Hydroprocessing Catalyst with Modified Zeolite and Clay
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Solution Overview
Problem
Current catalyst compositions for converting hydrocarbon feeds to diesel range fuel products are not efficient, as they lack the necessary active sites and metal components to effectively crack heavy hydrocarbons under hydrocracking conditions.
Innovation Solution
A catalyst precursor composition is developed, comprising surface modified clay and/or pore modified zeolite with metal species from Group VI B and VIII B, where the metal components are in intimate contact with the active sites, and a binder material is added to create a hydroprocessing catalyst with enhanced cracking and hydrogenation capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalyst compositions are used for hydrocracking, then the catalyst structure is simple and easy to manufacture, but the catalytic activity and efficiency for converting hydrocarbon feeds to diesel range products are insufficient
Solution Approach 1:
The patent employs a composite catalyst system combining modified zeolite (providing acidic cracking sites) with modified clay (providing hydrogenation sites) and metal components. This composite structure enables simultaneous cracking and hydrogenation functions, significantly improving diesel range product yield while managing the increased compositional complexity through synergistic material integration.
Solution Approach 2:
The catalyst design implements local quality enhancement by specifically modifying zeolite and clay components with particular metals and compounds at targeted locations within the catalyst structure. This creates localized active sites with optimized properties for specific reactions (cracking vs. hydrogenation), improving overall conversion efficiency without uniformly increasing complexity throughout the entire catalyst system.
2Productivity
If metal loading is increased to enhance catalytic activity, then the hydrogenation function is improved, but the cost of catalyst preparation increases
Solution Approach 1:
The patent optimizes metal loading parameters by controlling the amount and type of metals introduced to zeolite and clay components. Through careful parameter adjustment of metal concentration and distribution, the catalyst achieves sufficient hydrogenation activity while minimizing metal content, thereby balancing performance improvement with material cost reduction.
Solution Approach 2:
The catalyst design extracts and separates the hydrogenation function into specific metal-modified clay components, distinct from the cracking function in zeolite. This functional separation allows targeted metal loading only where hydrogenation is needed, reducing overall metal content while maintaining adequate hydrogenation activity for diesel production.
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 composition effectively converts heavy hydrocarbon feeds to diesel range products by providing both acidic and hydrogenation functions, improving the accessibility of bulky hydrocarbons to catalytic centers and optimizing metal loading for enhanced catalytic activity.
Implementation Method 1
a second component being metal species comprising of at least one metal selected from Group VI B and at least one metal selected from VIII B
Implementation Method 2
a first component comprising active sites, said first component being at least one of the surface modified clay and/or pore modified zeolite
Data Source
AI summary
The present invention relates to a catalyst precursor composition comprising a first component having active sites, said first component being at least one of the surface modified clay and/or pore modified zeolite; and a second component being metal species comprising of at least one metal selected from Group VI B and at least one metal selected from VIII B and the second component is in intimate contact with the active sites of the first component. The present invention also provides a process for preparing the catalyst precursor composition. The present invention also relates to a catalyst composition and process of preparation thereof by using the catalyst precursor. More particularly, the present invention provides a catalyst composition suitable for converting hydrocarbon feeds to diesel range product.