U.S. patent application number 16/921124 was filed with the patent office on 2022-01-06 for method of producing a cracking catalyst.
This patent application is currently assigned to Saudi Arabian Oil Company. The applicant listed for this patent is Saudi Arabian Oil Company. Invention is credited to Manal Al-Eid, Lianhui Ding.
Application Number | 20220001363 16/921124 |
Document ID | / |
Family ID | 1000006034650 |
Filed Date | 2022-01-06 |
United States Patent
Application |
20220001363 |
Kind Code |
A1 |
Ding; Lianhui ; et
al. |
January 6, 2022 |
METHOD OF PRODUCING A CRACKING CATALYST
Abstract
Embodiments of the present disclosure are directed to a method
of producing a cracking catalyst. The method of producing a
cracking catalyst may comprise producing a plurality of uncalcined
zeolite-beta nanoparticles via a dry-gel method, directly mixing
the plurality of uncalcined zeolite-beta nanoparticles with at
least one additional hydrocracking component to form a mixture, and
calcining the mixture to form the cracking catalyst. The plurality
of uncalcined zeolite-beta nanoparticles may have an average
diameter of less than 100 nm.
Inventors: |
Ding; Lianhui; (Dhahran,
SA) ; Al-Eid; Manal; (Dhahran, SA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Saudi Arabian Oil Company |
Dhahran |
|
SA |
|
|
Assignee: |
Saudi Arabian Oil Company
Dhahran
SA
|
Family ID: |
1000006034650 |
Appl. No.: |
16/921124 |
Filed: |
July 6, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B01J 37/0045 20130101;
B01J 35/1047 20130101; B01J 37/04 20130101; B01J 29/7007 20130101;
B01J 35/023 20130101; B01J 23/28 20130101; B01J 35/1023 20130101;
B01J 35/1042 20130101; C10G 11/05 20130101; B01J 37/0201 20130101;
B01J 6/001 20130101 |
International
Class: |
B01J 29/70 20060101
B01J029/70; B01J 6/00 20060101 B01J006/00; B01J 37/02 20060101
B01J037/02; B01J 37/04 20060101 B01J037/04; B01J 35/02 20060101
B01J035/02; B01J 35/10 20060101 B01J035/10; B01J 37/00 20060101
B01J037/00; C10G 11/05 20060101 C10G011/05 |
Claims
1. A method of producing a cracking catalyst, the method
comprising: producing a plurality of uncalcined zeolite-beta
nanoparticles via a dry-gel method, wherein the plurality of
uncalcined zeolite-beta nanoparticles has an average diameter of
less than 100 nm; directly mixing the plurality of uncalcined
zeolite-beta nanoparticles with at least one additional
hydrocracking component to form a mixture; and calcining the
mixture to form the cracking catalyst; wherein the plurality of
uncalcined zeolite-beta nanoparticles has not been subjected to
centrifugation before being mixed with the at least one additional
hydrocracking component.
2. The method of producing a cracking catalyst of claim 1, wherein
the plurality of uncalcined zeolite-beta nanoparticles has not been
subjected to centrifugation above 3,000 rpm, before being mixed
with the at least one additional hydrocracking component.
3. The method of producing a cracking catalyst of claim 1, wherein
the plurality of uncalcined zeolite-beta nanoparticles has not been
subjected to calcination above 200.degree. C. for more than 30
minutes, before being mixed with the at least one additional
hydrocracking component.
4. The method of producing a cracking catalyst of claim 1, wherein
the at least one additional hydrocracking component comprises one
or more of MoO.sub.3, WO.sub.3, NiO, large pore alumina, ZSM-5,
zeolite-Y, tungsten precursors, amorphous silica-alumina, and
binders.
5. The method of producing a cracking catalyst of claim 1, wherein
the cracking catalyst comprises from 14 wt. % to 16 wt. %
MoO.sub.3, 4 wt. % to 6 wt. % NiO, 10 wt. % to 50 wt. % of the
zeolite-beta nanoparticles, 0 wt. % to 40 wt. % zeolite-Y, 0 wt. %
to 20 wt. % large pore alumina, and 15 wt. % to 20 wt. % of a
binder.
6. The method of producing a cracking catalyst of claim 1, wherein
the mixture is calcined at 400.degree. C. to 700.degree. C. for 1
hour to 10 hours.
7. The method of producing a cracking catalyst of claim 1, wherein
the directly mixing comprises extrusion.
8. The method of producing a cracking catalyst of claim 1, wherein
the directly mixing comprises both extrusion and impregnation.
9. The method of producing a cracking catalyst of claim 1, wherein
the cracking catalyst is impregnated with metal compounds after the
mixture is calcined to form an impregnated cracking catalyst
support.
10. The method of producing a cracking catalyst of claim 9 wherein
the impregnated cracking catalyst support is further calcined.
11. The method of producing a cracking catalyst of claim 1, wherein
the plurality of uncalcined zeolite-beta nanoparticles has an
average diameter from 20 nm to 50 nm.
12. The method of producing a cracking catalyst of claim 1, wherein
at least 90% of the plurality of uncalcined zeolite-beta
nanoparticles have diameters from 20 nm to 50 nm.
13. The method of producing a cracking catalyst of claim 1, wherein
an average pore size of the plurality of uncalcined zeolite-beta
nanoparticles is from 3 nm to 10 nm.
14. The method of producing a cracking catalyst of claim 1, wherein
a microporous surface area of the plurality of uncalcined
zeolite-beta nanoparticles is from 300 m.sup.2/g to 500
m.sup.2/g.
15. The method of producing a cracking catalyst of claim 1, wherein
a BET surface area of the plurality of uncalcined zeolite-beta
nanoparticles is from 500 m.sup.2/g to 700 m.sup.2/g.
