SSZ-91 Hydrocracking Catalyst for Middle Distillate Yield and Quality
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Solution Overview
Problem
Existing hydrocracking processes face challenges in achieving high yields of middle distillates and unconverted oil with desirable properties, such as low pour point and viscosity index, often requiring additional processing steps that decrease product yields.
Innovation Solution
A hydrocracking catalyst comprising an SSZ-91 molecular sieve and modifying metals from Group 6 and/or Group 8 to 10 metals, optionally with additional zeolites and matrix materials, is used to produce middle distillates and unconverted oil under hydrocracking conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additional processing steps including higher levels of hydrocracking are applied to achieve low pour point and high viscosity index in middle distillate and unconverted oil, then product quality improves, but yields of desired products decrease
Solution Approach 1:
The patent applies parameter changes by modifying the catalyst composition parameters - specifically using SSZ-91 molecular sieve with controlled silicon-to-aluminum ratio (20-100), combined with Group 6 metals (Mo, W) at 0.1-10 wt% and Group 8-10 metals (Ni, Co, Rh, Pd, Pt) at 0.1-5 wt%. This catalyst formulation achieves optimal balance between hydrocracking activity and product quality, producing middle distillates with low pour point and high viscosity index while maintaining high yields without requiring additional processing steps
2Productivity
If conventional hydrocracking catalysts are used to maximize middle distillate yield, then productivity improves, but product quality (pour point and viscosity index) deteriorates
Solution Approach 1:
The patent employs composite materials by combining SSZ-91 molecular sieve with specific metal components (Group 6 metals Mo or W, and Group 8-10 metals Ni, Co, Rh, Pd, or Pt) to create a multifunctional catalyst. This composite catalyst structure integrates hydrocracking activity from the molecular sieve with metal-catalyzed hydrogenation functions, achieving both high productivity and superior product quality simultaneously
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 enhances the yield of middle distillates and unconverted oil with improved properties, including lower cloud and pour points, and viscosity indices, without the need for additional processing steps.
Implementation Method 1
The hydrocracking catalyst comprises an SSZ-91 molecular sieve and a modifying metal selected from one or more Group 6 metals, and, optionally, one or more Group 8 to 10 metals
Data Source
AI summary
Described herein is a hydrocracking catalyst and process that may be used to make middle distillates and unconverted oil having beneficial yield and product characteristics. The process generally comprises contacting a hydrocarbon feed with the hydrocracking catalyst under hydrocracking conditions to produce a product comprising middle distillates and unconverted oil products. The hydrocracking catalyst comprises an SSZ-91 molecular sieve and a modifying metal selected from one or more Group 6 metals, and, optionally, one or more Group 8 to 10 metals, or a modifying metal selected from Group 8 to 10 metals and combinations thereof, and, optionally, one or more Group 6 metals. The hydrocracking catalyst may comprise a matrix material and/or an additional zeolite.