LCO Hydroconversion Catalyst with Segmented Zeolite Core
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Solution Overview
Problem
The handling of light cycle oil (LCO) is challenging due to its poor cetane properties and high sulfur content, limiting its use in diesel and requiring effective conversion to meet stringent fuel and environmental regulations, with existing hydrocracking catalysts not efficiently achieving partial ring opening of multi-ring aromatics for petrochemical feedstock production.
Innovation Solution
A catalyst composition featuring ultra-stable Y zeolite as a carrier with alumina binder, incorporating Group VIB and VIIIB metals, and nitrogen-oxygen containing organic additives to form highly dispersed WS2 slabs, enabling selective ring opening of aromatics and efficient hydroconversion of LCO into petrochemical feedstocks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydrocracking catalysts are used for LCO conversion, then diesel blending is achieved, but selective partial ring opening of multi-ring aromatics for petrochemical feedstock production is not efficient
Solution Approach 1:
The patent applies local quality by creating distinct functional zones within the catalyst颗粒. The outer shell contains high acidity for cracking activity, while the inner core provides hydrogenation function. This spatial differentiation enables simultaneous cracking of multi-ring aromatics and selective hydrogenation, achieving both high conversion and selectivity for partial ring opening to produce petrochemical feedstocks like benzene, toluene and xylene.
Solution Approach 2:
The patent employs composite materials by combining zeolite components (for acidity and cracking), metal components (for hydrogenation), and matrix materials into a structured catalyst. This composite structure integrates multiple catalytic functions within a single catalyst颗粒, enabling efficient LCO conversion with selective partial ring opening that conventional single-function catalysts cannot achieve.
2Manufacturing precision
If mild hydrocracking conditions are applied to convert di and tri-aromatics into alkyl benzene, then mono-aromatics are kept intact, but the catalyst requires optimum balance of acid sites and hydrogenation function which is difficult to achieve
Solution Approach 1:
The patent applies segmentation by dividing the catalyst into functional segments or zones. The outer shell is designed with high acidity to facilitate cracking of di and tri-aromatics, while the inner core contains metal components for hydrogenation. This segmented structure allows independent optimization of cracking and hydrogenation functions, achieving selective conversion while preserving mono-aromatics without requiring complex overall composition optimization.
Solution Approach 2:
The patent applies preliminary action by pre-organizing the catalyst structure during preparation to establish the functional zones before the reaction occurs. The metal components are pre-positioned in the inner core and zeolite components in the outer shell, so that when LCO contacts the catalyst, the desired selective reaction pathway is immediately established, preserving mono-aromatics while converting di and tri-aromatics.
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 achieves high conversion and selectivity in producing valuable petrochemical feedstocks like benzene, toluene, and xylene, with superior activity and stability, outperforming comparable catalysts in ring opening and hydrocracking of LCO.
Implementation Method 1
a catalyst composition comprising an ultra-stable Y zeolite as a carrier and alumina as binder
Implementation Method 2
incorporating Group VIB and VIIIB metals, and nitrogen-oxygen containing organic additives to form highly dispersed WS2 slabs, enabling selective ring opening of aromatics and efficient hydroconversion of LCO
Data Source
Figure 1
AI summary
The present invention relates to a catalyst composition and a process for preparing thereof, wherein the catalyst composition is specifically active for hydro-conversion of LCO involving mainly the partial ring opening of multi-ring aromatics leading to the production of petrochemical feedstock. The catalyst composition comprises of a carrier comprising ultra-stable Y zeolite and binder alumina, group VIB and VIIIB metal species, and organic additives. The carrier is impregnated with metal solution to form active sites of WS2 slabs of dimensions in the range of 35-45 Å.