16. The method of producing a cracking catalyst of claim 1, wherein
a pore volume of the plurality of uncalcined zeolite-beta
nanoparticles is from 0.8 ml/g to 0.9 ml/g.
17. (canceled)
18. The method of producing a cracking catalyst of claim 1, wherein
the producing the plurality of uncalcined zeolite-beta
nanoparticles via the dry-gel method comprises: combining an
alumina source, a structure directing agent, and a silica source to
form a slurry; optionally, introducing NaOH to the slurry such that
the final concentration of NaOH in the slurry is from 0.000001 g/L
to 0.1 g/L; drying the slurry to form a dry-gel; and autoclaving
the dry-gel in a humidified autoclave to form an uncalcined
zeolite-beta.
19. The method of producing a cracking catalyst of claim 18,
wherein the water content of the dry-gel is less than 25 wt. %.
20. The method of producing a cracking catalyst of claim 18,
wherein the dry-gel is not agitated during autoclaving.
Description
TECHNICAL FIELD
[0001] The present disclosure relates to methods of making cracking
catalysts and, more specifically, to methods of making cracking
catalysts, which comprise zeolite-beta.
BACKGROUND
[0002] Converting crude oil to chemicals, such as olefins and
benzene, toluene, and xylene (BTX) aromatics is a growing area in
the petrochemical field. This conversion process may include hydro
processing feedstock. First by rejecting heavy and contaminated
components. Then, upgrading the crude oil to increase the
paraffinic content. The upgraded crude oil can be further directed
to a steam cracking unit to produce olefins and BTX with an
acceptable rate of coke formation.
[0003] In order to upgrade the crude oil for the steam cracking
unit, the crude may be passed over a hydrocracking catalyst to
remove undesired contents (such as sulfur, nitrogen and metals).
The hydrocracking catalyst may further convert large aromatic and
saturated molecules. As used herein, "large aromatic molecules" may
have molecular sizes larger than 3 nanometers (nm). The catalyst
used in the hydrocracking process has two functions, cracking of
large hydrocarbons and hydrogenating the unsaturated molecules.
However, the small pore size (less than 3 nm) of the traditional
hydrocracking catalysts, such as zeolite-beta, has a negative
impact on the performance of the catalyst by preventing the
diffusion of large molecules from the heavy oil fraction into
active sites located inside the zeolite. This causes low activity
and rapid deactivation of the catalyst.
[0004] One solution to the diffusion length and pore size problem
is to reduce the zeolite particle size, thereby increasing external
surface area and decreasing diffusion lengths. However, while
reduced particle size should lead to greatly improved catalytic
activity, agglomeration of the nano-sized zeolite particles of the
hydrocracking catalyst may occur, thereby preventing this improved
catalytic activity.
SUMMARY
[0005] Accordingly, there is a continual need for hydrocracking
catalysts and methods of making those hydrocracking catalysts,
which can eliminate the agglomeration of zeolite particles and
thereby improve the catalytic activity of the hydrocracking
catalysts. Embodiments of the present disclosure meet this need by
producing hydrocracking catalysts comprising zeolite-beta catalysts
synthesized by a dry-gel method. Embodiments further meet this need
by combining this dry-gel produced zeolite-beta with other
hydrocracking components before calcination.
[0006] According to one embodiment of the present disclosure, a
method of producing a cracking catalyst may comprise producing a
plurality of uncalcined zeolite-beta nanoparticles via a dry-gel
method, directly mixing the plurality of uncalcined zeolite-beta
nanoparticles with at least one additional hydrocracking component
to form a mixture, and calcining the mixture to form the cracking
catalyst. The plurality of uncalcined zeolite-beta nanoparticles
may have an average diameter of less than 100 nm.
[0007] In accordance with one embodiment of the present disclosure,
producing a plurality of uncalcined zeolite-beta nanoparticles via
a dry-gel method may comprise combining an alumina source, a
structure directing agent, and a silica source to form a slurry;
drying the slurry to form a dry-gel; and autoclaving the dry-gel in
a humidified autoclave to form an uncalcined zeolite-beta.
[0008] Although the concepts of the present disclosure are
described herein with primary reference to cracking catalysts, it
is contemplated that the concepts will enjoy applicability to any
catalytic system.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0009] The following detailed description of specific embodiments
of the present disclosure can be best understood when read in
conjunction with the following drawings:
[0010] FIG. 1 shows the layout of a humidified autoclave.
Abbreviations
[0011] BET surface area=Brunauer-Emmett-Teller surface area.
[0012] .degree. C.=degrees Celsius.
[0013] g=grams.
[0014] g/l=grams per liter.
[0015] hr.=hour.
[0016] min.=minute.
[0017] m.sup.2/g=meters squared per gram.
[0018] MoO.sub.3=molybdenum trioxide.
[0019] NiO=nickel oxide.
[0020] nm=nanometers.
[0021] OSDAs=organic structure-directing agents.
[0022] PSI=Pounds per square inch gauge.
[0023] rpm=revolutions per minute.
[0024] TEAOH=tetraethylammonium hydroxide.
[0025] TEOS=tetraethyl orthosilicate.
[0026] wt. %=weight percent.
[0027] .degree.=degrees.
DETAILED DESCRIPTION
[0028] In hydrocracking, smaller catalytic particles, such as
zeolite-beta nanoparticles, are theoretically desirable as smaller
particles have a higher surface area to mass ratio. However, a
practical limit on the size of nanoparticles is imposed by the
problem of agglomeration. When small particles are placed near one
another, the attractive forces can overwhelm the repulsive forces,
causing multiple particles to form a single larger particle. Thus,
negating the effect of the smaller particle size. As zeolite-beta
nanoparticles are used in cracking catalysts, it is desirable to
prevent agglomeration in the development of zeolite-beta
nanoparticles.
