Mesoporous Zeolite Catalyst Supports for Hydrocracking
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Solution Overview
Problem
Zeolites used as catalyst supports face significant challenges as a substantial portion of the catalytic material migrates out and agglomerates on the surface during severe reaction conditions, reducing their catalytic functionality.
Innovation Solution
The method involves incorporating catalytic nanoparticles into mesoporous zeolites with a total 20 to 80 Å diameter mesopore volume of at least 0.05 cc/g and heating or ion-exchanging them to ensure at least 20 weight percent of the nanoparticles remain within the mesopores, enhancing stability and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional zeolites are used as catalyst supports, then catalytic material can be incorporated, but under severe reaction conditions the catalytic material migrates out and agglomerates on the surface, reducing catalytic functionality
Solution Approach 1:
The patent employs mesoporous zeolite supports with controlled pore structures to confine catalytic nanoparticles within the pores. The mesoporous structure provides physical containment that prevents nanoparticle migration to the surface under severe reaction conditions, while maintaining catalytic activity through accessible active sites within the pore network.
Solution Approach 2:
The patent creates a composite catalyst system combining mesoporous zeolite supports with dispersed catalytic nanoparticles. This composite structure integrates the structural stability and pore architecture of the zeolite with the catalytic functionality of the nanoparticles, achieving both stability and catalytic performance.
2Productivity
If catalytic nanoparticles are incorporated into zeolites, then catalytic activity is achieved, but under severe conditions the nanoparticles migrate to the surface and agglomerate, decreasing catalytic functionality
Solution Approach 1:
The mesoporous zeolite structure provides a confined environment that retains catalytic nanoparticles within the pore network, preventing their migration and agglomeration on the external surface. This physical confinement maintains high catalytic activity by keeping nanoparticles dispersed and accessible, while preventing material loss through migration.
3Adaptability or versatility
If zeolites are used as catalyst supports, then catalytic reactions can proceed, but the catalytic material migrates out during severe reaction conditions, reducing functionality
Solution Approach 1:
The mesoporous zeolite support provides a versatile platform that can accommodate various catalytic nanoparticles while maintaining structural integrity under severe reaction conditions. The pore structure ensures reliable performance by confining nanoparticles, enabling the catalyst to adapt to different reactions while maintaining stability.
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
This approach significantly reduces nanoparticle migration and agglomeration on the surface, maintaining catalytic activity and longevity under severe conditions, and improves catalytic properties compared to conventional zeolites.
Implementation Method 1
subjecting a mesoporous zeolite having a total 20 to 80 Å diameter mesopore volume of at least 0.05 cc/g to ion-exchange with one or more ions of a catalyst metal to form an ion-exchanged catalytic zeolite
Implementation Method 2
contacting the ion-exchanged catalytic zeolite with one or more pH additives to thereby form a catalytic zeolite
Implementation Method 3
heating at least a portion of the initial catalytic zeolite at a temperature of at least 150° C. to thereby form a heat-modified catalytic zeolite
Data Source
AI summary
Compositions and methods for preparing a catalyst composition containing mesoporous materials are described herein. In particular, various embodiments described herein relate to the preparation of catalytic compositions containing a mesoporous zeolite and one or more catalytic nanoparticles dispersed therein. In various embodiments described herein, such catalyst compositions can be used in various catalytic conversion processes, such as hydrocracking.