USY Zeolite Hydrocracking Catalyst Acidity Control
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Solution Overview
Problem
Existing hydrocracking catalysts fail to achieve the desired levels of activity and selectivity for optimizing middle distillate production, as they lack the necessary properties such as adequate zeolite USY acidity and metal distribution.
Innovation Solution
A hydrocracking catalyst comprising greater than 10 wt % of zeolite USY with specific acidity and surface area characteristics, combined with a support and metals from Group 6 and 8-10 elements, which is formulated by mixing zeolite USY with support constituents, extruding, and impregnating with metal solutions, followed by drying and calcination to enhance selectivity and activity for middle distillate production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydrocracking catalysts are used, then the catalyst structure is simple and easy to manufacture, but the activity and selectivity for middle distillate production are insufficient
Solution Approach 1:
The patent employs a composite catalyst formulation combining zeolite USY (>10 wt%) with specific acidity (0.350-0.650 mmol/g) and surface area (>600 m²/g) properties, supported on a porous support material and combined with metals from Groups 6 and 8-10. This composite structure integrates multiple functional components to simultaneously achieve high activity and selectivity for middle distillate production while maintaining manufacturability through established catalyst preparation techniques.
2Productivity
If zeolite USY with higher total OD acidity is used, then the catalyst activity increases, but the manufacturing precision and control of acid site distribution become more difficult
Solution Approach 1:
The patent specifies precise parameter ranges for zeolite USY properties: total OD acidity of 0.350-0.650 mmol/g and ASDI of 0.05-0.15. These controlled parameter ranges optimize catalyst activity while maintaining manufacturability. The invention transforms the challenge of controlling acid site distribution into a solution by defining specific target ranges that balance activity enhancement with manufacturing feasibility.
3Productivity
If zeolite USY with higher BET surface area is used, then the catalyst selectivity for middle distillates improves, but the cost and manufacturing complexity increase
Solution Approach 1:
The patent establishes a minimum BET surface area threshold of >600 m²/g for zeolite USY to ensure adequate selectivity for middle distillate production. This parameter specification balances performance requirements with manufacturing considerations, providing a clear target for catalyst formulation while avoiding unnecessarily complex or expensive materials that would exceed this threshold.
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 exhibits improved selectivity for producing hydrocracked effluents with a True Boiling Point (TBP) of 250-550° F (121-288° C) and increased activity by 7-30° F (4-17° C) compared to conventional catalysts, effectively optimizing middle distillate production.
Implementation Method 1
a zeolite USY having: i. a total OD acidity of 0.350 to 0.650 mmol/g
Implementation Method 2
Hydrocracking refers to a process in which hydrogenation and dehydrogenation accompanies the cracking/fragmentation of hydrocarbons
Implementation Method 3
hydrogenation and dehydrogenation accompanies the cracking/fragmentation of hydrocarbons
Implementation Method 4
hydrogenation and dehydrogenation accompanies the cracking/fragmentation of hydrocarbons
Implementation Method 5
extruding the extrudable paste to form an extrudate base
Implementation Method 6
impregnating the extrudate base with a metal impregnation solution containing at least one metal
Implementation Method 7
post-treating the metal-loaded extrudate by subjecting the metal-loaded extrudate to drying and calcination
Implementation Method 8
post-treating the metal-loaded extrudate by subjecting the metal-loaded extrudate to drying and calcination
Data Source
AI summary
A hydrocracking catalyst is provided comprising: a) greater than 10 wt % of a zeolite USY having: i. a total OD acidity of 0.350 to 0.650 mmol/g; ii. an ASDI between 0.05 and 0.15; iii. a BET surface area greater than 600 m2/g; iv. a SAR greater than 10; v. less than 45 vol % of pores greater than 2 nm; b) a support; and c) at least one metal selected from the group consisting of elements from Group 6 and Groups 8 through 10 of the Periodic Table. A process for hydrocracking using a hydrocracking catalyst to produce middle distillates is provided. A method for making a hydrocracking catalyst is also provided.