USY-Beta Hydrocracking Catalyst Composition for Middle Distillate Selectivity
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Solution Overview
Problem
There is a need for more effective hydrocracking catalyst compositions that enhance the efficiency of hydrocarbon oil processing by improving the hydrocracking process, particularly in terms of catalyst activity and product selectivity.
Innovation Solution
A catalyst composition comprising framework-substituted ultra-stable Y-type (USY) and beta zeolites with titanium and zirconium, which are used in conjunction with a hydrogenative metal component, to enhance the hydrocracking process by increasing mesoporosity and medium strength acid sites while reducing strong acid sites.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydrocracking catalysts are used, then the hydrocracking process can proceed, but the catalyst activity and product selectivity are insufficient
Solution Approach 1:
The patent employs a composite catalyst system combining multiple zeolite types (USY and beta zeolites) with different pore structures and acid site characteristics. This composite approach leverages the strengths of each zeolite component to achieve both high hydrocracking activity and improved product selectivity, resolving the contradiction between productivity and reliability
Solution Approach 2:
The patent introduces mesoporosity into the catalyst structure to create localized regions with different pore sizes and acid site distributions. This local quality enhancement allows for optimized reactant access and product distribution, improving both hydrocracking rate and selectivity simultaneously
2Productivity
If zeolite framework is substituted with titanium and zirconium, then mesoporosity and medium strength acid sites increase, but the complexity of catalyst preparation increases
Solution Approach 1:
The patent systematically varies the substitution levels of titanium and zirconium in the zeolite framework, along with the ratio of different zeolite components, to optimize catalyst performance. By controlling these parameters within specific ranges, the patent achieves high catalyst activity while managing preparation complexity through defined compositional specifications
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 composition significantly improves the hydrocracking process by enhancing the hydrocracking rate and product selectivity, achieving higher yields of middle distillates with improved catalyst activity and stability.
Implementation Method 1
The hydrocracking catalyst is a key feature of hydrocracking process technologies. Two types of catalysts are used in hydrocracking: pretreat catalysts and cracking catalysts. Cracking catalysts are designed to split low-value heavy molecules into higher value transportation fuels.
Implementation Method 2
a catalyst composition including at least one framework-substituted ultra-stable Y-type (hereinafter 'USY') zeolite and at least one framework-substituted beta zeolite may greatly enhance the effectiveness of hydrocracking processes
Implementation Method 3
Beta zeolite may be added to the catalyst matrix for increased cracking activity and improvement of cold flow properties
Data Source
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AI summary
In accordance with one or more embodiments of the present disclosure, a catalyst composition includes a catalyst support and at least one hydrogenative metal component disposed on the catalyst support. The catalyst support includes at least one USY zeolite having a framework substituted with titanium and zirconium and at least one beta zeolite also having a framework substituted with titanium and zirconium. A method of using such a catalyst in a hydrocracking process is also disclosed.