[0029] In the formation of zeolite-beta nanoparticles according to
conventional methods, this agglomeration is believed to occur
primarily during the centrifuging, drying, and calcining steps.
Without being limited by theory, it is believed that certain
modifications will lead to decreased nanoparticle agglomeration.
Specifically, those modifications are the elimination of the
centrifuging step and postponing calcining until after the
plurality of uncalcined zeolite-beta nanoparticles are mixed with
at least one other hydrocracking component.
[0030] Embodiments of the present disclosure are directed to
improved methods that decrease agglomeration. For example, a method
of producing a cracking catalyst may include producing a plurality
of uncalcined zeolite-beta nanoparticles via a dry-gel method. The
plurality of uncalcined zeolite-beta nanoparticles may be directly
mixed with at least one additional hydrocracking component to form
a mixture. The mixture may then be calcined to form the cracking
catalyst.
[0031] The plurality of uncalcined zeolite-beta nanoparticles may
be produced via a dry-gel method. In one or more embodiments, the
dry-gel method may comprise combining an alumina source, a
structure directing agent, and a silica source to form a slurry;
drying the slurry to form a dry-gel; and autoclaving the dry-gel in
a humidified autoclave to form the plurality of uncalcined
zeolite-beta nanoparticles.
[0032] Producing the plurality of uncalcined zeolite-beta
nanoparticles may comprise drying the slurry to form a dry-gel. A
dry-gel may include a dried mixture where the water content of the
mixture is substantially equilibrated with the surrounding
atmosphere. The slurry may be converted to the dry-gel by drying in
an oven or under vacuum.
[0033] The water content of the dry-gel may be less than 25 wt. %.
For example, the water content of the dry-gel may be less than 20
wt. %, less than 15 wt. %, less than 10 wt. %, less than 5 wt. %,
or even less than 1 wt. %, or any subset thereof
[0034] The slurry may be dried at a specified temperature and
pressure. For example, the slurry may be dried at less than or
equal to atmospheric pressure and a temperature from 80.degree. C.
to 140.degree. C., from 90.degree. C. to 130.degree. C., or from
100.degree. C. to 120.degree. C., or any subset thereof. According
to some embodiments, the slurry may be dried at less than or equal
to -4 pounds per square inch of gauge pressure (PSIG) and a
temperature from 80.degree. C. to 140.degree. C., from 90.degree.
C. to 130.degree. C., or from 100.degree. C. to 120.degree. C., or
any subset thereof. According to further embodiments, the slurry
may be dried at less than or equal to -8 PSIG and a temperature
from 80.degree. C. to 140.degree. C., from 90.degree. C. to
130.degree. C., or from 100.degree. C. to 120.degree. C., or any
subset thereof.
[0035] The slurry may be dried for a specified period of time. For
example, the slurry may be dried for from 1 hr. to 7 days, from 6
hr. to 7 days, from 12 hr. to 7 days, from 24 hr. to 7 days, from 1
hr. to 6 days, from 1 hr. to 5 days, from 1 hr. to 4 days, from 1
hr. to 3 days, from 4 hr. to 3 days, from 8 hr. to 2 days, or any
subset thereof.
[0036] Drying the slurry may take place in the absence of
agitation. For example, the slurry may be dried without any mixing,
spinning, stirring, shaking, or other form of agitation.
[0037] The dry-gel may be autoclaved in a humidified autoclave to
form an uncalcined zeolite-beta. An autoclave may include any
device or combination of devices suitable to maintain a specified
temperature and humidity. Referring to FIG. 1, the humidified
autoclave 1000 may be a sealed chamber 100 with a sample holder
200, wherein the sealed chamber may be placed inside an oven.
Specifically as shown, the humidified autoclave 1000 may comprise a
sealed chamber 100. Inside the sealed chamber 100, there may be a
sample holder 200. Optionally, there may be a water holder 300. The
sample holder 200 may be connected to the exterior of the sealed
chamber 100 by a plurality of supports 400. The dry-gel 500 may be
placed in the sample holder 200.
[0038] A relative humidity in the humidified autoclave may be from
1% to 100%. For example, the relative humidity may be from 1% to
99%, from 1% to 75%, from 1% to 50%, from 25% to 100%, from 25% to
75%, from 25% to 50%, from 50% to 100%, from 50% to 75%, from 75%
to 100%, from 75% to 90%, from 90% to 10%, or any subset thereof.
According to some embodiments, the atmosphere within the humidified
autoclave may comprise saturated steam.
[0039] According to some embodiments, the dry-gel may not be
agitated during the autoclaving process. For example, the dry-gel
may be autoclaved without any mixing, spinning, shaking, or
stirring.
[0040] The dry-gel may be autoclaved at 100.degree. C. to
200.degree. C. for 1 day to 6 days. For example, the dry-gel may be
autoclaved at 100.degree. C. to 175.degree. C., 100.degree. C. to
150.degree. C., 125.degree. C. to 200.degree. C., 125.degree. C. to
175.degree. C., or 125.degree. C. to 150.degree. C.; for 1 day to 5
days, 1 day to 4 days, 1 day to 3 days, 1 day to 2 days, 2 days to
6 days, 2 days to 5 days, 2 days to 4 days, 3 days to 6 days, or
any subset thereof.
[0041] As stated above, the alumina source, structure directing
agent, and silica source may be combined to form a slurry. The
slurry may further comprise water or a non-aqueous solvent.
According to some embodiments, the structure directing agent itself
may serve as the solvent. The combining may take the form of
stirring, mixing, shaking, or agitating.
[0042] The alumina source may comprise any chemical precursor
capable of releasing aluminum ions or particles into the slurry.
For example, the alumina source may comprise sodium aluminate,
aluminum chloride, aluminum nitrate, powdered aluminum metal,
powdered alumina, or any combination thereof.
