Stabilized Y Zeolite Catalyst for Hydrocracking Selectivity
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Solution Overview
Problem
Conventional hydrocracking catalysts using SY zeolites produce less profitable naphtha products due to insufficient selectivity towards heavy middle distillate products, particularly diesel, from unwanted secondary hydrocracking of materials in the jet boiling range.
Innovation Solution
A hydrocracking catalyst with a high nanopore volume (HNPV) SY zeolite component, characterized by enhanced acid site distribution and increased nanopore volume in the 20-50 nm range, which improves selectivity towards heavier middle distillate products in the 380-700°F boiling range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional SY zeolite is used in hydrocracking catalyst, then the catalyst can perform basic hydrocracking function, but it produces excessive gas-make and reduces heavy middle distillate yield due to insufficient selectivity
Solution Approach 1:
The patent modifies the local quality of the zeolite by creating a specific pore size distribution with enhanced nanopore volume (0.20-0.45 mL/g) in the 20-50 nm range and controlling acid site distribution (0.03-0.10 mmol/g). This local structural optimization within the zeolite framework selectively promotes hydrocracking reactions that produce heavy middle distillates while suppressing excessive gasification reactions, thereby resolving the contradiction between maximizing distillate yield and minimizing gas-make.
Solution Approach 2:
The patent applies parameter changes by precisely controlling the nanopore volume (0.20-0.45 mL/g), acid site distribution (0.03-0.10 mmol/g), and pore size distribution (20-50 nm range) of the SY zeolite. These parameter optimizations enhance the catalyst's selectivity towards heavy middle distillate products (380-700°F) while reducing unwanted gas-make, effectively resolving the technical contradiction between product yield and loss.
2Manufacturing precision
If conventional SY zeolite with standard pore structure is used, then the catalyst structure is simple and easy to manufacture, but the selectivity towards heavy middle distillate products is insufficient
Solution Approach 1:
The patent achieves enhanced manufacturing precision by controlling specific parameters of the SY zeolite: nanopore volume (0.20-0.45 mL/g), acid site distribution (0.03-0.10 mmol/g), and pore size distribution centered in the 20-50 nm range. These precise parameter specifications enable superior selectivity control for heavy middle distillate production while maintaining a zeolite structure that can be manufactured using established hydrothermal synthesis and post-treatment methods.
3Use of energy by moving object
If conventional hydrocracking catalyst is used, then the process operates under standard conditions, but hydrogen efficiency is reduced and heavy middle distillate quality is compromised
Solution Approach 1:
The patent enhances hydrogen efficiency by optimizing the local quality of the catalyst through controlled nanopore distribution (20-50 nm range) and acid site density (0.03-0.10 mmol/g). This localized structural optimization promotes selective hydrocracking reactions that efficiently utilize hydrogen to produce high-quality heavy middle distillates with reduced gas-make, thereby simultaneously improving hydrogen efficiency and product quality reliability.
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 HNPV SY zeolite-based catalyst exhibits reduced gas make and increased heavy middle distillate product yield and quality, enhancing refinery margins by increasing diesel production while minimizing undesirable gas and naphtha yields.
Implementation Method 1
a high nanopore volume (HNPV) SY zeolite component, characterized by enhanced acid site distribution and increased nanopore volume in the 20-50 nm range
Implementation Method 2
Hydrocracking is an important refining process used manufacture middle distillate products boiling in the 250-700°F (121-371°C) range
Data Source
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AI summary
An improved hydrocracking catalyst containing a stabilized Y zeolite (SY) having an enhanced acid site distribution as compared to conventional SY zeolites. The SY zeolite is also characterized as having a high nanopore volume (HNPV).