Zr-Ti Modified Zeolite Hydrocracking Catalyst for Acidity Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydrocracking catalysts using zeolites often over or under-crack hydrocarbon feeds due to varying acidity levels, affecting product selectivity, and there is a need for catalysts that can efficiently produce middle distillates.
Innovation Solution
The development of post-modified zeolites with zirconium and titanium atoms coordinated differently within the framework, specifically 4-coordinated Ti and 5-coordinated Zr, to achieve controlled acidity and enhance the production of middle distillates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional zeolites are used as hydrocracking catalysts, then the catalyst provides basic cracking activity, but the acidity levels are not controllable leading to over or under-cracking of hydrocarbon feeds
Solution Approach 1:
The patent applies local quality by introducing specific metal atoms (zirconium, titanium, hafnium) at controlled positions within the zeolite framework to create localized acid sites with precise strength characteristics. This allows different regions of the catalyst to have tailored acidity levels, enabling controlled cracking activity and improved product selectivity without over or under-cracking the hydrocarbon feeds.
Solution Approach 2:
The patent employs parameter changes by varying the type and amount of metal atoms incorporated into the zeolite framework (e.g., Zr, Ti, Hf at different concentrations) to precisely adjust the acidity parameters of the catalyst. This systematic modification of compositional parameters enables fine-tuning of cracking activity to achieve optimal product distribution and selectivity.
2Productivity
If zeolites with modified acidity are used to improve product selectivity, then middle distillate production increases, but the catalyst structure becomes more complex
Solution Approach 1:
The patent utilizes composite materials by combining zeolite frameworks with metal atoms (Zr, Ti, Hf) to create composite catalyst structures. This integration of different materials with complementary properties enhances middle distillate production while the systematic approach to composite formation maintains reasonable structural complexity. The metal-zeolite composite provides both the structural integrity of zeolite and the tunable acidity of metal centers.
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 modified zeolites provide improved acidity levels, leading to increased production of middle distillates and better product selectivity in hydrocracking processes.
Implementation Method 1
a post-modified zeolite framework having zirconium atoms and titanium atoms substituting for aluminum atoms
Implementation Method 2
The modified zeolites provide improved acidity levels, leading to increased production of middle distillates and better product selectivity in hydrocracking processes
Data Source
AI summary
A hydrocracking catalyst comprises an active cracking support. The active cracking support comprises a post-modified zeolite framework having zirconium atoms and titanium atoms substituting for aluminum atoms; wherein: a portion of the zirconium atom are substituted in the post-modified zeolite via 4-coordination; a portion of the zirconium atom are grafted to the post-modified zeolite via 5-coordination; and the titanium atoms are substituted in the post-modified zeolite framework via 4-coordination.