Hydrocracking Catalyst Preparation via Surfactant Decomposition
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Solution Overview
Problem
Existing methods for preparing hydrocracking catalysts face challenges such as explosibility risks during air calcination due to surfactant presence and high CAPEX intensity from using inert gases like nitrogen at commercial scales.
Innovation Solution
A method involving zeolite Y with a bulk silica to alumina ratio of at least 10, mixed with a base and surfactant to create a slurry, followed by reducing water content with a binder, shaping, and calcining above 300°C in the presence of surfactant, eliminating the need for high-temperature heat treatment before shaping and allowing calcination in air without inert gases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If air calcination is performed on catalyst carrier containing surfactant at commercial scale, then the process can be simplified and costs reduced, but explosion risk increases due to carbon content of surfactant
Solution Approach 1:
The patent applies preliminary action by performing a first drying step at elevated temperature (50-150°C) before calcination to remove free water and partially decompose the surfactant. This preliminary treatment reduces the surfactant carbon content that could cause explosions during subsequent air calcination, while still allowing the calcination to proceed in air rather than requiring inert atmosphere
Solution Approach 2:
The patent applies beforehand cushioning by conducting the drying step at moderate temperatures (50-150°C) before the high-temperature calcination. This intermediate step cushions the transition by progressively removing water and partially decomposing surfactant, preventing sudden explosive reactions during the subsequent calcination at higher temperatures
2Reliability
If inert gas (nitrogen) is used during calcination to prevent explosion, then safety is improved, but CAPEX intensity increases
Solution Approach 1:
The patent eliminates the need for expensive inert gas systems by applying preliminary drying at elevated temperatures before calcination. This preliminary treatment sufficiently reduces surfactant content to allow safe air calcination, removing the requirement for CAPEX-intensive nitrogen infrastructure while maintaining safety
Solution Approach 2:
The patent replaces the expensive inert gas (nitrogen) infrastructure with a simple thermal drying step that uses readily available heat and air. This substitution uses cheap, short-lived thermal energy instead of requiring permanent, expensive gas handling infrastructure
3Stability of the object's composition
If heat treatment above 500°C is performed before shaping, then surfactant decomposition is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the drying and surfactant decomposition steps into a single elevated temperature drying step performed before shaping. This combines what could be separate operations into one integrated step, simplifying the manufacturing process while still achieving sufficient surfactant decomposition
Solution Approach 2:
The patent performs preliminary decomposition of surfactant through elevated temperature drying (50-150°C) before shaping and final calcination. This preliminary action reduces surfactant content in advance, eliminating the need for additional high-temperature treatment steps and simplifying the overall manufacturing process
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
This method reduces explosion risks, simplifies the calcination process, and enhances middle distillate selectivity (150°C-370°C) in hydrocarbon conversion, improving manufacturing ease and catalyst performance.
Implementation Method 1
mixing the zeolite Y provided in step a) with a base, water and a surfactant, thereby obtaining a slurry of the zeolite Y
Implementation Method 2
reducing the water content of the slurry obtained in step b) thereby obtaining solids with reduced water content
Implementation Method 3
calcining the shaped catalyst carrier obtained in step d) at a temperature above 300° C. in the presence of the surfactant of step b)
Data Source
AI summary
The present invention provides a method of preparing a supported catalyst, preferably a hydrocracking catalyst, the method at least comprising the steps of: a) providing a zeolite Y having a bulk silica to alumina ratio (SAR) of at least 10; b) mixing the zeolite Y provided in step a) with a base, water and a surfactant, thereby obtaining a slurry of the zeolite Y; c) reducing the water content of the slurry obtained in step b) thereby obtaining solids with reduced water content, wherein the reducing of the water content in step c) involves the addition of a binder; d) shaping the solids with reduced water content obtained in step c) thereby obtaining a shaped catalyst carrier; e) calcining the shaped catalyst carrier obtained in step d) at a temperature above 300° C. in the presence of the surfactant of step b), thereby obtaining a calcined catalyst carrier; f) impregnating the catalyst carrier calcined in step e) with a hydrogenation component thereby obtaining a supported catalyst; wherein no heat treatment at a temperature of above 500° C. takes place between the mixing of step b) and the shaping of step d).