[0043] Various compositions are contemplated for the structure
directing agent. In one or more embodiments, the structure
directing agent may comprise tetraethylammonium hydroxide (TEAOH).
The structure directing agent may comprise organic
structure-directing agents (OSDAs) such as organic ammonium,
inorganic cations such as hydroxide, or both.
[0044] The silica source may comprise any chemical precursor
capable of releasing silica into the slurry. For example, the
silica source may comprise one or more of fumed silica, solid
silica gel, white carbon, or tetraethyl orthosilicate (TEOS).
[0045] According to some embodiments, the dry-gel method may
comprise introducing NaOH to the slurry such that the final
concentration of NaOH in the slurry is from 0.000001 g/L to 0.1
g/L. For example, the final concentration of NaOH in the slurry may
be from 0.000001 g/L to 0.01 g/L, from 0.000001 g/L to 0.001 g/L,
from 0.000001 g/L to 0.001 g/L, or even from 0.000001 g/L to
0.000002 g/L. In embodiments where NaOH is present, it may be
preferable to have a relatively small amount of NaOH. Without being
limited by theory it is believed that the presence of NaOH has
detrimental effects including irregular zeolite crystal formation
and large particle sizes. Another disadvantage of NaOH is when NaOH
is present, further NH.sub.4.sup.+ ion exchange is required to
reduce the amount of detrimental sodium in the zeolite. Thus, the
yield is increased and the cost is decreased when NaOH is minimized
or not present at all.
[0046] As stated previously, the plurality of uncalcined
zeolite-beta nanoparticles produced by the dry-gel method may be
directly mixed with at least one additional hydrocracking component
to form a mixture. According to some embodiments, only a portion of
the uncalcined zeolite-beta nanoparticles may be directly mixed
with the at least one additional hydrocracking component.
Alternatively, all of the produced uncalcined zeolite-beta
nanoparticles may be directly mixed with the at least one
additional hydrocracking component.
[0047] The mixture may comprise a mixture of solids, a mixture of
liquids, or a mixture of some solids and some liquids. For example,
the mixture may comprise a slurry, a powder mixture, an aqueous
solution, a colloid, a gel, or any other mixture. According to some
embodiments, the mixture may include additional solvents, such as
water or a non-aqueous solvent. According to other embodiments, the
mixture may not include additional solvents.
[0048] As used herein, "zeolite-beta" may refer to a hydrated
alumino-silicate with a three dimensional intersecting
twelve-membered ring channel system. The zeolite-beta may be
characterized by X-ray diffraction (XRD). The XRD may show that
zeolite-beta is present when the highest characteristic peaks are
around 22.4.degree. 2-Theta.
[0049] As used herein, "directly mixed" refers to combining the
plurality of uncalcined zeolite-beta nanoparticles with the at
least one additional hydrocracking component, without any
processing steps which may cause agglomeration, between autoclaving
the dry-gel and combining the plurality of uncalcined zeolite-beta
nanoparticles with the at least one additional hydrocracking
component. For example, the excluded processing steps may include
one or more of calcination, centrifuging, washing, or
ion-exchange.
[0050] The step of directly mixing may include any mixing step. For
example, direct mixing may include mechanical mixing. The
mechanical mixing may encompass extrusion, such as extrusion
performed in a twin screw extruder. Mechanical mixing may take
place in a static mixer, rotary mixer, mortar and pestle, extruder,
or a combination of these. Directly mixing may also include other
mixing steps such as impregnation. For example, directly mixing may
include both extrusion and impregnation. As used herein,
impregnation refers to a process wherein a metal precursor is
dissolved in a solution, the catalyst support is inserted into the
solution, and finally the metal precursor is drawn into the support
by capillary and diffusive forces.
[0051] The at least one additional hydrocracking component may
comprise one or more of MoO.sub.3, WO.sub.3, NiO, large pore
alumina, ZSM-5, zeolite-Y, tungsten precursors, amorphous
silica-alumina, and binders.
[0052] The at least one additional hydrocracking component may
comprise large pore alumina. The large pore alumina may have a pore
volume of 0.7 ml/g to 1.2 ml/g. For example, the pore volume may be
from 0.8 ml/g to 1.1 ml/g, or from 0.9 ml/g to 1.0 ml/g. The large
pore alumina may have a pore size of 18 nm to 26 nm. For example,
the pore size may be from 20 nm to 24 nm. The pore volume and pore
size of the large pore alumina may be calculated according to the
Barret-Joyner-Halenda (BJH) method.
[0053] According to some embodiments, the cracking catalyst may
comprise from 12 wt. % to 18 wt. % MoO.sub.3. For example, the
cracking catalyst may comprise from 14 wt. % to 18 wt. % or from 12
wt. % to 16 wt. %, or from 14 wt. % to 16 wt. % MoO.sub.3.
[0054] The cracking catalyst may comprise from 2 wt. % to 8 wt. %
NiO. For example, the cracking catalyst may comprise from 2 wt. %
to 6 wt. %, or from 4 wt. % to 8 wt. %, or from 4 wt. % to 6 wt. %
NiO.
[0055] The cracking catalyst may comprise from 10 wt. % to 50 wt. %
of the uncalcined zeolite-beta nanoparticles. For example, the
cracking catalyst may comprise from 10 wt. % to 40 wt. %, or from
10 wt. % to 30 wt. %, or from 10 wt. % to 20 wt. %, or from 20 wt.
% to 50 wt. %, or from 20 wt. % to 40 wt. %, or from 20 wt. % to 30
wt. %, or from 30 wt. % to 50 wt. %, or from 30 wt. % to 40 wt. %
of the uncalcined zeolite-beta nanoparticles.
