Hydrocracking Catalyst Preparation via Homogeneous Mixing
Solution Overview
Problem
Existing hydrocracking catalysts face issues with uneven distribution of hydrogenating metals, leading to variations in catalyst performance, and often require phosphorus treatment of zeolites, which is not necessary in this process.
Innovation Solution
A process involving combining a zeolite with a binder and a hydrogenating metal compound, forming a mixture, and calcining it to create a catalyst without prior phosphorus treatment, ensuring homogeneous metal distribution and optimal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If phosphorus treatment is applied to zeolites in existing processes, then catalyst performance is improved, but the process complexity and additional treatment steps increase
Solution Approach 1:
The invention extracts and eliminates the phosphorus treatment step from the catalyst preparation process. By removing this unnecessary intermediate treatment, the process becomes simpler while maintaining catalyst performance, as the zeolite can be directly combined with the binder and hydrogenating metal compound without prior phosphorus modification
Solution Approach 2:
The invention changes the preparation parameters by eliminating the phosphorus treatment step and directly combining zeolite with binder and metal compound. This parameter change simplifies the process while achieving the same or better catalyst performance through direct integration of components
2Reliability
If hydrogenating metals are distributed in existing catalysts, then catalyst activity is achieved, but uneven distribution leads to performance variations
Solution Approach 1:
The invention merges the zeolite, binder, and hydrogenating metal compound into a single homogeneous mixture before forming the catalyst. This combining step ensures uniform distribution of metals throughout the catalyst structure, eliminating performance variations caused by uneven metal distribution in conventional catalysts
Solution Approach 2:
The invention achieves homogeneity by thoroughly mixing the zeolite, binder, and hydrogenating metal compound together before catalyst formation. This homogeneous mixing ensures uniform metal distribution throughout the catalyst, leading to consistent activity and performance across the entire catalyst bed
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 prevents uneven metal distribution, enhancing catalyst performance and producing a hydrocracking catalyst with improved activity and stability, specifically achieving high benzene purity and efficient hydrocracking of C5-C12 hydrocarbons.
Implementation Method 1
calcining it to create a catalyst
Implementation Method 2
combining a zeolite with a binder and a hydrogenating metal compound, forming a mixture
Implementation Method 3
efficient hydrocracking of C5-C12 hydrocarbons
Data Source
AI summary
Disclosed herein is a process for preparing a hydrocracking catalyst, comprising (i) combining a zeolite, a binder, water and a hydrogenating metal compound which is a complex or a salt of a hydrogenating metal to obtain a mixture, wherein the zeolite has not been treated with a phosphorus-containing compound and the zeolite has a silica to alumina molar ratio of 5-200; (ii) forming the mixture into a shaped body; and (iii) calcining the shaped body to form the catalyst.