Hydrocracking Catalyst with Balanced Pore Distribution
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Solution Overview
Problem
Existing catalysts for hydrocracking heavy oil fail to balance high conversion and desulfurization activity, with increased crystalline aluminosilicate leading to insufficient desulfurization and increased alumina resulting in insufficient conversion.
Innovation Solution
A catalyst with a support comprising 45-60% crystalline aluminosilicate and 40-55% porous inorganic oxide, including alumina, and an active metal from Groups 6, 8, and 10, optimized for pore distribution and metal support, enhancing both conversion and desulfurization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the amount of crystalline aluminosilicate in the support is increased to improve conversion, then conversion increases, but desulfurization activity becomes insufficient
Solution Approach 1:
The patent applies parameter changes by precisely controlling the mixing ratio of crystalline aluminosilicate (2-35% by mass) and alumina (65-98% by mass) in the support, along with controlling pore diameter (6-12.5 nm) and pore volume (0.30-0.70 cm³/g), to achieve optimal balance between conversion and desulfurization activity
Solution Approach 2:
The patent uses a composite support material combining crystalline aluminosilicate and alumina in specific ratios, where each component contributes different functions - crystalline aluminosilicate provides conversion activity while alumina provides desulfurization activity, achieving synergistic effect
2Reliability
If the amount of alumina in the support is increased to improve desulfurization activity, then desulfurization activity increases, but conversion becomes insufficient
Solution Approach 1:
The patent controls the alumina content within 65-98% by mass of the support, combined with specific pore structure parameters (pore diameter 6-12.5 nm, pore volume 0.30-0.70 cm³/g), to ensure sufficient conversion activity while maintaining high desulfurization activity
Solution Approach 2:
The composite support structure combines alumina (for desulfurization) with crystalline aluminosilicate (for conversion), where the interfacial interaction and pore structure enable both functions to operate effectively simultaneously
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 balanced conversion and desulfurization activity, improving the yield of light fractions and maintaining high desulfurization and denitrogenation performance, suitable for hydrocracking heavy oil.
Implementation Method 1
a catalyst for hydrocracking of heavy oil which has excellent desulfurization activity and excellent conversion
Implementation Method 2
the catalyst has a pore distribution in which a total pore volume of pores having a diameter of 5 to 1000 nm is 0.40 dm3/kg or more, and a volume of intermediate mesopores having a diameter of 10 nm or more and less than 20 nm accounts for 60% or more of the total pore volume
Data Source
AI summary
Provided is a catalyst for hydrocracking of heavy oil which is excellent in both functions of cracking activity and desulfurization activity with respect to heavy oil by striking a balance between the cracking activity and desulfurization activity and which includes a support including a crystalline aluminosilicate and a porous inorganic oxide excluding the crystalline aluminosilicate, with an active metal being supported on the support, in which (a) the support includes the crystalline aluminosilicate in an amount of 45% by mass or greater and smaller than 60% by mass and the porous inorganic oxide excluding the crystalline aluminosilicate in an amount of greater than 40% by mass and 55% by mass or smaller, based on the sum of an amount of the crystalline aluminosilicate and an amount of the porous inorganic oxide excluding the crystalline aluminosilicate, (b) the active metal is at least one kind of metal selected from metals belonging to Groups 6, 8, 9, and 10 of the Periodic Table, and (c) the catalyst for hydrocracking of heavy oil has a distribution of pores in which an entire pore volume of pores defined as pores having a diameter of 5 to 1000 nm is 0.40 dm3/kg or greater, and a volume of intermediate mesopores having a diameter of 10 nm or larger and smaller than 20 nm accounts for 60% or greater of the entire pore volume.