Framework-Substituted Zeolite Hydrocracking Catalyst for Heavy Oil
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional hydrotreating catalysts with titanium and/or zirconium on mesopores are not suitable for hydrocracking heavy hydrocarbon oils like vacuum gas oil and deasphalted oil due to pore clogging, leading to reduced yields of middle distillates.
Innovation Solution
A hydrocracking catalyst with a hydrogenative metal component supported by an ultra-stable Y-type zeolite, where part of the aluminum atoms in the zeolite framework are substituted with zirconium and/or hafnium atoms, enhancing the diffusion of heavy hydrocarbons and cracking activity while inhibiting excessive cracking of kerosene-gas oil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional hydrotreating catalysts with titanium and/or zirconium on mesopores are used, then the catalyst structure is simple and easy to manufacture, but the mesopores become clogged leading to reduced diffusion of heavy hydrocarbons and reduced productivity
Solution Approach 1:
The patent changes the chemical composition parameters of the zeolite framework by substituting aluminum atoms with zirconium and/or hafnium atoms. This framework substitution modifies the pore structure and chemical properties to prevent clogging while maintaining catalytic activity, directly resolving the pore clogging issue that reduces productivity
Solution Approach 2:
The patent creates a composite catalyst system combining ultra-stable Y-type zeolite with framework-substituted zirconium and/or hafnium atoms, and further combines this with a hydrogenative metal component. This composite structure leverages the advantages of each component: the zeolite provides porosity and shape selectivity, the framework-substituted metals prevent clogging and enhance diffusion, and the hydrogenative metal provides catalytic activity for hydrocracking
2Ease of manufacture
If titanium and/or zirconium are carried on mesopores of zeolite, then the catalyst is easy to manufacture, but the catalyst is not suitable for hydrocracking heavy hydrocarbon oils due to pore clogging
Solution Approach 1:
The patent modifies the zeolite framework composition by substituting aluminum atoms with zirconium and/or hafnium atoms at controlled levels (0.1-5% by mass). This parameter change transforms the zeolite from a conventional structure prone to clogging to an ultra-stable framework that resists clogging while maintaining ease of manufacture through established framework substitution techniques
Solution Approach 2:
The patent develops a composite catalyst system that integrates framework-substituted zeolite with hydrogenative metal components. This composite approach enables the catalyst to handle heavy hydrocarbon oils effectively by combining the clogging-resistant pore structure of the framework-substituted zeolite with the hydrocracking activity of the hydrogenative metal, expanding adaptability while maintaining manufacturing feasibility
3Productivity
If framework-substituted zeolite with zirconium and/or hafnium is used, then the diffusion of heavy hydrocarbons is improved, but the cracking activity must be controlled to prevent excessive cracking of kerosene-gas oil
Solution Approach 1:
The patent precisely controls the framework substitution parameters by limiting zirconium and/or hafnium content to 0.1-5% by mass. This parameter control optimizes the balance between improving heavy hydrocarbon diffusion through the pore structure and maintaining appropriate cracking activity to prevent excessive cracking of lighter products like kerosene-gas oil
Solution Approach 2:
The patent applies framework substitution locally within the zeolite structure, creating specific active sites with modified properties while preserving the overall zeolite framework integrity. This local modification approach enhances heavy hydrocarbon diffusion at specific locations without uniformly increasing cracking activity throughout the entire catalyst, thereby preventing excessive cracking
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 facilitates high yields of middle distillates by improving the diffusion of heavy hydrocarbons into mesopores and controlling cracking activity, resulting in enhanced hydrocracking performance.
Implementation Method 1
part of the aluminum atoms in the zeolite framework are substituted with zirconium and/or hafnium atoms
Implementation Method 2
A hydrocracking catalyst with a hydrogenative metal component supported by an ultra-stable Y-type zeolite
Implementation Method 3
enhancing the diffusion of heavy hydrocarbons into mesopores
Data Source
AI summary
The present invention relates to a hydrocracking catalyst for hydrocarbon oil comprising a support containing a framework-substituted zeolite-1 in which zirconium atoms and/or hafnium atoms form a part of a framework of an ultrastable y-type zeolite and a hydrogenative metal component carried thereon and a method for producing the same. The hydrocracking catalyst of the present invention makes it easy to diffuse heavy hydrocarbon oils such as VGO, DAO and the like into mesopores, is improved in a cracking activity and makes it possible to obtain a middle distillate at a high yield as compared with catalysts prepared by using zeolite comprising titanium and/or zirconium carried thereon.