Middle distillate hydrocracking catalyst containing zeolite USY, and zeolite beta with low acidity and large domain size

Patent metadata

Field	Value
Publication number	US-10040058-B2
Application number	US-201514823807-A
Country	US
Kind code	B2
Filing date	Aug 11, 2015
Priority date	Aug 11, 2015
Publication date	Aug 7, 2018
Grant date	Aug 7, 2018

Abstract

A hydrocracking catalyst is provided comprising: a zeolite beta having an OD acidity of 20 to 50 μmol/g and an average crystal size from 300 to 800 nanometers; a zeolite USY; wherein a wt % of the zeolite beta is less than the wt % of the zeolite USY; a support comprising an amorphous silica aluminate and a second support material; and 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 a hydrocarbonaceous feedstock is provided, comprising: contacting the hydrocarbonaceous feedstock with the hydrocracking catalyst under hydrocracking conditions to produce a hydrocracked effluent that comprises middle distillates. A method for making the hydrocracking catalyst is also provided.

First claim

It is claimed:

1. A hydrocracking catalyst comprising:
a. a zeolite beta having an OD acidity of 20 to 50 μmol/g and an average domain size from 800 to 1500 nm 2 ;
b. a zeolite USY; wherein a wt % of the zeolite beta is less than the wt % of the zeolite USY;
c. a support comprising an amorphous silica aluminate and a second support material; 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.

2. The hydrocracking catalyst of claim 1 , wherein the zeolite beta has a SiO 2 /Al 2 O 3 ratio (SAR) from 50 to 200.

3. The hydrocracking catalyst of claim 1 , wherein the OD acidity is from 30 to 40 μmol/g.

4. The hydrocracking catalyst of claim 1 , wherein the average domain size is from 900 to 1250 nm 2 .

5. The hydrocracking catalyst of claim 1 , wherein the zeolite beta has more large domains that have a domain size from 1200 to 2000 nm 2 than small domains that the domain size from 200 to 600 nm 2 .

6. The hydrocracking catalyst of claim 1 , wherein the zeolite beta has a standard deviation of domain sizes greater than 700 nm 2 .

7. The hydrocracking catalyst of claim 1 , wherein a weight ratio of the zeolite beta to the zeolite USY is from 0.10 to 0.95.

8. The hydrocracking catalyst of claim 1 , wherein the zeolite USY has an ASDI between 0.05 and 0.12.

9. The hydrocracking catalyst of claim 1 , wherein the second support is a pseudo-boehmite alumina.

10. The hydrocracking catalyst of claim 1 , comprising at least one Group 6 metal and at least one metal selected from Groups 8 through 10 of the Periodic Table.

11. A process for hydrocracking a hydrocarbonaceous feedstock, comprising contacting the hydrocarbonaceous feedstock with the hydrocracking catalyst of claim 1 under hydrocracking conditions to produce a hydrocracked effluent that comprises middle distillates.

12. The process of claim 11 , wherein the hydrocarbonaceous feedstock has a TBP within 700 to 1200° F. (371 to 649° C.).

13. The process of claim 11 , wherein the zeolite beta has a SiO 2 /Al 2 O 3 ratio (SAR) from 50 to 200.

14. The process of claim 11 , wherein the OD acidity is from 30 to 40 μmol/g.

15. The process of claim 11 , wherein the average domain size is from 900 to 1250 nm 2 .

16. The process of claim 11 , wherein the zeolite beta has more large domains that have a domain size from 1200 to 2000 nm 2 than small domains that the domain size from 200 to 600 nm 2 .

17. The process of claim 11 , wherein the zeolite beta has a standard deviation of domain sizes greater than 700 nm 2 .

18. The process of claim 11 , wherein a weight ratio of the zeolite beta to the zeolite USY is from 0.10 to 0.95.

19. The process of claim 11 , wherein the zeolite USY has an ASDI between 0.05 and 0.12.

20. The process of claim 11 , wherein the second support is a pseudo-boehmite alumina.

21. The process of claim 11 , comprising at least one Group 6 metal and at least one metal selected from Groups 8 through 10 of the Periodic Table.

22. The process of claim 11 , wherein the hydrocracked effluent comprises from greater than 50 vol % to 95 vol % of a heavy middle distillate having a TBP of 380-700° F. (193-371° C.).

23. A method for making the hydrocracking catalyst of claim 1 , comprising:
a. mixing together a zeolite beta having an OD acidity of 20 to 50 μmol/g and an average domain size from 800 to 1500 nm 2 ; a zeolite USY in an amount greater than the zeolite beta; an amorphous silica aluminate; a second support material; and enough liquid to form an extrudable paste;
b. extruding the extrudable paste to form an extrudate base;
c. impregnating the extrudate base with a metal impregnation solution containing at least one metal selected from the group consisting of elements from Group 6 and Group 8 through 10 of the Periodic Table to make a metal-loaded extrudate; and
d. post-treating the metal-loaded extrudate by subjecting the metal-loaded extrudate to drying and calcination; wherein the hydrocracking catalyst has improved selectivity for producing a hydrocracked effluent having a TBP of 380-700° F. (193-371° C.).

Assignees

• Zhang Yihua
• Maesen Theodorus Ludovicus Michael
• Hao Yalin
• Rea Thomas Michael
• Chevron Usa Inc

Inventors

• Zhang Yihua
• Maesen Theodorus Ludovicus Michael
• Hao Yalin
• Rea Thomas Michael

Classifications

• B01J37/0018

  Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat) · CPC title

• B01J29/7007

  Zeolite Beta · CPC title

• B01J37/0201

  Impregnation · CPC title

• B01J29/80 Primary

  Mixtures of different zeolites · CPC title

• B01J37/0207

  Pretreatment of the support · CPC title