is provided by acidic supports whose surfaces generally vary from 150 to 800 m2
Implementation Method 2
a first active hydrogenating phase consisting of a quantity of nickel of between 0.8 and 3% by weight relative to the total mass of the zeolite
Implementation Method 3
a second hydrogenating active phase deposited on the support or contained in the porous mineral matrix, constituting the support. The second active hydrogenating phase comprises at least one hydro-dehydogenic element
Data Source
AI summary
Preparing a catalyst comprising at least one hydro-dehydrogenating element comprising elements of non-noble group VIB and/or group VIII of the periodic table, and a support comprising at least one porous mineral matrix and dealuminated zeolite (USY), comprises: (a) preparing a dealuminated zeolite; (b) depositing on the dealuminated zeolite of the nickel element in an amount of 0.5-3 wt.%; (c) mixing with a porous mineral matrix and forming to obtain the support; (d) introducing at least one hydro-dehydrogenating element on the matrix; and (e) drying and calcining the product. Preparing a catalyst comprising at least one hydro-dehydrogenating element comprising elements of non-noble group VIB and/or Group VIII of the periodic table, and a support comprising at least one porous mineral matrix and at least one dealuminated zeolite USY, comprises: (a) preparing a dealuminated zeolite having an overall atomic ratio of silicon to aluminum of 2.5-10, a weight fraction of extra network aluminum atom of greater than 10 mass% with respect to the total mass of the aluminum present in the zeolite, a mesoporous volume measured by nitrogen porosimetry of greater than 0.07 ml.g -> 1>and a crystalline parameter (a0) of the unit cell greater than 24.28 A[deg] ; (b) depositing on the dealuminated zeolite of the nickel element in an amount of 0.5-3 wt.% with respect to the total weight of the zeolite; (c) mixing with a porous mineral matrix and forming to obtain the support; (d) introducing at least one hydro-dehydrogenating element on the matrix by (i) adding at least one compound of the element during forming to introduce at least one part of the component, and (ii) impregnating the support with at least one compound of the element; and (e) drying and calcining the obtained final product. An independent claim is included for process for hydrocracking and/or hydrotreating of hydrocarbon feeds using a catalyst, where the catalyst is in sulfate form.