Fibrous zeolite catalyst for hydrocracking

Patent metadata

Field	Value
Publication number	US-10850262-B2
Application number	US-201716470432-A
Country	US
Kind code	B2
Filing date	Dec 19, 2017
Priority date	Dec 19, 2016
Publication date	Dec 1, 2020
Grant date	Dec 1, 2020

Abstract

A hydrocracking catalyst for petroleum hydrocracking is provided, the hydrocracking catalyst provided in a form of at least one fiber, and the at least one fiber comprising at least one zeolite and at least one metal oxide. Methods are also provided to form the hydrocracking catalyst in the form of at least one fiber, particularly electrospinning.

First claim

What is claimed is:

1. A hydrocracking catalyst for petroleum hydrocracking, comprising:
at least one fiber comprising zeolite nanoparticles and at least one metal oxide, wherein the fiber has a diameter in the range of 50-800 nm, 81-87% by weight of the at least one fiber is the zeolite nanoparticles and 2-10% by weight of the at least one fiber is the at least one metal oxide.

2. The catalyst of claim 1 , wherein:
the zeolite nanoparticles are Y-zeolite.

3. The catalyst of claim 2 , wherein:
the Y-zeolite has a SiO 2 /Al 2 O 3 mole ratio of at least 30 to 1.

4. The catalyst of claim 1 , wherein:
the at least one metal oxide is one of nickel oxide and tungsten trioxide.

5. The catalyst of claim 1 , wherein:
the at least one metal oxide further comprises at least a first metal oxide and second metal oxide.

6. The catalyst of claim 5 , wherein:
the first metal oxide is nickel oxide; and
the second metal oxide is tungsten trioxide.

7. The catalyst of claim 1 , wherein:
85-87% by weight of the at least one fiber is the zeolite nanoparticles.

8. A hydrocracking catalyst for petroleum hydrocracking, comprising:
the hydrocracking catalyst provided in a form of at least one fiber; and
the at least one fiber comprising at least one zeolite and at least one metal oxide, wherein:
the at least one fiber has a length in a range of 0.1-500 microns; and
the at least one fiber has a diameter in a range of 50-800 nanometers.

9. The catalyst of claim 1 , wherein:
the at least one fiber has a length-to-diameter aspect ratio in a range of 50:1 to 1,000:1.

10. The catalyst of claim 1 , wherein:
the hydrocracking catalyst is binder free.

11. The catalyst of claim 1 , wherein:
the at least one fiber comprises a plurality of fibers.

12. The catalyst of claim 11 , wherein:
the plurality of fibers form a fiber mat.

13. The catalyst of claim 1 , wherein the zeolite nanoparticles have a size in a range of 50-350 nm, and a percent crystallinity greater than 35%.

14. A method of making a hydrocracking catalyst for petroleum hydrocracking, comprising:
creating a mixture comprising zeolite nanoparticles, at east one metal oxide precursor, at least one polymer, ethanol and water;
obtaining a stable suspension of the mixture;
electrospinning the mixture to form a fiber having a diameter in the range of 50-800 nm; and
calcinating the at least one fiber to remove the at least one polymer from the at least one fiber and to form at least one metal oxide from the at least one metal oxide precursor;
whereby 81-87% by weight of the at least one fiber is the zeolite nanoparticles and 2-10% by weight of the at least one fiber is the at least one metal oxide.

15. The method of claim 14 , further comprising ball-milling zeolite microparticles to produce the zeolite nanoparticles.

16. The method of claim 14 , wherein the at least one metal oxide precursor comprises nickel acetate and ammonium metatungstate.

17. The method of claim 16 , wherein the at least one polymer is polyvinylpyrrolidone.

18. The method of claim 17 , wherein:
a weight ratio of the zeolite nanoparticles to the nickel acetate ranges from 1:0.1 to 1:0.15;
a weight ratio of the zeolite nanoparticles to the ammonium eta tungstate ranges from 1:1.5 to 1:1.8;
a weight ratio of the zeolite nanoparticles to the polyvinylpyrrolidone ranges from 1:0.7 to 1:1;
a weight ratio of the zeolite nanoparticles to the ethanol ranges from 1:5 to 1:5.2; and
a weight ratio of the zeolite nanoparticles to the water ratio range from 1:4 to 1:4.2.

19. The method of claim 14 , wherein the zeolite nanoparticles have a size in a range of 50-350 nm, and a percent crystallinity greater than 35%.

Assignees

• Univ Khalifa Science & Technology

Inventors

• Hashaikeh Raed
• Anis Shaheen
• Singaravel Gnana P

Classifications

• C04B2235/3463

  Alumino-silicates other than clay, e.g. mullite · CPC title

• C10G47/18

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

• C04B35/6263

  characterised by their solids loadings, i.e. the percentage of solids · CPC title

• C04B2235/526

  characterised by the length of the fibers · CPC title

• C10G47/16

  Crystalline alumino-silicate carriers · CPC title