[0056] The cracking catalyst may comprise from 0 wt. % to 40 wt. %
zeolite-Y. For example, the cracking catalyst may comprise from 10
wt. % to 30 wt. %, or from 10 wt. % to 20 wt. %, or from 20 wt. %
to 40 wt. %, or from 20 wt. % to 30 wt. %, or from 30 wt. % to 40
wt. % zeolite-Y.
[0057] The cracking catalyst may comprise from 0 wt. % to 20 wt. %
large pore alumina. For example, the cracking catalyst may comprise
from 0 wt. % to 15 wt. %, or from 0 wt. % to 10 wt. %, or from 0
wt. % to 5 wt. %, or from 5 wt. % to 15 wt. %, or from 5 wt. % to
10 wt. %, 5 wt. % to 20 wt. %, 10 wt. % to 20 wt. %, or from 10 wt.
% to 15 wt. %, or from 15 wt. % to 20 wt. % large pore alumina.
[0058] The cracking catalyst may comprise from 10 wt. % to 25 wt. %
of a binder. For example, the cracking catalyst may comprise from
15 wt. % to 20 wt. %, or from 10 wt. % to 20 wt. % or from 15 wt. %
to 25 wt. % of a binder.
[0059] As used herein, a binder may refer to any substance capable
of holding the hydrocracking components together. However, it is
known that the choice of binder can have a significant effect on
acidity and thus on the suitability of a zeolite based catalyst for
its particular catalytic task. According to some embodiments, the
binder may comprise one or more of a clay, a mineral, an alumina,
or a silica. The clay may comprise kaolin. The alumina may comprise
one or more of attapulgite, boehmite, or partially acid peptized
alumina. According to some specific embodiments, the binder may
comprise a partially acid peptized alumina. The partially acid
peptized alumina may comprise small pore alumina with an alumina
pore volume of 0.4 ml/g to 0.6 ml/g and a HNO.sub.3/alumina molar
ratio of 0.2 to 0.3.
[0060] Centrifugation, drying, and calcination are believed to be
the most significant causes of agglomeration during the production
of zeolite-beta nanoparticles. By eliminating or postponing these
processes until after the zeolite-beta nanoparticles are mixed with
the at least one other hydrocracking component, agglomeration can
be greatly reduced. Without being limited by theory, it is believed
that the centripetal forces of centrifugation tend to compress the
nanoparticles into a smaller space, causing them to come into
contact and agglomerate.
[0061] The plurality of uncalcined zeolite-beta nanoparticles may
have not been subjected to centrifugation before being mixed with
the at least one additional hydrocracking component. As used
herein, "centrifugation" may refer to spinning in a centrifuge
above 3,000 rpm, 5,000 rpm, 8,000 rpm, 10,000 rpm, 20,000 rpm, or
any subset thereof.
[0062] The plurality of uncalcined zeolite-beta nanoparticles may
also not have been subjected to calcination prior to being mixed
with the at least one additional hydrocracking component. As used
herein "calcination" may refer to exposure to temperatures above
200.degree. C., above 300.degree. C., above 400.degree. C., or
above 500.degree. C.; for more than 30 minutes, more than 45
minutes, more than 60 minutes, more than 90 minutes, more than 180
minutes, more than 5 hours, more than 8 hours, more than 12 hours,
more than 24 hours, more than 48 hours, or more than 5 days, or any
subset thereof.
[0063] Without being limited by theory, it is believed that
calcination may cause agglomeration through a process known as
sintering. At elevated temperatures, diffused matter may form
bridge-like structures between the surfaces.
[0064] It should be understood that the plurality of uncalcined
zeolite-beta nanoparticles may not have been subjected to either
centrifugation or calcination during the time between formation and
mixing with the at least one other hydrocracking component. For
example, the plurality of uncalcined zeolite-beta nanoparticles may
not have been centrifuged or calcined after autoclaving the dry-gel
and before mixing the dry-gel with the at least one other
hydrocracking component. The plurality of uncalcined zeolite-beta
nanoparticles may not have been centrifuged or calcined after the
combining of the alumina source, the silica source, and the
structure directing agent and before mixing with the at least one
other hydrocracking component.
[0065] While the process of calcination may cause undesirable
agglomeration before the uncalcined zeolite-beta nanoparticles have
been combined with the at least one additional hydrocracking
component, it is useful in the formation of a catalyst. The
sintered catalyst is believed to better withstand the rigors of a
chemical reactor.
[0066] The catalyst may be dried before calcination. Drying the
catalyst may comprise exposing the catalyst to temperatures between
25.degree. C. and 350.degree. C. For example, the temperature may
be between 50.degree. C. and 325.degree. C., 75.degree. C. and
300.degree. C., 100.degree. C. and 275.degree. C., 150.degree. C.
and 225.degree. C., or any subset thereof. Drying the catalyst may
comprise exposing the catalyst to the elevated temperatures for
from 2 hr. to 24 hr. For example, the catalyst may be exposed to
the elevated temperature for from 6 hr. to 20 hr., or 12 hr. to 14
hr., or any subset thereof. Without being limited by theory, it is
believed that drying may be necessary to prevent steam explosions
within the catalyst during calcination.
[0067] The mixture may be calcined to form the cracking catalyst.
It should be understood that the mixture which may be calcined
comprises both the uncalcined zeolite-beta nanoparticles and the at
least one additional hydrocracking component.
[0068] The mixture may be calcined at 400.degree. C. to 700.degree.
C., for 1 hour to 10 hours. For example, the mixture may be
calcined at from 400.degree. C. to 600.degree. C., from 400.degree.
C. to 500.degree. C., from 500.degree. C. to 700.degree. C., from
600.degree. C. to 700.degree. C., or from 500.degree. C. to
600.degree. C.; for 1 hour to 9 hours, 1 hour to 8 hours, 1 hour to
6 hours, 2 hours to 10 hours, 2 hours to 9 hours, 2 hours to 7
hours, 4 hours to 10 hours, 4 hours, to 8 hours, or 4 hours to 6
hours, or any subset thereof.
