Zeolite Beta USY Hydrocracking Catalyst for Middle Distillate Selectivity
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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 performance to efficiently convert hydrocarbonaceous feedstocks into middle distillates with a True Boiling Point (TBP) of 380 - 700°F (193-371°C).
Innovation Solution
A hydrocracking catalyst comprising 0.5 to 10 wt% zeolite beta with OD acidity of 20 to 400 µmol/g and average domain size from 800 to 1500 nm², combined with 0 to 5 wt% zeolite USY having an ASDI between 0.05 and 0.12, and a catalyst support, along with at least one metal from Group 6 and Groups 8 through 10 of the Periodic Table, is used. This catalyst is prepared by mixing the zeolites with a catalyst support, forming an extrudable paste, impregnating it with a metal solution, and subjecting it to drying and calcination.
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 system combining zeolite beta (0.5-10 wt%) with specific OD acidity and domain size, zeolite USY (0-5 wt%) with controlled ASDI, and a catalyst support. This composite structure leverages the shape-selective cracking ability of zeolite beta for middle distillate production while using zeolite USY to suppress excessive gas formation, achieving superior activity and selectivity compared to conventional single-zeolite catalysts.
Solution Approach 2:
The patent specifies precise local properties of the zeolite components: zeolite beta with OD acidity of 20-400 μmol/g and average domain size of 800-1500 nm², and zeolite USY with ASDI of 0.05-0.12. These localized quality parameters optimize the catalyst's interaction with hydrocarbon feedstocks at specific active sites, enhancing both activity and selectivity for middle distillate production.
2Manufacturing precision
If zeolite beta with high domain size is used to improve selectivity, then the selectivity for middle distillate increases, but the catalyst preparation becomes more complex
Solution Approach 1:
The patent optimizes the domain size parameter of zeolite beta to 800-1500 nm² and OD acidity to 20-400 μmol/g, along with controlling zeolite USY ASDI to 0.05-0.12. These parameter specifications balance selectivity for middle distillate with manageable preparation complexity, as the defined ranges allow for standardized synthesis procedures while achieving the desired performance.
3Productivity
If multiple zeolite components are combined to enhance performance, then the catalytic activity and selectivity improve, but the catalyst structure becomes more complex
Solution Approach 1:
The patent creates a composite catalyst incorporating zeolite beta (0.5-10 wt%) for shape-selective cracking, zeolite USY (0-5 wt%) for suppressing gas formation through its low ASDI, and a catalyst support. This composite structure achieves synergistic effects where each component contributes specific functions, resulting in superior overall performance for middle distillate production.
Solution Approach 2:
Each zeolite component in the composite is assigned specific local quality parameters: zeolite beta with OD acidity of 20-400 μmol/g and domain size of 800-1500 nm² for optimal cracking activity, and zeolite USY with ASDI of 0.05-0.12 for controlled acid site distribution. These localized properties enable the composite catalyst to achieve high activity and selectivity while maintaining a manageable structural complexity.
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 and activity, producing a hydrocracked effluent with a TBP of 380 - 700°F (193-371°C) and achieving 1 to 20°F higher activity compared to conventional catalysts, with increased yields of middle distillates and reduced yields of lighter products.
Implementation Method 1
a hydrocracking catalyst comprising: from 0.5 to 10 wt% zeolite beta having an OD acidity of 20 to 400 μmol/g and an average domain size from 800 to 1500 nm²
Implementation Method 2
at least one metal from Group 6 and Groups 8 through 10 of the Periodic Table
Data Source
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AI summary
A hydrocracking catalyst is provided comprising: a. from 0.5 to 10 wt% zeolite beta having an OD acidity of 20 to 400 µmol/g and an average domain size from 800 to 1500 nm2; b. from 0 to 5 wt% zeolite USY having an ASDI between 0.05 and 0.12; wherein a wt% of the zeolite beta is greater than the wt% of the zeolite USY; c. a catalyst support; and d. 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 the hydrocracking catalyst to produce middle distillates is provided. A method for making the hydrocracking catalyst is also provided.