Hydrocracking Catalyst with Y and SAPO-34 Sieves for Jet Fuel Yield
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Solution Overview
Problem
Existing hydrocracking catalysts fail to adequately increase jet fuel yield and improve selectivity of middle distillate products, particularly in the hydrocracking process, which is crucial for meeting market demands and environmental standards.
Innovation Solution
A hydrocracking catalyst comprising a carrier with Y molecular sieves and SAPO-34 molecular sieves, loaded with VIB group metals like molybdenum and tungsten, and VIII group metals like cobalt and nickel, along with silica generated in situ from silane, which enhances catalytic activity and jet fuel yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydrocracking catalysts are used, then the catalytic reaction can proceed, but the jet fuel yield is insufficient and cannot meet market demands
Solution Approach 1:
The patent employs a composite molecular sieve carrier system combining Y molecular sieves (2-35 wt%) and SAPO-34 molecular sieves (2-25 wt%), along with silica (0.5-5 wt%) generated from silane. This composite structure integrates the high crystallinity and acidity of Y molecular sieves with the pore structure advantages of SAPO-34, creating synergistic effects that enhance both jet fuel yield and middle distillate production simultaneously
Solution Approach 2:
The patent optimizes multiple parameters including the weight ratios of Y molecular sieves (2-35 wt%) and SAPO-34 molecular sieves (2-25 wt%), the silicon-aluminum ratio of Y molecular sieves (25-150), and the content of silica (0.5-5 wt%) generated from silane. These parameter adjustments enable fine-tuning of catalyst acidity and pore structure to maximize jet fuel yield while maintaining adequate middle distillate production
2Productivity
If the catalyst has high activity and selectivity, then target product yield increases, but the preparation complexity and cost increase
Solution Approach 1:
The patent utilizes silane as a precursor that generates silica in situ during the catalyst preparation process. This self-service approach eliminates the need for separate silica addition steps, simplifying the preparation procedure while ensuring uniform silica distribution and strong interaction with the molecular sieve carrier, thereby maintaining high catalyst activity without increasing preparation complexity
Solution Approach 2:
The composite molecular sieve carrier system serves multiple functions simultaneously: Y molecular sieves provide high acidity and crystallinity, SAPO-34 molecular sieves contribute optimal pore structure for product selectivity, and silica enhances the overall stability and acidity. This multi-functional design achieves high catalyst activity and selectivity through a integrated structure rather than separate additive steps
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 significantly increases jet fuel yield by about 40% compared to conventional yields, producing high-quality hydrocracking tail oil while maintaining strong acidity and pore structure synergy.
Implementation Method 1
The hydrocracking catalyst comprises two parts, namely a carrier and active ingredients, wherein the carrier mainly serves to provide a place for dispersing the metal active ingredients, and the carrier per se provides the suitable acidity in the catalytic reaction process
Implementation Method 2
the hydrogenation component is a metal oxide selected from the VIII groups and VIB groups in the Periodic Table
Implementation Method 3
the acidic component is mainly consisting of molecular sieves and an inorganic oxide
Implementation Method 4
the carrier comprises Y molecular sieves and SAPO-34 molecular sieves
Implementation Method 5
silica generated in situ from silane
Data Source
AI summary
Disclosed is a hydrocracking catalyst, a preparation method and an application thereof. The catalyst comprises a carrier, silicon dioxide and active ingredients loaded on the carrier, wherein the carrier comprises Y molecular sieves and SAPO-34 molecular sieves. The preparation method of the hydrocracking catalyst comprises the following steps: (1) mixing materials comprising Y molecular sieves and SAPO-34 molecular sieves, and then subjecting the mixture to molding, drying and calcinating to obtain a carrier; (2) introducing silane and the active ingredients into the carrier prepared in the step (1), subsequently performing the drying and calcinating to prepare the hydrocracking catalyst. The catalyst prepared with the method can be used for hydrocracking reaction, thereby significantly increase yield of jet fuel.