[0069] The plurality of uncalcined zeolite-beta nanoparticles may
have an average diameter of less than 100 nm. For example, the
plurality of uncalcined zeolite-beta nanoparticles may have an
average diameter of less than 80 nm, less than 70 nm, less than 60
nm, less than 50 nm, less than 40 nm, or even less than 30 nm, or
any subset thereof. It should be understood that the average
diameter is the mean diameter and is to be calculated using all the
uncalcined zeolite-beta nanoparticles introduced into the
mixture.
[0070] The uncalcined zeolite-beta nanoparticles may have an
average diameter from 20 nm to 50 nm. For example, the average
diameter may be from 20 nm to 40 nm, from 20 nm to 30 nm, from 30
nm to 50 nm, from 40 nm to 50 nm, or any subset thereof.
[0071] At least 90% of the individual uncalcined zeolite-beta
nanoparticles may have diameters from 20 nm to 50 nm. For example,
substantially all of the zeolite-beta nanoparticles may have
diameters from 20 nm to 40 nm, from 20 nm to 30 nm, from 30 nm to
50 nm, or from 40 nm to 50 nm, or any subset thereof.
[0072] A silica/alumina ratio of the uncalcined zeolite-beta
nanoparticles may be from 20 to 100. For example, the
silica/alumina molar ratio may be from 20 to 90, 20 to 75, 20 to
50, 20 to 40, 30 to 100, 30 to 90, 30 to 75, 30 to 50, 30 to 40, 35
to 40, 36 to 40, or any subset thereof.
[0073] An average pore size of the uncalcined zeolite-beta
nanoparticles may be from 3 nm to 10 nm. For example, the average
pore size of the uncalcined zeolite-beta nanoparticles may be from
3 nm to 8 nm, from 3 nm to 5 nm, from 5 nm to 10 nm, from 8 nm to
10 nm, or any subset thereof.
[0074] The surface area of both the calcined and uncalcined ZSM-5
nanoparticles may be measured using BET analysis and calculated
with the multipoint BET equation. Pore volume of both the calcined
and uncalcined ZSM-5 nanoparticles may be calculated from the
maximum adsorption amount of nitrogen. The pore size distribution
of both the calcined and uncalcined ZSM-5 nanoparticles may be
determined based on the Barrett-Joyner-Halenda (BJH) method and the
desorption branch of the isotherm. The average pore sizes of both
the calcined and uncalcined ZSM-5 nanoparticles may be calculated
by the equation Ps=4V/S, where Ps=pore size, V=pore volume, and
S=surface area.
[0075] The microporous surface area of the uncalcined zeolite-beta
nanoparticles may be from 300 m.sup.2/g to 500 m.sup.2/g. For
example, the microporous surface area of the uncalcined
zeolite-beta may be from 300 m.sup.2/g to 400 m.sup.2/g.
[0076] A BET surface area of the uncalcined zeolite-beta
nanoparticles may be from 500 m.sup.2/g to 700 m.sup.2/g. For
example, the BET surface area may be from 500 m.sup.2/g to 600
m.sup.2/g.
[0077] The pore volume of the uncalcined zeolite-beta nanoparticles
may be from 0.8 ml/g to 0.9 ml/g. For example, the pore volume of
the uncalcined zeolite-beta nanoparticles may be from 0.84 ml/g to
0.9 ml/g.
[0078] A crystallinity of the uncalcined zeolite-beta nanoparticles
may be from 125% to 200%, relative to CP-814E. For example, the
relative crystallinity of the uncalcined zeolite-beta nanoparticles
may be from 125% to 200%, from 150% to 200%, from 170% to 190%, or
any subset thereof, relative to CP-814E. CP-814E may be
commercially available from Zeolyst products.
[0079] The crystallinity and phase purity of solid products may be
measured by powder X-ray diffraction (XRD) using a diffractometer,
such as a Rigaku Ultima IV multi-purpose diffractometer with a
copper X-ray tube. The scanning range may be set between 2.degree.
to 50.degree. in 20 Bragg-angles with a step size of 0.04.degree.
and a total counting time of 1.degree. per minute. The
crystallinity percentage may be calculated by PANalytical High
Score Plus software through the comparison of the area under the
most intense diffraction peaks to that of patterns of a reference
zeolite ZSM 5. The reference zeolite ZSM-5 may be a commercially
available zeolite, such as CP-814E.
[0080] The calcined mixture may include a plurality of zeolite-beta
nanoparticles incorporated within the calcined mixture. The
plurality of zeolite-beta nanoparticles incorporated within the
calcined mixture may have an average diameter of less than 100 nm.
For example, the plurality of zeolite-beta nanoparticles may have
an average diameter of less than 80 nm, less than 70 nm, less than
60 nm, less than 50 nm, less than 40 nm, or even less than 30 nm,
or any subset thereof.
[0081] The plurality of zeolite-beta nanoparticles incorporated
within the calcined mixture may have an average diameter from 20 nm
to 50 nm. For example, the average diameter may be from 20 nm to 40
nm, from 20 nm to 30 nm, from 30 nm to 50 nm, from 40 nm to 50 nm,
or any subset thereof.
[0082] Particle sizes may be measured by transmission electron
microscopy (TEM). The TEM may be operated at about 200 kV. The
average particle sizes may be obtained by measuring all the
particles in 5 to 8 TEM images and taking the mean.
[0083] At least 90% of the individual zeolite-beta nanoparticles
incorporated within the calcined mixture may have diameters from 20
nm to 50 nm. For example, substantially all of the zeolite-beta
nanoparticles may have diameters from 20 nm to 40 nm, from 20 nm to
30 nm, from 30 nm to 50 nm, or from 40 nm to 50 nm, or any subset
thereof.
