Hydrocracking Catalyst with High Nanopore Volume ASA
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Solution Overview
Problem
Conventional hydrocracking catalysts exhibit limited hydrogen efficiency and poor product yield and quality due to the limited hydrogen solubility and diffusivity in heavy hydrocarbon feedstocks, which hinders the hydrogenation function and results in unconverted oil products of poor quality.
Innovation Solution
A hydrocracking catalyst is developed using a high nanopore volume (HNPV) amorphous silica-alumina (ASA) component combined with a HNPV alumina support, characterized by a low particle density and specific pore size distribution, allowing for increased metal loading and improved hydrogen efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional hydrocracking catalysts are used, then the catalyst structure is simple and easy to manufacture, but hydrogen efficiency is limited and product yield and quality are poor
Solution Approach 1:
The patent employs a composite catalyst structure combining HNPV ASA component with HNPV alumina support. This composite material approach allows the catalyst to simultaneously achieve improved hydrogen efficiency through enhanced nanopore volume and maintained manufacturability through extrusion成型 technology. The specific combination of ASA (30-70 wt%) and alumina (20-50 wt%) creates a synergistic effect that resolves the contradiction between manufacturing simplicity and catalytic performance.
Solution Approach 2:
The patent utilizes porous materials with high nanopore volume (NPV ≥ 0.65 mL/g for ASA and NPV ≥ 0.30 mL/g for alumina) to enhance hydrogen diffusion and access. The porous structure increases the internal surface area available for catalytic reactions while maintaining an extrudable form factor. This resolves the contradiction by providing high productivity through enhanced mass transfer while keeping the manufacturing process relatively simple through extrusion成型.
2Productivity
If HNPV ASA component with low particle density is used, then hydrogen efficiency and product yield are improved, but the catalyst structure becomes more complex
Solution Approach 1:
The patent changes key physical parameters of the catalyst components, specifically targeting nanopore volume (NPV ≥ 0.65 mL/g for ASA) and particle density (0.60-0.85 g/cm³ for ASA). By optimizing these parameters within specific ranges, the patent achieves improved hydrogen efficiency and product yield while maintaining a manageable structural complexity through controlled pore size distribution (peak diameter 70-120 Å) and defined compositional ranges.
3Power
If increased metal loading is implemented, then catalytic activity is enhanced, but the base extrudate particle density increases
Solution Approach 1:
The patent employs the low-density HNPV ASA component (0.60-0.85 g/cm³) as a counterbalancing matrix that offsets the weight increase from higher metal loading. The ASA component's low particle density and high nanopore volume provide a lightweight framework that accommodates increased metal content (NiO: 5-20 wt%, WO3: 15-30 wt%) while maintaining overall catalyst density suitable for industrial application. This allows enhanced catalytic activity through increased metal loading without proportionally increasing the catalyst's weight burden.
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 exhibits enhanced hydrogen efficiency and greater product yield and quality, particularly suited for processing disadvantaged feedstocks, by facilitating better hydrogen access and diffusion through the catalyst pores.
Implementation Method 1
The HNPV ASA component and HNPV alumina support are combined to form a HNPV base extrudate suitable for manufacturing the finished improved hydrocracking catalyst of the present invention. The catalyst exhibits enhanced hydrogen efficiency and greater product yield and quality by facilitating better hydrogen access and diffusion through the catalyst pores.
Implementation Method 2
Heavy hydrocarbonaceous oils boiling in the gas oil range can have sulfur contents ranging from about 500 ppmw to about 100,000 ppmw elemental sulfur. The HNPV ASA component is characterized as having a low particle density and narrower pore size distribution, while the alumina support has a broader pore size distribution.
Implementation Method 3
Catalytic hydroprocessing refers to petroleum refining processes in which a carbonaceous feedstock is brought into contact with hydrogen and a catalyst, at a higher temperature and pressure, for the purpose of removing undesirable impurities and/or converting the feedstock to an improved product.
Data Source
AI summary
The present invention is directed to an improved hydrocracking catalyst containing an amorphous silica-alumina (ASA) base and alumina support. The ASA base is characterized as having a high nanopore volume and low particle density. The alumina support is characterized as having a high nanopore volume. Hydrocracking catalysts employing the combination high nanopore volume ASA base and alumina support exhibit improved hydrogen efficiency, and greater product yield and quality, as compared to hydrocracking catalysts containing conventional ASA base and alumina components.