Structured Metal Oxide Catalyst for Naphtha-Maximizing Hydrocracking
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Solution Overview
Problem
Existing hydrocracking processes struggle to significantly increase naphtha yield from petroleum feedstocks, particularly heavy petroleum feedstocks, while producing middle distillates as the major product, and existing catalyst systems are expensive and do not effectively maximize naphtha content.
Innovation Solution
A catalyst comprising molybdenum (Mo) and a second metal oxide, such as iron (Fe), aluminium (Al), or silicon (Si), with an atomic ratio of Mo to Fe, Al, or Si ranging from 0.8 to 6, is used for hydrocracking, prepared by a method involving mixing metal precursors, refluxing, aging, and drying to form a structured catalyst for slurry phase reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If conventional hydrocracking processes are used to process heavy petroleum feedstock, then middle distillates are produced as major product, but naphtha yield does not increase significantly
Solution Approach 1:
The invention changes the chemical composition parameters of the catalyst system by using a specific ratio of Group VIB metal oxide (0.1-10 wt%) combined with zeolite (90-99.9 wt%), where zeolite provides both cracking and hydrogenation functions. This parameter change in catalyst composition enables simultaneous production of high naphtha yield (25-40% of feedstock) and high conversion of heavy hydrocarbons (75-90%), resolving the contradiction between naphtha yield and processing efficiency.
2Quantity of substance
If existing catalyst systems are used for hydrocracking of heavy petroleum feedstock, then processing is possible, but catalyst cost is high and naphtha content is not maximized
Solution Approach 1:
The invention creates a composite catalyst material combining Group VIB metal oxide (Mo, W) with zeolite (Y, USY, beta, ZSM-5). The zeolite component provides acidic sites for cracking while the metal oxide provides hydrogenation sites, creating a bifunctional composite that maximizes naphtha production. This composite structure reduces reliance on expensive single-metal catalysts while achieving superior naphtha yield (25-40%) compared to conventional systems.
3Ease of manufacture
If carbon rejection route is used for processing heavy petroleum feedstock, then processing is simplified, but light hydrocarbon yield is low
Solution Approach 1:
The invention makes the catalyst system universally applicable to multiple reaction pathways by combining cracking and hydrogenation functions in a single bifunctional catalyst. The zeolite component handles cracking while metal oxide handles hydrogenation, allowing the system to simultaneously produce both light hydrocarbons (through cracking) and naphtha (through hydrogenation), thus achieving high light hydrocarbon yield without sacrificing processing simplicity.
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 achieves a high conversion of heavy hydrocarbons to naphtha and middle distillates, with a yield of at least 75-90% conversion of hydrocarbons above 540°C and 25-40% yield of naphtha in the product stream, improving naphtha production efficiency.
Implementation Method 1
hydrocracking of petroleum feedstock
Implementation Method 2
catalytic cracking of vacuum gas oil
Implementation Method 3
hydrogen addition route involves cracking and hydrogenation reactions
Implementation Method 4
adding a solution of a first metal precursor to an aqueous solution of a second metal precursor and formic acid
Implementation Method 5
refluxing the reaction mixture followed by ageing to obtain a solid product
Implementation Method 6
adding a solution of a first metal precursor to an aqueous solution of a second metal precursor and formic acid
Data Source
AI summary
The present invention pertains to a catalyst comprising well-defined structured metal oxides and mixed metal oxide and a method for the preparation of the catalyst by hydrolysis and precipitation methods. The catalyst comprises a first metal oxide and a second metal oxide, wherein metal of the first metal oxide is molybdenum (Mo) and metal of the second metal oxide is selected from a group comprises iron (Fe), aluminium (Al), silicon (Si) and a mixture thereof; wherein the catalyst has an atomic ratio of Mo to Fe, Al or Si in a range of 0.8 to 6. The catalyst is utilized for the maximization of naphtha through hydrocracking of petroleum feedstock.