[0084] An average pore size of the plurality of zeolite-beta
nanoparticles incorporated within the calcined mixture may be from
3 nm to 10 nm. For example, the average pore size of the plurality
of zeolite-beta nanoparticles incorporated within the calcined
mixture may be from 3 nm to 8 nm, from 3 nm to 5 nm, from 5 nm to
10 nm, from 8 nm to 10 nm, or any subset thereof. The average pore
size may be determined using a gas absorption analyzer, such as the
Quantachrome Autosorb iQ.
[0085] The microporous surface area of the plurality of
zeolite-beta nanoparticles incorporated within the calcined mixture
may be from 300 m.sup.2/g to 500 m.sup.2/g. For example, the
microporous surface area of the zeolite-beta may be from 300
m.sup.2/g to 400 m.sup.2/g.
[0086] A BET surface area of the plurality of zeolite-beta
nanoparticles incorporated within the calcined mixture may be from
500 m.sup.2/g to 700 m.sup.2/g. For example, the BET surface area
may be from 500 m.sup.2/g to 600 m.sup.2/g, or from 550 m.sup.2/g
to 650 m.sup.2/g.
[0087] The pore volume of the plurality of zeolite-beta
nanoparticles incorporated within the calcined mixture may be from
0.8 ml/g to 0.9 ml/g. For example, the pore volume of the
zeolite-beta nanoparticles incorporated within the calcined mixture
may be from 0.84 ml/g to 0.9 ml/g.
[0088] A crystallinity of the plurality of zeolite-beta
nanoparticles incorporated within the calcined mixture may be from
125% to 200%, relative to CP-814E. For example, the relative
crystallinity of the plurality of zeolite-beta nanoparticles
incorporated within the calcined mixture may be from 150% to 200%,
from 175% to 200%, from 170% to 190%, or any subset thereof.
[0089] An impregnated cracking catalyst support may be prepared by
impregnating the cracking catalyst with metal compounds after the
mixture is calcined to form an impregnated cracking catalyst
support. The metal compounds may include any catalytically active
metal. For example, the metal compounds may include W, Ni, Mo, Cr,
Mn, Fe, Co, V, Cu, Zn, Ga, Ge, Sn, Cd, Ag, Pd, Rh, Ru, Nb, Zr, Ga,
or a combination of these. According to some embodiments, the metal
compounds may include one or both of W and Ni.
[0090] The impregnated cracking catalyst support may be prepared by
inserting the calcined cracking catalyst into an impregnation
solution. The impregnation solution may comprise metal precursor
compounds which disassociate in the solution to form metals or
metal ions. For example, an impregnation solution may comprise
ammonium metatungstate and nickel nitrate.
[0091] After impregnation, the impregnated cracking catalyst
support may be further calcined to form an impregnated cracking
catalyst. Without being limited by theory, calcination may be used
to drive off remaining volatile compounds such as ammonium and
water. The impregnated cracking catalyst support may be calcined at
400.degree. C. to 700.degree. C. for 1 hour to 10 hours. For
example, the impregnated cracking catalyst support may be calcined
at 400.degree. C. to 600.degree. C., 400.degree. C. to 500.degree.
C., 500.degree. C. to 700.degree. C., 600.degree. C. to 700.degree.
C., or 500.degree. C. to 600.degree. C.; for 1 hour to 9 hours, 1
hour to 8 hours, 1 hour to 6 hours, 2 hours to 10 hours, 2 hours to
9 hours, 2 hours to 7 hours, 4 hours to 10 hours, 4 hours, to 8
hours, or 4 hours to 6 hours, or any subset thereof.
EXAMPLES
[0092] Exemplary cracking catalysts were prepared according to a
conventional method and according to the present method. Both
catalysts had a composition of 15 wt. % MoO.sub.3, 5 wt. % NiO, 10
wt. % large pore alumina, 20 wt. % partially acid peptized alumina
binder, and 50 wt. % of the zeolite-beta nanoparticles
characterized in table 1.
Comparative Example 1
[0093] In COMPARATIVE EXAMPLE 1, a zeolite-beta based catalyst was
prepared according to the traditional hydrogel method. 0.27 g
aluminum powder was mixed with 25 g of TEAOH and stirred. In a
separate container, 15 g fumed silica was mixed with 38 g of TEAOH
and 4.05 g water. The two solutions were mixed together and the
mixture was stirred at room temperature for 4 hours. The liquid
mixture was then placed in an autoclave and spun at 60 RPM and
140.degree. C. for three days. After three days, a colloid was
formed. The colloid was repeatedly spun in a high speed centrifuge
and washed with water until the pH was 9.0. The solid product was
then dried in an oven at 110.degree. C. overnight. The dried sample
was calcined at 550.degree. C. for 4 hours and is characterized in
Table 1.
[0094] The calcined product was then mixed with appropriate amounts
of MoO.sub.3, NiO, large pore alumina, and partially acid peptized
alumina binder, to form a mixture. The mixture was then extruded
into a shaped catalyst (the shape was 1.8 mm cylinders). The shaped
catalyst was then dried at 110.degree. C. overnight. Finally, the
dried sample was calcined at 550.degree. C. for 4 hours.
Inventive Example 1
[0095] In INVENTIVE EXAMPLE 1, a zeolite-beta based catalyst was
prepared according to the present, modified, dry-gel method. 0.27 g
alumina powder was mixed with 12.5 g of TEAOH. In a separate
container, 7.5 g of fumed silica was mixed with 19 g of 35% TEAOH
and 2.0 g of water. The two solutions were mixed together to form a
slurry. The slurry was stirred at room temperature for 4 hours. The
slurry was then dried in an oven at 110.degree. C. overnight. The
sample was placed in an autoclave with about 30 ml of water, the
autoclave was sealed and held at 140.degree. C. for three days. The
resulting uncalcined zeolite-beta is characterized in Table 1.
