Hydrothermal Mesoporous Zeolite Beta for Heavy Oil Conversion
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Solution Overview
Problem
Conventional beta zeolites have small pore sizes that hinder the diffusion of large molecules in heavy oil conversion processes, leading to low catalytic activity and catalyst deactivation, and existing synthesis methods for nano-sized zeolites face issues with aggregation and decreased yield due to calcination and ion exchange steps.
Innovation Solution
A hydrothermal treatment process is used to synthesize nano-sized mesoporous zeolite beta without drying or calcination, preserving the structure and eliminating the need for a structure directing agent, resulting in improved crystallinity and mesoporosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional beta zeolites with small pore sizes are used, then the zeolite structure is stable, but the diffusion of large molecules is hindered leading to low catalytic activity
Solution Approach 1:
The patent creates mesoporous zeolite beta with pore sizes of 2-50 nm through hydrothermal treatment, which is larger than conventional microporous zeolites. This mesoporous structure allows large heavy oil molecules to diffuse into the zeolite interior and access active sites, thereby improving catalytic activity while maintaining the zeolite crystalline structure for stability
Solution Approach 2:
The patent changes the pore size parameter from conventional microporous (<2 nm) to mesoporous (2-50 nm) through hydrothermal treatment at temperatures of 400-600°C for 0.5-5 hours. This parameter change enables both large molecule diffusion and structure stability to be achieved simultaneously
2Area of stationary object
If nano-sized particles are synthesized to increase external surface area, then mass transfer is enhanced, but aggregation occurs reducing manufacturing precision
Solution Approach 1:
The patent performs preliminary stabilization of nano-sized particles during the hydrothermal treatment process itself, rather than requiring subsequent drying and calcination steps. The hydrothermal treatment at 400-600°C stabilizes the particles in situ, preventing aggregation and maintaining uniform particle size distribution while achieving the desired nano-scale dimensions and high external surface area
3Reliability
If drying and calcination steps are used in synthesis, then the zeolite structure is stabilized, but crystallinity decreases indicating partial destruction
Solution Approach 1:
The patent extracts or eliminates the conventional drying and calcination steps from the synthesis process. Instead, the zeolite beta is directly hydrothermally treated at 400-600°C for 0.5-5 hours, which stabilizes the structure without the harsh conditions of traditional calcination. This removal of destructive steps preserves crystallinity while achieving structure stability
Solution Approach 2:
The patent changes the thermal treatment parameters from conventional high-temperature calcination (often >500°C in air) to controlled hydrothermal treatment (400-600°C in aqueous environment). This parameter change stabilizes the zeolite structure through hydrothermal conditions rather than oxidative calcination, preserving crystallinity while achieving structural stability
4Manufacturing precision
If structure directing agents are used to synthesize mesoporous zeolites, then pore structure is controlled, but synthesis complexity and cost increase
Solution Approach 1:
The patent employs the zeolite beta crystals themselves as the structure-directing template during hydrothermal treatment. The pre-formed zeolite crystals undergo structural reorganization and mesopore formation through hydrothermal treatment at 400-600°C, eliminating the need for external structure directing agents like surfactants or block copolymers. This self-service approach simplifies the synthesis process and reduces cost while maintaining precise pore structure control
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 process enhances the diffusion of large molecules, increases catalytic performance in heavy oil conversion processes, and reduces synthesis complexity and cost by maintaining zeolite structure integrity and yield.
Implementation Method 1
subjecting the zeolite beta product to a hydrothermal treatment at a pressure and second temperature for a second time period to produce the nano-sized mesoporous zeolite beta composition
Implementation Method 2
heating the aluminosilicate fluid gel for at a first temperature for a first time period to form a zeolite beta product
Data Source
AI summary
A nano-sized mesoporous zeolite beta composition and processes for the synthesis and use of the nano-sized mesoporous zeolite beta. The nano-sized mesoporous zeolite beta is synthesized using a hydrothermal treatment without drying and calcination of the zeolite prior to or after hydrothermal treatment. A process for hydrocracking a hydrocarbon feedstock using the nano-sized mesoporous zeolite beta is also provided.