Hydrocracking Catalyst Carbonaceous Substance Selectivity

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Solution Overview

Problem

Conventional hydrocracking catalysts exhibit reduced activity and middle distillate selectivity over time, leading to unsatisfactory yields of middle distillate in the stable phase of catalyst operation, especially when processing wax fractions in hydrocarbon raw oils.

Innovation Solution

A hydrocracking catalyst comprising a zeolite-supported amorphous composite metal oxide with a noble metal and a carbonaceous substance derived from organic compounds, maintaining 0.05 to 1% carbon content by mass, which enhances moderate hydrocracking activity while suppressing excessive hydrocracking, thereby maintaining high middle distillate selectivity and yield over a long period.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the cracking rate is enhanced to increase middle distillate yield, then the production of light fraction increases due to excessive hydrocracking, but the middle distillate selectivity reduces

Engineering Contradiction:

Improvemiddle distillate yieldVSAvoidmiddle distillate selectivity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The catalyst employs a dual-function catalyst support structure where zeolite components provide specific acid sites for controlled cracking while amorphous composite metal oxide provides different acid sites for hydrogenation. This local differentiation of catalytic functions within the support structure enables selective suppression of excessive hydrocracking while maintaining moderate cracking activity, thereby preserving middle distillate selectivity even at enhanced cracking rates

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The catalyst support is constructed as a composite material combining zeolite and amorphous composite metal oxide, each contributing distinct catalytic properties. The zeolite portion provides structured porosity and specific acid sites, while the amorphous metal oxide portion provides different acid site characteristics. This composite structure creates a balanced catalytic environment that simultaneously achieves high cracking activity and high middle distillate selectivity by distributing different catalytic functions across different material phases

Inventive Principle:

Principle #40Composite materials

2Power

If a conventional hydrocracking catalyst is used, then high hydrocracking activity is achieved in the early stage, but the activity reduces significantly over time, leading to shortened catalyst life

Engineering Contradiction:

Improvehydrocracking activityVSAvoidcatalyst life

Core Design Contradiction:

PowerVSDuration of action of stationary object

Solution Approach 1:

The catalyst support incorporates components with complementary stability characteristics - the zeolite provides structured stability while the amorphous composite metal oxide provides chemical stability. This beforehand cushioning through dual-stability design prevents rapid activity decay by distributing the stabilizing function across different material phases, each resistant to different deactivation mechanisms, thereby extending catalyst operational life while maintaining high activity

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 catalyst achieves high middle distillate yield and selectivity by balancing hydrocracking activity and suppressing excessive cracking, even in the stable phase, using a carbonaceous substance to inhibit excessive hydrocracking sites, thus extending catalyst life and maintaining performance.

Implementation Method 1

the catalyst contains a carbonaceous substance comprising a carbon atom... which enhances moderate hydrocracking activity while suppressing excessive hydrocracking, thereby maintaining high middle distillate selectivity

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

at least one active metal supported by the catalyst support and selected from noble metals of Group 8 to Group 10 in the periodic table... enhances moderate hydrocracking activity

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS9186658B2Hydrocracking catalyst and method for producing a hydrocarbon oil

Publication Date: 2015.11.17 INPEX CORP

AI summary

The hydrocracking catalyst of the present invention is a hydrocracking catalyst comprising a catalyst support comprising a zeolite and an amorphous composite metal oxide having solid acidity, and at least one active metal supported by the catalyst support and selected from noble metals of Group 8 to Group 10 in the periodic table, wherein the hydrocracking catalyst contains a carbonaceous substance comprising a carbon atom, and the content of the carbonaceous substance in the hydrocracking catalyst is 0.05 to 1% by mass in terms of the carbon atom.