[0096] The uncalcined zeolite-beta product was mixed with
appropriate amounts of MoO.sub.3, NiO, large pore alumina, and
partially acid peptized alumina binder to form a mixture. The
mixture was then extruded into a shaped catalyst (the shape was 1.8
mm cylinders). The shaped catalyst was dried at 110.degree. C.
overnight. Finally, the dried sample was calcined at 500.degree. C.
for 4 hours.
[0097] It should be understood that the catalyst of INVENTIVE
EXAMPLE 1 as characterized in Table 1 has not been calcined. The
catalyst of COMPARATIVE EXAMPLE 1, as characterized in Table 1 has
been calcined.
TABLE-US-00001 TABLE 1 Zeolite-Beta Characterization COMPARATIVE
INVENTIVE EXAMPLE 1 EXAMPLE 1 Particle sizes (nm) 90 30
SiO.sub.2/Al.sub.2O.sub.3 molar ratio 35 37 Synthesis Yield (wt. %)
65 95 XRD phase Beta Beta Crystallinity (CP-814E as reference) 102
187 (%) BET surface area (m.sup.2/g) 590 600 Microporous Surface
Area (m.sup.2/g) 284 347 Mesoporous Surface Area (m.sup.2/g) 306
253 Pore Volume (ml/g) 0.83 0.85 Microporous Volume (ml/g) 0.15
0.18 Mesoporous Volume (ml/g) 0.68 0.67 Average pore size (nm) 2.8
5.7 Mesopore percentage 82 79
[0098] As is shown in Table 1, INVENTIVE EXAMPLE 1 had increased
synthesis yields and crystallinity relative to COMPARATIVE EXAMPLE
1. Further, the catalyst of INVENTIVE EXAMPLE 1 had smaller
particle sizes relative to COMPARATIVE EXAMPLE 1 (30 nm vs 90
nm).
[0099] It was discovered through TEM images that when the
uncalcined nano-sized zeolite particles are directly mixed with the
at least one additional hydrocracking component, no aggregation
occurs.
Catalytic Testing
[0100] To determine the difference between the two catalysts, a
pilot plant scale hydrocracking process was performed. The feed
(hydrotreated Arab light crude) is characterized in Table 2. The
conditions were temperature=390.degree. C., liquid hourly space
velocity=1.5 h.sup.-1, pressure=150 bar, H.sub.2/oil volume
ratio=1200:1. The testing results are summarized in Table 3.
TABLE-US-00002 TABLE 2 Feed properties Density (g/ml) 0.8389 S, ppm
(weight) 53 N, ppm (weight) 75 Feed Composition, wt. %
C.sub.5-180.degree. C. 17.0 180.degree. C.-350.degree. C. 37.9
350.degree. C.-540.degree. C. 32.7 >540.degree. C. 13.6
TABLE-US-00003 TABLE 3 Reaction performance comparison COMPARATIVE
INVENTIVE Catalyst EXAMPLE 1 EXAMPLE 1 Liquid product properties
Density, g/ml 0.8288 0.7903 S, ppm (weight) 28.4 7.0 N, ppm
(weight) 15.5 1.2 Product Yields, wt. % C.sub.1-C.sub.4 7.3 8.5
C.sub.5-180.degree. C. 21.8 51.9 180.degree. C.-350.degree. C. 39.8
33.9 350.degree. C.-540.degree. C. 21.5 6.2 >540.degree. C. 1.9
0
[0101] One distinction between COMPARATIVE EXAMPLE 1 and INVENTIVE
EXAMPLE 1 is that in COMPARATIVE EXAMPLE 1, the zeolite-beta is
centrifuged and calcined before mixing with the other hydrocracking
components. In contrast, the zeolite-beta of INVENTIVE EXAMPLE 1 is
neither centrifuged nor calcined before introduction to the other
hydrocracking components.
[0102] As is shown in Table 3, the catalyst of INVENTIVE EXAMPLE 1
completely converts the >540.degree. C. fraction. The catalyst
of COMPARATIVE EXAMPLE 1 cannot accomplish this conversion.
Additionally, the inventive catalyst produces a significantly
higher light gas fraction (light gas fraction may be defined as
compounds ranging from Cs to those having a boiling point of
180.degree. C.) than the comparative catalyst. Further, the
catalyst of INVENTIVE EXAMPLE 1 is significantly better at reducing
the quantity of nitrogen and sulfur compounds in the final product,
relative to the catalyst of COMPARATIVE EXAMPLE 1.
[0103] It is also noted that recitations herein of "at least one"
component, element, etc., should not be used to create an inference
that the alternative use of the articles "a" or "an" should be
limited to a single component, element, etc.
[0104] Having described the subject matter of the present
disclosure in detail and by reference to specific embodiments
thereof, it is noted that the various details disclosed herein
should not be taken to imply that these details relate to elements
that are essential components of the various embodiments described
herein, even in cases where a particular element is illustrated in
each of the drawings that accompany the present description.
Further, it will be apparent that modifications and variations are
possible without departing from the scope of the present
disclosure, including, but not limited to, embodiments defined in
the appended claims. More specifically, although some aspects of
the present disclosure are identified herein as preferred or
particularly advantageous, it is contemplated that the present
disclosure is not necessarily limited to these aspects.
[0105] It is noted that one or more of the following claims utilize
the term "wherein" as a transitional phrase. For the purposes of
defining the present invention, it is noted that this term is
introduced in the claims as an open-ended transitional phrase that
is used to introduce a recitation of a series of characteristics of
the structure and should be interpreted in like manner as the more
commonly used open-ended preamble term "comprising."
* * * * *