PROCESS FOR PREPARING HYDROCRACKING CATALYST

• US 20190321809A1
• Filed: 08/01/2017
• Published: 10/24/2019
• Est. Priority Date: 08/02/2016
• Status: Active Grant

• Current Assignee: SABIC Global Technologies BV (Government of Saudi Arabia)
• Original Assignee: SABIC Global Technologies BV (Government of Saudi Arabia)
• Inventors: Ghosh, Ashim Kumar, Khanmamedova, Alla
• Granted Patent: US 10,710,058 B2
• Time in Patent Office: Days
• CPC Class Codes: B01J 2229/186 not in framework positions
• CPC Class Codes: B01J 2229/20 to introduce other elements in the catalyst composition comprising the molecular sieve, but not specially in or on the molecular sieve itself
• CPC Class Codes: B01J 2229/42 Addition of matrix or binder particles
• CPC Class Codes: B01J 29/068 Noble metals
• CPC Class Codes: B01J 29/123 X-type faujasite
• CPC Class Codes: B01J 29/126 Y-type faujasite
• CPC Class Codes: B01J 29/22 Noble metals
• CPC Class Codes: B01J 29/44 Noble metals
• CPC Class Codes: B01J 29/67 Noble metals
• CPC Class Codes: B01J 29/74 Noble metals
• CPC Class Codes: B01J 35/23 in a colloidal state
• CPC Class Codes: B01J 35/30 characterised by their physical properties
• CPC Class Codes: B01J 35/393 Metal or metal oxide crystallite size
• CPC Class Codes: B01J 35/50 characterised by their shape or configuration
• CPC Class Codes: B01J 37/0009 Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
• CPC Class Codes: B01J 37/04 Mixing B01J37/0009, B01J37/0018 take precedence
• CPC Class Codes: B01J 37/08 Heat treatment B01J37/0009, B01J37/0018 take precedence
• CPC Class Codes: C07C 15/04 Benzene
• CPC Class Codes: C07C 2521/04 Alumina
• CPC Class Codes: C07C 2529/06 Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
• CPC Class Codes: C07C 2529/068 : Noble metals
• CPC Class Codes: C07C 2529/08 : of the faujasite type, e.g. type X or Y
• CPC Class Codes: C07C 2529/12 : Noble metals
• CPC Class Codes: C07C 2529/18 : of the mordenite type
• CPC Class Codes: C07C 2529/22 : Noble metals
• CPC Class Codes: C07C 2529/40 : of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11
• CPC Class Codes: C07C 2529/44 : Noble metals
• CPC Class Codes: C07C 2529/65 : of the ferrierite type, e.g. types ZSM-21, ZSM-35 or ZSM-38
• CPC Class Codes: C07C 2529/67 : Noble metals
• CPC Class Codes: C07C 2529/70 : of types characterised by their specific structure not provided for in groups C07C2529/08 - C07C2529/65
• CPC Class Codes: C07C 5/387 : of cyclic compounds containing non six-membered ring to compounds containing a six-membered aromatic ring
• CPC Class Codes: C07C 5/41 : Catalytic processes
• CPC Class Codes: C10G 2300/1044 : Heavy gasoline or naphtha having a boiling range of about 100 - 180 °C
• CPC Class Codes: C10G 2300/4006 : Temperature
• CPC Class Codes: C10G 2300/4018 : Spatial velocity, e.g. LHSV, WHSV
• CPC Class Codes: C10G 2300/70 : Catalyst aspects
• CPC Class Codes: C10G 2400/30 : Aromatics
• CPC Class Codes: C10G 47/18 : the catalyst containing platinum group metals or compounds thereof
• CPC Class Codes: C10G 7/00 : Distillation of hydrocarbon oils
• CPC Class Codes: Y02P 20/52 : using catalysts, e.g. selective catalysts

Abstract

Disclosed herein is a process for preparing a hydrocracking catalyst, comprising (i) combining a zeolite, a binder, water and a hydrogenating metal compound which is a complex or a salt of a hydrogenating metal to obtain a mixture, wherein the zeolite has not been treated with a phosphorus-containing compound and the zeolite has a silica to alumina molar ratio of 5-200; (ii) forming the mixture into a shaped body; and (iii) calcining the shaped body to form the catalyst.

