Hierarchical zeolite Y and nano-sized zeolite beta composite

Patent metadata

Field	Value
Publication number	US-11148124-B2
Application number	US-201916703461-A
Country	US
Kind code	B2
Filing date	Dec 4, 2019
Priority date	Dec 4, 2019
Publication date	Oct 19, 2021
Grant date	Oct 19, 2021

Abstract

A method is provided for forming composite of nano-sized zeolite beta and hierarchical zeolite Y. The method includes synthesizing a hierarchical zeolite Y, synthesizing a gel of a nano-sized zeolite beta, forming a slurry of the nano-sized zeolite beta from the gel, and mixing the hierarchical zeolite Y with the slurry to form a composite. The composite is dried and an extrudable paste is formed from the dried composite. The extrudable paste is extruded to form extrudates, which are calcined to form calcined extrudates.

First claim

What is claimed is:

1. A method for directly hydroprocessing a crude oil to form petrochemicals, comprising:
flowing a feedstock comprising at least a portion of the crude oil into a hydroprocessing unit; and
hydroprocessing the feedstock using a catalyst comprising a composite of nano-sized zeolite beta and hierarchical zeolite Y to form a product stream, wherein the product stream is fed to a steam cracker.

2. The method of claim 1 , wherein the composite of nano-sized zeolite beta and hierarchical zeolite Y, is formed by method comprising:
synthesizing the hierarchical zeolite Y;
synthesizing a gel of nano-sized zeolite beta;
forming a slurry of the nano-sized zeolite beta;
mixing the hierarchical zeolite Y with the slurry to form a composite;
drying the composite to form a dried composite;
forming an extrudable paste from the dried composite;
extruding the extrudable paste to form extrudates; and
calcining the extrudates to form calcined extrudates.

3. The method of claim 2 , wherein forming the extrudable paste comprises incorporating molybdenum and nickel, and wherein treating the extrudable paste further comprises:
extruding the extrudable paste to form extrudates; and
calcining the extrudates to form calcined extrudates.

4. The method of claim 2 , wherein treatment of the extrudable paste comprises:
extruding the extrudable paste to form extrudates; and
calcining the extrudates to form calcined extrudates followed by impregnation of the calcined extrudates with nickel and tungsten.

5. The method of claim 1 , wherein the feedstock comprises greater than about 5% hydrocarbons with a boiling point of greater than about 540° C.; and the product stream comprises less than about 1% hydrocarbons with a boiling point of greater than about 540° C.

6. The method of claim 1 , wherein the catalyst comprises a composite of nano-sized zeolite beta and hierarchical zeolite Y, comprising:
particles of nano-sized zeolite beta of less than about 100 nm; and
particles of hierarchical zeolite Y of about 500 nm.

7. The method of claim 1 , comprising a ratio of the nano-sized zeolite beta to the hierarchical zeolite Y of about 20/80 by weight.

8. The method of claim 1 , comprising a ratio of the nano-sized zeolite beta to the hierarchical zeolite Y of about 40/60by weight.

9. The method of claim 1 , the catalyst comprising:
between about 14 weight percent and about 16 weight percent molybdenum oxide; and
about 4 weight percent and about 6 weight percent nickel oxide.

10. The method of claim 1 , wherein the composite is formed by:
synthesizing a hierarchical zeolite Y;
synthesizing a nano-sized zeolite beta gel;
forming a slurry of the nano-sized zeolite beta;
mixing the hierarchical zeolite Y with the slurry to form a composite;
drying the composite to form a dried composite;
forming an extrudable paste from the dried composite;
extruding the extrudable paste to form extrudates; and
calcining the extrudates to form calcined extrudates.

11. The method of claim 10 , wherein forming the extrudable paste comprises mixing the extrudable paste with molybdenum oxide and nickel nitrate.

12. The method of claim 10 , wherein the calcined extrudates are impregnated with tungsten and nickel.

Assignees

• Saudi Arabian Oil Co

Inventors

• Ding Lianhui
• Al-Nutaifi Ibrahim
• Al-Eid Manal

Classifications

• B01J2235/30

  Scanning electron microscopy; Transmission electron microscopy · CPC title

• B01J2235/15

  X-ray diffraction · CPC title

• B01J35/45

  Nanoparticles · CPC title

• B01J35/70

  characterised by their crystalline properties, e.g. semi-crystalline (catalysts comprising carbon B01J21/18; molecular sieves B01J29/00) · CPC title

• B01J2235/00

  Indexing scheme associated with group B01J35/00, related to the analysis techniques used to determine the catalysts form or properties · CPC title