Hydrogen Spillover Catalyst in Structurally Collapsed Zeolite
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Solution Overview
Problem
Current hydrogen spillover-based catalysts face limitations in achieving high hydroprocessing activity while suppressing C-C bond cleavage and maintaining thermal stability, especially in sulfur-containing environments.
Innovation Solution
A hydrogen spillover-based catalyst is developed with a hydrogen activation metal cluster encapsulated in structurally collapsed zeolite, specifically P-type, A-type, or X-type zeolites with a silica/alumina molar ratio of 2 or less, which is ion-exchanged with ammonium ions and thermally treated to form crystalline or amorphous aluminosilicate, enhancing hydroprocessing activity and thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If precious metal-based catalyst (Pt, Pd) is used for hydroprocessing, then high activity is achieved in the absence of sulfur, but the catalyst is rapidly deactivated in the presence of sulfur
Solution Approach 1:
The patent embeds precious metal particles inside the cages of zeolite Y, creating a nested structure where the metal is protected within the porous framework. This nesting prevents direct contact between sulfur compounds and the metal active sites, thereby maintaining catalyst stability in sulfur-containing environments while preserving high hydroprocessing activity
Solution Approach 2:
The patent utilizes the microporous structure of zeolite Y with specific pore sizes (3.7-4.1 nm) to selectively allow hydrogen molecules to reach the encapsulated metal particles while blocking larger sulfur-containing molecules. This porous confinement strategy enables the catalyst to maintain high activity and resistance to sulfur poisoning simultaneously
2Reliability
If molybdenum sulfide-based catalyst (NiMo, CoMo) is used for hydroprocessing, then resistance to sulfur is improved, but activity is reduced
Solution Approach 1:
The patent creates a composite catalyst system combining precious metal particles (0.1-5 nm) with zeolite Y support, forming a hybrid material that exhibits both high activity from the precious metal and high sulfur resistance from the zeolite framework. This composite structure overcomes the limitations of using either molybdenum sulfide or precious metal alone
3Reliability
If metal particles are supported in microporous zeolite to enhance stability, then catalyst stability is improved, but C-C bond cleavage (hydrogenolysis) is not sufficiently suppressed
Solution Approach 1:
The patent creates locally differentiated environments within the zeolite Y structure by controlling the size and distribution of metal particles in different cage types (α-cages and β-cages). This local quality control ensures that hydrogenation reactions occur preferentially while C-C bond cleavage is suppressed, achieving both stability and selectivity
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 high hydroprocessing activity, low C-C hydrogenolysis activity, and superior thermal stability, outperforming conventional Pt/SiO2 catalysts by encapsulating hydrogen activation metal in structurally stable aluminosilicate, preventing sintering and maintaining activity under severe conditions.
Implementation Method 1
a hydrogen activation metal (M) cluster encapsulated in the aluminosilicate
Implementation Method 2
hydrogen spillover-based catalyst wherein a hydrogen activation metal cluster is dispersed in a crystalline or amorphous aluminosilicate matrix
Implementation Method 3
ion-exchanging the zeolite with an ammonium ion
Implementation Method 4
thermally treated to form crystalline or amorphous aluminosilicate
Data Source
Figure 1~2
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AI summary
This invention relates to a hydrogen spillover-based catalyst and use thereof, wherein a hydrogen activation metal cluster is dispersed in the form of being encapsulated in a crystalline or amorphous aluminosilicate matrix which is partially or fully structurally collapsed zeolite, thereby exhibiting high hydroprocessing or dehydrogenation activity and suppressed C-C hydrogenolysis activity.