IZM-2 Zeolite Catalyst for Hydrocracking Activity and Selectivity
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Solution Overview
Problem
Conventional hydrocracking catalysts face challenges in achieving high activity and selectivity for producing middle distillates, jet fuels, and gas oils, with amorphous substrate-based catalysts exhibiting low activity and zeolite-based catalysts showing lower selectivity.
Innovation Solution
A catalyst comprising a crystallised IZM-2 solid with an active phase containing hydro-dehydrogenating elements from group VIB and/or non-noble group VIII, specifically a sulphide phase catalyst, which provides high conversion levels in hydrocracking, hydroconversion, and hydrotreatment processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If amorphous substrate-based catalysts are used, then good-quality middle distillates are produced, but catalytic activity is low
Solution Approach 1:
The patent employs a composite catalyst system combining crystallised IZM-2 zeolite (providing high activity) with amorphous silica-alumina matrix (providing stability and selectivity). This composite structure allows the catalyst to achieve both high conversion rates and good product quality, resolving the contradiction between catalytic activity and middle distillate quality that plagues conventional single-material catalysts.
Solution Approach 2:
The patent modifies the chemical and physical parameters of the catalyst by controlling the crystallisation conditions, Si/Al ratio, and particle size distribution of the IZM-2 zeolite. These parameter changes enable the catalyst to achieve optimal balance between activity and selectivity, transforming the low-activity amorphous catalyst into a high-performance composite system.
2Productivity
If zeolite-based catalysts are used, then catalytic activity is high, but selectivity for middle distillates is lower
Solution Approach 1:
The patent creates local quality differentiation within the catalyst structure by using IZM-2 zeolite crystals with specific pore size distributions and acid site densities. The external surface and internal pores provide different catalytic environments, allowing simultaneous high activity from the crystalline structure and good selectivity from the controlled pore architecture, thus resolving the activity-selectivity trade-off.
Solution Approach 2:
The patent exploits the porous structure of IZM-2 zeolite with controlled pore dimensions and connectivity. The porous architecture provides high surface area for activity while the pore size acts as a molecular sieve for selectivity, allowing the catalyst to simultaneously achieve high conversion rates and preferential production of middle distillates, overcoming the limitations of conventional zeolite catalysts.
3Productivity
If strong acid function is used, then catalytic activity increases, but selectivity for middle distillates decreases
Solution Approach 1:
The patent precisely controls the acid function strength by adjusting the Si/Al ratio, cation exchange, and crystallisation conditions of the IZM-2 zeolite. This parameter optimization creates an intermediate acid strength that provides sufficient activity for hydrocracking while maintaining selectivity for middle distillates, resolving the contradiction between strong acid function and product selectivity.
Solution Approach 2:
The patent creates spatial differentiation of acid sites within the catalyst structure, with different densities and strengths of acid sites located at different positions (external surface vs. internal pores). This local quality variation allows the catalyst to perform multiple functions simultaneously, achieving both high activity from strong acid sites and good selectivity from moderate acid sites, thus overcoming the activity-selectivity trade-off.
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 achieves high conversion rates and selectivity for producing lighter fractions such as petrol, kerosene, and gas oils, improving the efficiency of hydrocracking processes compared to conventional catalysts.
Implementation Method 1
The acid function is provided by substrates, the surface areas of which vary generally from 150 to 800 m2·g−1 and displaying superficial acidity
Implementation Method 2
The hydrogenating function is provided either by one or more metals from group VIB of the periodic table or by a combination of at least one metal from group VIB of the periodic table and at least one group VIII metal
Implementation Method 3
an active phase containing at least one hydro-dehydrogenating element from group VIB and/or from non-noble group VIII of the periodic table
Implementation Method 4
said catalyst being a sulphide phase catalyst
Data Source
AI summary
The present invention relates to a catalyst comprising at least one IZM-2 zeolite, at least one amorphous matrix, at least one hydro-dehydrogenating element selected from the group formed by the elements from group VIB and from group VIII of the periodic table and excluding platinum and palladium. The catalyst also optionally contains a controlled quantity of at least one doping element selected from phosphorus, boron and silicon, optionally at least one element from group VB of the periodic table of the elements, and optionally a group VIIA element. The invention also relates to hydrocracking and hydrotreatment processes implementing this catalyst.