Claims

1. A process for preparing a hydrocracking catalyst, comprising:

(i) combining a zeolite, a binder, water and a hydrogenating metal compound which is a complex or a salt of a hydrogenating metal to obtain a mixture, wherein the zeolite has not been treated by a phosphorus-containing compound and the zeolite has a silica to alumina molar ratio of 5-200;

(ii) forming the mixture into a shaped body; and

(iii) calcining the shaped body at 250- to less than 300°

C., for 2-8 hours to form the catalyst.

2. The process according to claim 1, wherein the catalyst has an average hydrogenating metal particle size of less than or equal to 5 nm, as determined using TEM.

3. The process according to claim 1, wherein the mixture is can extrudable paste.

5. The process according to claim 1, wherein the shaped body is calcined at 250-295°

C.

6. The process according to claim 1, the preceding claims, wherein the catalyst comprises less than 0.01 parts tin, less than 0.02 parts lead, and less than 0.01 parts bismuth, on the basis of 100 parts by weight of the catalyst.

7. The process according to claim 1, wherein step (i) involves

combining the zeolite and the hydrogenating metal compound and subsequently adding the binder to the combination of the zeolite and the hydrogenating metal compound;

or

combining the hydrogenating metal compound and the binder and subsequently adding the zeolite to the combination of the binder and the hydrogenating metal compound.

8. The process according to claim 1, wherein the zeolite is selected from the group consisting of ZSM-5, MCM-22, ZSM-11, beta zeolite, EU-1 zeolite, faujasite (zeolite Y), ferrierite and mordenite.

9. The process according to claim 1, wherein the silica to alumina molar ratio is 25-75.

10. The process according to claim 1, wherein the zeolite is an H⁺-form or NH₄⁺-form.

11. The process according to claim 1, wherein the binder is selected from the group consisting of alumina, clay, silica-alumina, aluminum phosphate and combinations thereof.

12. The process according to claim 1, wherein the binder has been treated with a mineral acid such as nitric acid, hydrochloric acid, phosphoric acid or sulfuric acid.

13. The process according to claim 1, wherein the hydrogenating metal is at least one of palladium and platinum.

14. The process according to claim 1, wherein the hydrogenating metal compound is selected from the group consisting of H₂PtCl₆, (NH₃)₄Pt(NO₃)₂, (NH₃)₄Pt(OH)₂ and (NH₃)₄PtCl₂.

15. The process according to claim 1, wherein the amount of the hydrogenating metal is 0.010-0.30 wt %, with respect to the total catalyst.

16. The process according to claim 1, wherein the shaped body is an extrudate having an average diameter of 0.5-5 mm.

17. The process according to claim 1, wherein the only metal in the catalyst is the hydrogenating metal and binder, and wherein the hydrogenating metal is at least one element selected from Group 10 of the periodic table of elements, rhodium, and iridium.

18. The hydrocracking catalyst obtained by the process according to claim 1.

19. A process for hydrocracking a feed stream comprising hydrocarbons comprising:

contacting the feed stream in the presence of hydrogen with the hydrocracking catalyst according to claim 18 under process conditions including a temperature of 400-580°

C., a pressure of 300-5000 kPa gauge and a Weight Hourly Space Velocity of 0.1-30 hr<sup>−

1</sup> to produce a hydrocracking product stream comprising benzene, toluene and xylene, wherein the hydrocracking feed stream comprises C₅-C₁₂ hydrocarbons; and

separating the benzene, toluene, and xylene from the hydrocracking product stream.

21. The process according to claim 1, wherein the shaped body is calcined at 260-290°

C.

4. A process for preparing a hydrocracking catalyst, comprising:

(i) combining a zeolite, a binder, and a hydrogenating metal compound which is a complex or a salt of a hydrogenating metal, with water to form a paste, wherein the zeolite has not been treated by a phosphorus-containing compound;

(ii) forming the paste into a shaped body; and

(iii) calcining the shaped body at 250-295°

C. to form the catalyst;

wherein the catalyst has an average hydrogenating metal particle size of less than or equal to 5 nm, as determined using TEM.

20. (canceled)