Stabilized Zeolite Y Aggregates for Hydrocracking Catalysts

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Solution Overview

Problem

Conventional zeolite Y catalysts face challenges in maintaining the performance advantages of small particle sizes while ensuring easy processability and sufficient mesoporosity for hydrocracking processes, often requiring high binder concentrations to achieve optimal hydrocarbon conversion.

Innovation Solution

The development of stabilized aggregated forms of zeolite Y, comprising small primary crystallites clustered into larger secondary particles with high relative mesoporosity, allowing for low binder concentrations and enhanced thermal stability, which are incorporated into hydrocracking catalysts with specific binder materials and additional components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If small primary crystallites of zeolite Y are used, then catalytic activity and selectivity are improved, but manufacturing difficulty increases due to filtration and formulation problems

Engineering Contradiction:

Improvecatalytic activityVSAvoidmanufacturing ease

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

Multiple small primary crystallites (0.1-1.0 μm) are merged into larger secondary particles (1-10 μm) through aggregation, maintaining the high surface area and catalytic activity of small crystals while achieving the ease of handling and manufacturing associated with larger particles. The aggregated structure allows for improved filtration and formulation without sacrificing the catalytic benefits of small crystallite size.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If conventional zeolite Y with large crystal size is used, then manufacturing is easier, but mass transportation rates are reduced due to diffusion limitations

Engineering Contradiction:

Improvemanufacturing easeVSAvoidmass transportation rate

Core Design Contradiction:

Ease of manufactureVSSpeed

Solution Approach 1:

The zeolite Y is segmented into small primary crystallites (0.1-1.0 μm) that are then aggregated into secondary particles. This segmentation reduces the diffusion path length within each crystallite, improving mass transportation rates and reducing diffusion limitations while the aggregated structure maintains manufacturing ease.

Inventive Principle:

Principle #1Segmentation

3Reliability

If high binder concentrations are used, then catalyst stability is improved, but mesoporosity is reduced affecting hydrocarbon conversion

Engineering Contradiction:

Improvecatalyst stabilityVSAvoidmesoporosity

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The aggregated zeolite Y structure inherently provides mesoporosity through the interstitial spaces between primary crystallites within secondary particles. This natural porosity reduces the need for high binder concentrations to maintain structural stability, allowing for low binder content while preserving both catalyst stability and adequate mesoporosity for hydrocarbon conversion.

Inventive Principle:

Principle #31Porous materials

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

This approach results in hydrocracking catalysts with improved diesel selectivity and yield, maintaining high mesoporosity and stability with reduced binder usage, thereby optimizing hydrocarbon conversion processes.

Implementation Method 1

Small primary crystallites of zeolite Y can cluster into larger secondary particles, at least 80% of which may comprise at least 5 primary crystallites

Methodology Applied

Scientific EffectAggregation: Coagulation

Implementation Method 2

Hydrocracking catalysts containing stabilized aggregates of small crystallites of zeolite Y associated hydrocarbon conversion processes

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS8778171B2Hydrocracking catalysts containing stabilized aggregates of small crystallites of zeolite Y associated hydrocarbon conversion processes

Publication Date: 2014.07.15 EXXONMOBIL TECHNOLOGY & ENGINEERING CO

AI summary

This invention relates to hydrocracking catalysts utilizing stabilized aggregates of small primary crystallites of zeolite Y that are clustered into larger secondary particles. At least 80% of the secondary particles may comprise at least 5 primary crystallites. The size of the primary crystallites may be at most about 0.5 micron, or at most about 0.3 micron, and the size of the secondary particles may be at least about 0.8 micron, or at least about 1.0 μm. The silica to alumina ratio of the resulting stabilized aggregated Y zeolite may be 4:1 or more. This invention also relates to the use of such catalysts in hydrocracking processes for the conversion of heavy oils into lighter fuel products. The invention is particularly suited for the selective production of diesel range products from gas oil range feedstock materials under hydrocracking conditions.