Noble metal zeolite catalyst for second-stage hydrocracking to make middle distillate

Patent metadata

Field	Value
Publication number	US-10183286-B2
Application number	US-201514823839-A
Country	US
Kind code	B2
Filing date	Aug 11, 2015
Priority date	Aug 11, 2015
Publication date	Jan 22, 2019
Grant date	Jan 22, 2019

Abstract

A second-stage hydrocracking catalyst is provided, comprising: a) a zeolite beta having an OD acidity of 20 to 400 μmol/g and an average domain size from 800 to 1500 nm2; b) a zeolite USY having an ASDI between 0.05 and 0.12; c) a catalyst support; and d) 0.1 to 10 wt % noble metal; wherein the second-stage hydrocracking catalyst provides a hydrogen consumption less than 350 SCFB across a range of synthetic conversions up to 37 wt % when used to hydrocrack hydrocarbonaceous feeds having an initial boiling point greater than 380° F. (193° C.). A second-stage hydrocracking process using the second-stage hydrocracking process is provided. A method to make the second-stage hydrocracking catalyst is also provided.

First claim

It is claimed:

1. A second-stage hydrocracking catalyst, comprising:
a. a zeolite beta having an OD acidity of 20 to 400 μmol/g and an average domain size from 800 to 1500 nm 2 ;
b. a zeolite USY having an ASDI between 0.05 and 0.12;
c. a catalyst support; and
d. 0.1 to 10 wt % noble metal;
wherein the second-stage hydrocracking catalyst provides a hydrogen consumption less than 350 SCFB across a range of synthetic conversions up to 37 wt % when used to hydrocrack hydrocarbonaceous feeds having an initial boiling point greater than 380° F. (193° C.).

2. The second-stage hydrocracking catalyst of claim 1 ; wherein a wt % of the zeolite beta is greater than the wt % of the zeolite USY.

3. The second-stage hydrocracking catalyst of claim 1 , wherein the OD acidity is from 30 to 100 μmol/g.

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

5. The second-stage hydrocracking catalyst of claim 1 , wherein the zeolite USY has a total Brönsted acid sites determined by FTIR after H/D exchange of 0.080 to 0.200 mmol/g.

6. The second-stage hydrocracking catalyst of claim 1 , wherein the second-stage hydrocracking catalyst has the hydrogen consumption between 250 and 350 SCFB over the range of synthetic conversion <625° F. (329° C.) from 23 to 37 wt %.

7. The second-stage hydrocracking catalyst of claim 1 ; wherein the second-stage hydrocracking catalyst has a compacted bulk density from 420 to 620 g/l.

8. The second-stage hydrocracking catalyst of claim 1 , wherein the second-stage hydrocracking catalyst has a LOI (1000° F. [538° C.]) less than 12 wt %.

9. The second-stage hydrocracking catalyst of claim 1 , wherein the noble metal comprises platinum, palladium, or mixture thereof.

10. A method for making the second-stage hydrocracking catalyst of claim 1 , the method comprising:
a. mixing together a zeolite beta having an OD acidity of 20 to 400 μmol/g and an average domain size from 800 to 1500 nm 2 , a zeolite USY having an ASDI between 0.05 and 0.12, a catalyst support, 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 noble metal to make a metal-loaded extrudate; and
d. post-treating the metal-loaded extrudate by subjecting the metal-loaded extrudate to drying and calcination.

11. The method of claim 10 , wherein a wt % of the zeolite beta is greater than the wt % of the zeolite USY in the second-stage hydrocracking catalyst.

Assignees

• Jia Jifei
• Rainis Andrew
• Maesen Theodorus Luvidocus Michael
• Coser Richard Joseph
• Zhang Yihua
• Rea Thomas Michael
• Chevron Usa Inc

Inventors

• Jia Jifei
• Rainis Andrew
• Maesen Theodorus Luvidocus Michael
• Coser Richard Joseph
• Zhang Yihua
• 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

• B01J2229/42

  Addition of matrix or binder particles · CPC title

• B01J37/0207

  Pretreatment of the support · CPC title

• B01J37/0236

  Drying, e.g. preparing a suspension, adding a soluble salt and drying · CPC title

• C10G47/18

  the catalyst containing platinum group metals or compounds thereof · CPC title