Hydrocracking Catalyst Carrier Calcination
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Solution Overview
Problem
Current hydrocracking catalysts do not effectively produce a product slate with increased gas oil yield and improved denitrogenation, particularly in two-stage hydrocracking processes, where a catalyst with high selectivity for gas oil and reduced acidity is needed.
Innovation Solution
A hydrocracking catalyst carrier is prepared by calcining a carrier comprising an amorphous binder and zeolite Y at a temperature of 700 to 900°C, with a silica to alumina molar ratio of at least 10, which results in a catalyst with reduced acidity and increased gas oil selectivity, using Group VIII and VIB metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a catalyst carrier comprising amorphous binder and zeolite Y is calcined at high temperature (700-900°C), then gas oil selectivity and denitrogenation properties are enhanced, but the zeolitic structure may break down
Solution Approach 1:
The patent applies parameter changes by optimizing the calcination temperature range to 700-900°C, which is higher than conventional temperatures but carefully controlled to achieve the desired gas oil selectivity and denitrogenation properties without complete breakdown of the zeolitic structure. This parameter optimization resolves the contradiction between enhancing manufacturing precision (gas oil selectivity) and maintaining reliability (zeolitic structure stability).
Solution Approach 2:
The patent uses a composite material system comprising amorphous binder and zeolite Y with a specific silica to alumina molar ratio of at least 10. This composite structure allows the amorphous binder to provide structural support while the zeolite Y provides the catalytic function, enabling high gas oil selectivity while maintaining structural integrity during calcination at 700-900°C.
2Productivity
If calcination temperature is increased to improve gas oil selectivity, then denitrogenation properties are enhanced, but catalyst carrier structure may deteriorate
Solution Approach 1:
The patent optimizes the calcination temperature parameter to the range of 700-900°C, which enhances denitrogenation efficiency while maintaining catalyst carrier structure stability. This parameter optimization allows the system to achieve high productivity in denitrogenation without compromising the structural integrity of the catalyst carrier.
Solution Approach 2:
The patent specifies a local quality requirement for the zeolite Y component with a silica to alumina molar ratio of at least 10. This local compositional characteristic enhances the denitrogenation efficiency at the molecular level while the overall composite structure maintains stability during high-temperature calcination.
3Reliability
If conventional calcination temperature (close to 535°C) is used to maintain zeolitic structure, then gas oil selectivity is reduced, but structure stability is preserved
Solution Approach 1:
The patent fundamentally changes the calcination temperature parameter from conventional temperatures (around 535°C) to a higher range of 700-900°C. This parameter change enables the system to achieve superior gas oil selectivity and denitrogenation properties while the composite structure with amorphous binder and high-silica zeolite Y maintains adequate structural stability.
Solution Approach 2:
The patent employs a composite material system where amorphous binder provides structural framework and zeolite Y with silica to alumina ratio of at least 10 provides catalytic activity. This composite structure enables the system to withstand higher calcination temperatures (700-900°C) that would otherwise degrade conventional zeolitic structures, thereby achieving high gas oil selectivity while maintaining reliability.
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 enhances gas oil selectivity and denitrogenation properties, maintaining catalyst activity over time with a reduced acidity level, achieving higher yields of diesel-grade products.
Implementation Method 1
subjecting a carrier comprising an amorphous binder and zeolite Y having a silica to alumina molar ratio of at least 10 to calcination at a temperature of from 700 to 900° C.
Implementation Method 2
a carrier comprising an amorphous binder and zeolite Y having a silica to alumina molar ratio of at least 10
Implementation Method 3
the catalysts employed in hydrocracking are generally made from a carrier material on which there are deposited catalytically active metals such as nickel, molybdenum, tungsten and palladium
Data Source
AI summary
Process for preparing a hydrocracking catalyst carrier which process comprises subjecting a carrier comprising an amorphous binder and zeolite Y having a silica to alumina molar ratio of at least 10 to calcination at a temperature of from 700 to 900° C., hydrocracking catalyst carrier comprising amorphous binder and zeolite Y having a silica to alumina molar ratio of at least 10, the infrared spectrum of which catalyst has a peak at 3690 cm−1, substantially reduced peaks at 3630 cm−1 and 3565 cm−1 and no peak at 3600 cm−1, hydrocracking catalyst carrier comprising an amorphous binder and zeolite Y having a silica to alumina molar ratio of at least 10, which catalyst has an acidity as measured by exchange with perdeuterated benzene of at most 20 micromole/gram, hydrocracking catalyst derived from such carrier and hydrocracking process with the help of such catalyst.