Mesoporous Zeolite Y Catalyst for Heavy Oil Hydrocracking
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Solution Overview
Problem
Conventional zeolites used in hydrocracking catalysts have pore sizes too small to effectively convert large molecules in heavy oil feedstocks, leading to inefficient aromatics conversion and increased coking during steam cracking, which limits the production of light olefins.
Innovation Solution
Incorporating mesopores into zeolite Y to increase its pore size, allowing for the diffusion and conversion of larger molecules, and using a method involving ammonium hexafluorosilicate to modify the zeolite framework and introduce mesopores, resulting in a mesoporous zeolite Y that can be used as a hydrocracking catalyst.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional zeolites with small pore sizes are used in hydrocracking catalysts, then the catalyst structure is simple and easy to manufacture, but the pore size is too small to allow diffusion of large molecules in heavy oil feedstocks, leading to inefficient aromatics conversion
Solution Approach 1:
The patent applies the porous materials principle by transforming conventional microporous zeolites into mesoporous zeolites with pore sizes of 2-50 nm. This is achieved through chemical etching processes that create larger pores while maintaining the crystalline structure, enabling efficient diffusion of large heavy oil molecules to active sites for aromatics conversion
Solution Approach 2:
The patent creates composite materials by combining zeolite frameworks with mesoporous structures. The resulting mesoporous zeolites integrate the catalytic activity of zeolites with the enhanced mass transfer properties of mesoporous materials, achieving both high aromatics conversion and reduced coking
2Productivity
If conventional zeolites are used, then the catalyst is easier to manufacture, but coking increases during steam cracking, requiring shutdown for coke removal
Solution Approach 1:
The mesoporous structure with larger pore sizes facilitates better mass transfer and reduces the accumulation of heavy residues that lead to coking. The enhanced diffusion capabilities allow reactants to access active sites more efficiently and products to leave the catalyst pores more readily, preventing coke formation and extending continuous operation time
Solution Approach 2:
The patent changes the physical parameters of the zeolite by creating mesopores with sizes of 2-50 nm, which fundamentally alters the mass transfer characteristics. This parameter change in pore size enables the catalyst to maintain activity for longer periods by reducing coking, thereby increasing productivity and continuous operation time
3Productivity
If conventional zeolites are used, then the synthesis process is simpler, but the conversion of polyaromatics and saturated polyaromatics is ineffective due to weak acidity and small pore size
Solution Approach 1:
The transformation to mesoporous zeolites creates a dual-function structure that combines the acid catalysis of conventional zeolites with enhanced mass transfer. The larger pores allow polyaromatics and saturated polyaromatics to reach active sites efficiently, while the maintained acidity ensures effective conversion, achieving high aromatics conversion efficiency
Solution Approach 2:
The mesoporous zeolite represents a composite structure that integrates the catalytic properties of zeolites with the mass transfer advantages of mesoporous materials. This composite approach enables effective conversion of difficult-to-crack aromatic compounds while managing the increased synthesis complexity through systematic chemical etching processes
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 mesoporous zeolite Y catalyst enhances the conversion of aromatics and reduces coking, enabling the partial or complete conversion of heavy oil fractions to light olefins with high paraffin content, improving the efficiency of light olefin production.
Implementation Method 1
contacting an initial zeolite material with ammonium hexafluorosilicate to modify the framework of the initial zeolite material, and forming mesopores in the framework-modified zeolite material
Implementation Method 2
Incorporating mesopores into zeolite Y to increase its pore size, allowing for the diffusion and conversion of larger molecules
Implementation Method 3
The mesoporous zeolite Y catalyst enhances the conversion of aromatics and reduces coking, enabling the partial or complete conversion of heavy oil fractions to light olefins
Data Source
AI summary
According to one or more embodiments disclosed herein, a mesoporous zeolite may be made by a method comprising contacting an initial zeolite material with ammonium hexafluorosilicate to modify the framework of the initial zeolite material, and forming mesopores in the framework-modified zeolite material. The contacting may form a framework-modified zeolite material. The mesoporous zeolites may be incorporated into catalysts.