Metal carbide based catalyst and method of making

Patent metadata

Field	Value
Publication number	US-12168223-B2
Application number	US-202017630786-A
Country	US
Kind code	B2
Filing date	Jul 28, 2020
Priority date	Aug 1, 2019
Publication date	Dec 17, 2024
Grant date	Dec 17, 2024

Abstract

A method for making a metal carbide based catalyst for crude oil cracking includes mixing a clay with a phosphorous based stabilizer material to obtain a liquid slurry; adding an aluminosilicate zeolite and an ultrastable Y zeolite to the liquid slurry; adding Al 2 Cl(OH) 5 to the liquid slurry; adding metal carbide particles, having a given diameter, to the liquid slurry to obtain a mixture; and spray drying the mixture to obtain the metal carbide based catalyst. The metal carbide particles are coated with the aluminosilicate zeolite and the ultrastable Y zeolite.

First claim

What is claimed is:

1. A method for making a metal carbide based catalyst for crude oil cracking, the method comprising:
mixing a clay with a phosphorous based stabilizer material to obtain a liquid slurry;
adding an aluminosilicate zeolite and an ultrastable Y zeolite to the liquid slurry;
adding Al 2 Cl(OH) 5 to the liquid slurry;
adding metal carbide particles, having a given diameter, to the liquid slurry to obtain a mixture; and
spray drying the mixture to obtain the metal carbide based catalyst,
wherein the metal carbide particles are coated with the aluminosilicate zeolite and the ultrastable Y zeolite.

2. The method of claim 1 , wherein the metal carbide is SiC.

3. The method of claim 1 , wherein the metal carbide is TiC.

4. The method of claim 1 , wherein the metal carbide is WC.

5. The method of claim 1 , further comprising:
adding zirconium oxide beads to the liquid slurry; and
ball milling the liquid slurry with the zirconium oxide beads.

6. The method of claim 5 , further comprising:
separating the zirconium oxide beads from the mixture before the step of spray drying.

7. The method of claim 1 , wherein the steps are performed one after another.

8. The method of claim 1 , wherein the aluminosilicate zeolite is a Zeolite Socony Mobil-5 catalyst.

9. The method of claim 1 , wherein the given diameter of the metal carbide particles is between 1 and 1000 nm.

10. The method of claim 1 , wherein the clay is Kaolin and the phosphorous based stabilized material is (NH 4 ) 2 HPO 4 and (NaPO 3 ) 6 .

11. A metal carbide based catalyst for crude oil cracking, the catalyst comprising:
Kaolin clay;
a phosphorous based stabilizer material;
an aluminosilicate zeolite material;
an ultrastable Y zeolite (USY) material; and
metal carbide particles having a given diameter,
wherein the metal carbide particles are coated with the aluminosilicate zeolite and the USY zeolite materials.

12. The catalyst of claim 11 , wherein the metal carbide is SiC.

13. The catalyst of claim 11 , wherein the metal carbide is TiC.

14. The catalyst of claim 11 , wherein the metal carbide is WC.

15. The catalyst of claim 11 , wherein the aluminosilicate zeolite material is a Zeolite Socony Mobil-5 catalyst.

16. A method for cracking crude with a metal carbide based catalyst, the method comprising:
placing a porous substrate inside a reactor;
placing the metal carbide based catalyst over the porous substrate;
passing the crude over the metal carbide based catalyst to crack the crude; and
collecting at an output of the reactor a cracked gas.

17. The method of claim 16 , wherein the metal carbide based catalyst includes:
Kaolin clay;
a phosphorous based stabilizer material;
an aluminosilicate zeolite material;
an ultrastable Y zeolite (USY) material; and
metal carbide particles having a given diameter,
wherein the metal carbide particles are coated with the aluminosilicate zeolite and the USY zeolite materials.

18. The method of claim 17 , wherein the metal carbide is SiC, or TiC or WC.

19. The method of claim 17 , wherein the aluminosilicate zeolite material is a Zeolite Socony Mobil-5 catalyst.

20. The method of claim 16 , wherein the reactor is a fixed bed reactor catalytic cracking system.

Assignees

• Univ King Abdullah Sci & Tech
• Saudi Arabian Oil Co

Inventors

• Gascon Jorge
• Shoinkhorova Tuiana B
• Dikhtiarenko Alla
• Alabdullah Mohammed
• Rodriguez Gomez Alberto
• Vittenet Jullian
• Osorio Isidoro Morales
• Ali Ola
• Xu Wei

Classifications

• B01J2235/00

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

• B01J2235/30

  Scanning electron microscopy; Transmission electron microscopy · CPC title

• B01J2235/15

  X-ray diffraction · CPC title

• B01J35/45

  Nanoparticles · CPC title

• C10G11/05

  Crystalline alumino-silicates, e.g. molecular sieves · CPC title