Middle distillate hydrocracking catalyst containing zeolite usy with enhanced acid sites

Patent metadata

Field	Value
Publication number	US-2016296922-A1
Application number	US-201514683435-A
Country	US
Kind code	A1
Filing date	Apr 10, 2015
Priority date	Apr 10, 2015
Publication date	Oct 13, 2016
Grant date	—

Abstract

A hydrocracking catalyst is provided comprising: a) greater than 10 wt % of a zeolite USY having: i. a total OD acidity of 0.350 to 0.650 mmol/g; ii. an ASDI between 0.05 and 0.15; iii. a BET surface area greater than 600 m 2 /g; iv. a SAR greater than 10; v. less than 45 vol % of pores greater than 2 nm; b) a support; and c) 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 using a hydrocracking catalyst to produce middle distillates is provided. A method for making a hydrocracking catalyst is also provided.

First claim

It is claimed:

1 . A hydrocracking catalyst comprising:
a. greater than 10 wt % of a zeolite USY having:
i. a total OD acidity of 0.350 to 0.650 mmol/g;
ii. an ASDI between 0.05 and 0.15;
iii. a BET surface area greater than 600 m 2 /g;
iv. a SAR greater than 10;
v. less than 45 vol % of pores greater than 2 nm;
b. a support; and c. at least one metal selected from the group consisting of elements from Group 6 and Groups 8 through 10 of the Periodic Table; wherein the hydrocracking catalyst is conducive to making middle distillates.

2 . The hydrocracking catalyst of claim 1 , wherein the hydrocracking catalyst has at least 7° F. (4° C.) more activity than a comparable hydrocracking catalyst comprising a different zeolite USY with a lower total OD acidity of at most 0.34 mmol/g.

3 . The hydrocracking catalyst of claim 1 , wherein the hydrocracking catalyst has improved selectivity for producing a hydrocracked effluent having a TBP of 250-550° F. (121-288° C.) compared to a comparable hydrocracking catalyst comprising a different zeolite USY with a higher ASDI of 0.16 or greater.

4 . The hydrocracking catalyst of claim 1 , wherein the total OD acidity is from 0.450 to 0.600 mmol/g.

5 . The hydrocracking catalyst of claim 1 , wherein the zeolite USY has a unit cell size from 24.20 to 24.50 Å.

6 . The hydrocracking catalyst of claim 5 , wherein the unit cell size is from 24.39 to 24.49 Å.

7 . The hydrocracking catalyst of claim 1 , wherein an amount of the zeolite USY is from 11 wt % to 80 wt % in a finished hydrocracking catalyst.

8 . The hydrocracking catalyst of claim 1 , wherein the zeolite USY has a SAR from 5 to 29.

9 . The hydrocracking catalyst of claim 8 , wherein the SAR is from 11 to 15.

10 . The hydrocracking catalyst of claim 1 , wherein the zeolite USY has less than 45 vol % of pores greater than 2 nm.

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

12 . A process for hydrocracking a hydrocarbonaceous feedstock, comprising contacting the hydrocarbonaceous feedstock with a hydrocracking catalyst under hydrocracking conditions to produce a hydrocracked effluent that comprises middle distillates; wherein the hydrocracking catalyst comprises:
a. greater than 10 wt % of a zeolite USY having a total OD acidity of 0.350 to 0.650 mmol/g and an ASDI between 0.05 and 0.15; b. a support; and c. at least one metal selected from the group consisting of elements from Group 6 and Groups 8 through 10 of the Periodic Table.

13 . The process of claim 12 , wherein the hydrocracking catalyst is at least 7° F. more active than a comparable hydrocracking catalyst comprising a different zeolite USY with a lower total OD acidity of at most 0.34 mmol/g.

14 . The process of claim 12 , wherein the hydrocracking catalyst has improved selectivity for producing the hydrocracked effluent having a TBP of 250-550° F. (121-288° C.) compared to a comparable hydrocracking catalyst comprising a different zeolite USY with a higher ASDI of 0.16 or greater.

15 . The process of claim 12 , wherein the total OD acidity is from 0.450 to 0.600 mmol/g.

16 . The process of claim 12 , wherein the zeolite USY additionally has:
a. a BET surface area greater than 600 m 2 /g; b. a SAR greater than 10; and c. less than 45 vol % of pores greater than 2 nm.

17 . The process of claim 12 , wherein the zeolite USY has a unit cell size from 24.20 to 24.50 Å.

18 . The process of claim 12 , wherein an amount of the zeolite USY is from 11 wt % to 80 wt % in a finished hydrocracking catalyst used for the contacting.

19 . The process of claim 12 , wherein the zeolite USY has a SAR from 5 to 29.

20 . The process of claim 12 , wherein the hydrocracking catalyst comprises at least one Group 6 metal and at the at least one metal selected from Groups 8 through 10 of the Periodic Table.

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

22 . The process of claim 12 , wherein the hydrocracked effluent comprises from 20 vol % to 50 vol % of a middle distillate having a TBP of 250-550° F. (121-288° C.).

23 . A method for making a hydrocracking catalyst, comprising:
a. mixing together a zeolite USY having a total OD acidity of 0.350 to 0.650 mmol/g and an ASDI between 0.05 and 0.15; one or more support constituents; 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; d. post-treating the metal-loaded extrudate by subjecting the metal-loaded extrudate to drying and calcination; wherein the hydrocracking catalyst is conducive to making middle distillates and has an improved property compared to a comparable hydrocracking catalyst comprising a different zeolite USY with a lower total OD acidity of at most 0.34 mmol/g or a higher ASDI of 0.16 or greater; and wherein the improved property is selected from the group of:
i. a higher selectivity for producing a hydrocracked effluent having a TBP of 250-550° F. (121-288° C.),
ii. an activity that is 7° F. (4° C.) to 30° F. (17° C.) higher, and
iii. a combination thereof.

24 . The method of claim 23 , wherein the hydrocracking catalyst comprises greater than 10 wt % of the zeolite USY, and the zeolite USY additionally has:
a. a BET surface area greater than 600 m 2 /g; b. a SAR greater than 10; and c. less than 45 vol % of pores greater than 2 nm.

Assignees

• Zhang Yihua
• Maesen Theodorus Ludovicus Michael
• Rainis Andrew
• Le Bao Quoc
• Chevron Usa Inc

Inventors

• Zhang Yihua
• Maesen Theodorus Ludovicus Michael
• Rainis Andrew
• Le Bao Quoc

Classifications

• B01J35/80

  characterised by their amorphous structures · 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

• B01J35/77

  Compounds characterised by their crystallite size · CPC title

• B01J35/30

  characterised by their physical properties · CPC title