Mesoporous Y Zeolite Catalyst for Hydrocracking Distillate Yield
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Solution Overview
Problem
Conventional hydrocracking catalysts using Y zeolites face challenges in achieving high conversion rates and selectivity for distillate yields at lower temperatures, leading to reduced overall product conversions and leaving behind higher boiling range hydrocarbons that are not commercially useful without additional processing steps.
Innovation Solution
A hydrocracking catalyst comprising an Extra Mesoporous Y (EMY) zeolite with a suppressed small mesopore peak and increased large mesopore volume, combined with an inorganic matrix and active metals from Group 6 and Group 8/9/10, which enhances cracking efficiency and selectivity for distillate products at lower temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional Y zeolite hydrocracking catalysts are used, then high conversion rates can be achieved, but distillate yield selectivity decreases and higher boiling range hydrocarbons remain unconverted
Solution Approach 1:
The patent employs EMY zeolite with engineered pore size distribution, specifically suppressing small mesopores (30-50 Å) while enhancing large mesopores (50-500 Å), to optimize reactant access and product diffusion pathways. This pore structure modification enables selective cracking of high boiling hydrocarbons into distillate range products while preventing excessive cracking to lighter fractions, thereby simultaneously improving conversion rate and distillate yield selectivity
Solution Approach 2:
The patent modifies the pore size distribution parameters of the Y zeolite by suppressing small mesopores and enhancing large mesopores through specific synthesis and post-treatment methods. This parameter change in the catalyst's physical structure alters the reaction pathway selectivity, enabling high conversion rates while maintaining preferential formation of distillate range hydrocarbons (400-700°F) over lighter or heavier products
2Manufacturing precision
If hydrocracking is run at low severity to maintain distillate selectivity, then distillate yield selectivity improves, but overall product conversion decreases
Solution Approach 1:
The EMY zeolite's enhanced large mesopore structure provides efficient diffusion pathways for high boiling point hydrocarbons to access active sites and for cracked distillate products to exit rapidly. This pore architecture enables the catalyst to operate at higher severities without sacrificing distillate selectivity, as the improved mass transfer prevents secondary cracking reactions that would otherwise reduce distillate yield at high conversion levels
3Device complexity
If conventional catalysts are used, then processing is simpler, but higher boiling range hydrocarbons remain unusable without additional processing steps
Solution Approach 1:
By fundamentally changing the pore size distribution parameters of the Y zeolite catalyst, the patent enables complete conversion of high boiling range hydrocarbons (700°F+) into valuable distillate range products (400-700°F) in a single hydrocracking step. This eliminates the need for additional downstream processing such as coking or further cracking units, thereby increasing the quantity of usable fuel products while maintaining processing simplicity
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 EMY zeolite-based catalyst exhibits improved heavy oil cracking rates and distillate yield selectivity, allowing for increased conversion of high boiling point materials into valuable distillate range products while maintaining stability across various hydrothermal conditions.
Implementation Method 1
hydrocracking catalyst that is comprised of a new Y zeolite which exhibits an exceptionally low small mesoporous peak height around the 40 Å (angstrom) range as determined by nitrogen adsorption measurements
Implementation Method 2
as determined by nitrogen adsorption measurements and shown in the BJH N2 Desorption Plot
Data Source
AI summary
This invention relates to the composition, method of making and use of a hydrocracking catalyst that is comprised of a new Y zeolite which exhibits an exceptionally low small mesoporous peak around the 40 Å (angstrom) range as determined by nitrogen adsorption measurements. The hydrocracking catalysts of invention exhibit improved distillate yield and selectivity as well as improved conversions at lower temperatures than conventional hydrocracking catalysts containing Y zeolites. The hydrocracking catalysts herein are particularly useful in the hydrocracking processes as disclosed herein, particularly for conversion of heavy hydrocarbon feedstocks such as gas oils and vacuum tower bottoms and an associated maximization and/or improved selectivity of the distillate yield obtained from such hydrocracking processes.