New insights into parameters controlling the selectivity in hydrocracking reactions

Study on the Effect of Structure and Acidity of Hydrocracking Catalyst Support on the Selectivity of Middle Distillate

Hydrocracking has become the main technology for producing diesel fuel in many refineries, the key process to meeting new product specifications as environmental regulations for transportation fuels become more stringent. The efficacy of the hydrocracking catalyst is a pivotal determinant of the reaction performance. This study leveraged high-throughput experimentation to closely examine the impact of support properties on both the catalytic activity and the selectivity of middle distillates. The findings show that the catalyst's activity is mainly controlled by the amount of Brönsted acid sites and the presence of strong Lewis acid sites within the carrier. An inverse relationship was observed between middle distillate selectivity and catalyst activity, highlighting a trade-off between these two measures of performance. Furthermore, the hydrocracking performance index (HPI), serving as a composite measure of catalyst efficacy, revealed that an optimal pore size and strong Brönsted acidity are important for increasing the HPI value, thereby signifying enhanced catalytic performance. The experimental result matches the bimolecular hydrogen transfer reaction, which is essential in determining the hydrocracking performance index (HPI) value.

Molecular Views on Mechanisms of Brønsted Acid-Catalyzed Reactions in Zeolites

The Brønsted acidity of proton-exchanged zeolites has historically led to the most impactful applications of these materials in heterogeneous catalysis, mainly in the fields of transformations of hydrocarbons and oxygenates. Unravelling the mechanisms at the atomic scale of these transformations has been the object of tremendous efforts in the last decades. Such investigations have extended our fundamental knowledge about the respective roles of acidity and confinement in the catalytic properties of proton exchanged zeolites. The emerging concepts are of general relevance at the crossroad of heterogeneous catalysis and molecular chemistry. In the present review, emphasis is given to molecular views on the mechanism of generic transformations catalyzed by Brønsted acid sites of zeolites, combining the information gained from advanced kinetic analysis, in situ, and operando spectroscopies, and quantum chemistry calculations. After reviewing the current knowledge on the nature of the Brønsted acid sites themselves, and the key parameters in catalysis by zeolites, a focus is made on reactions undergone by alkenes, alkanes, aromatic molecules, alcohols, and polyhydroxy molecules. Elementary events of C-C, C-H, and C-O bond breaking and formation are at the core of these reactions. Outlooks are given to take up the future challenges in the field, aiming at getting ever more accurate views on these mechanisms, and as the ultimate goal, to provide rational tools for the design of improved zeolite-based Brønsted acid catalysts.

High-efficiency hydrocracking of phenanthrene into BTX aromatics over a Ni-modified lamellar-crystal HY zeolite

A new Ni-HY zeolite with lamellar-crystals was prepared as a catalyst for phenanthrene hydrocracking. It showed significantly improved reactivity and BTX (benzene, toluene and xylene) selectivity (up to 99.1% and 75.6%, respectively), depending on a reasonable synergistic effect between its excellent internal-diffusion and the high-efficiency concerted catalysis of surface metal-Ni active sites and acid sites. In particular, compared with a conventional Ni-HY with diamond-shaped crystals, its significantly shortened diffusion-reaction path of the micropore system in the lamellar crystals greatly enhanced the diffusion-reaction efficiency of large-molecule phenanthrene and polycyclic intermediates and remarkably improved the utilization of both pores and internal reactive sites, powerfully promoting phenanthrene into benzene series conversion. The much decreased diffusion-residence time of benzene-series products in shortened channels also effectively weakened the further cracking loss of the benzene-ring, leading to enhanced BTX selectivity. Moreover, this shorter-channel Ni-HY catalyst with a higher external surface area and mesoporous volume also exhibited greatly improved catalytic stability attributed to its stronger capabilities of accommodating coke and resisting coke-deposition. The phenanthrene conversion of >76.3% and the BTX yield of >46.3% were obtained during a 60 h on-stream reaction.

Control and Impact of Metal Loading Heterogeneities at the Nanoscale on the Performance of Pt/Zeolite Y Catalysts for Alkane Hydroconversion

The preparation of zeolite-based bifunctional catalysts with low noble metal loadings while maintaining optimal performance has been studied. We have deposited 0.03 to 1.0 wt % Pt on zeolite H-USY (Si/Al ∼ 30 at./at.) using either platinum(II) tetraammine nitrate (PTA, Pt(NH₃)₄(NO₃)₂) or hexachloroplatinic(IV) acid (CPA, H₂PtCl₆·6H₂O) and studied the nanoscale Pt loading heterogeneities and global hydroconversion performance of the resulting Pt/Y catalysts. Pt/Y samples prepared with PTA and a global Pt loading as low as 0.3 wt % Pt (n_Pt/n_A = 0.08 mol/mol, where n_Pt is the number of Pt surface sites and n_A is the number of acid sites) maintained catalytic performance during n-heptane (T = 210–350 °C, P = 10 bar) as well as n-hexadecane (T = 170–280 °C, P = 5 bar) hydroisomerization similar to a 1.0 wt % Pt sample. For Pt/Y catalysts prepared with CPA, a loading of 0.3 wt % Pt (n_Pt/n_A = 0.08 mol/mol) sufficed for n-heptane hydroisomerization, whereas a detrimental effect on n-hexadecane hydroisomerization was observed, in particular undesired secondary cracking occurred to a significant extent. The differences between PTA and CPA are explained by differences in Pt loading per zeolite Y crystal (size ∼ 500 nm), shown from extensive transmission electron microscopy energy-dispersive X-ray spectroscopy experiments, whereby crystal-based n_Pt/n_A ratios could be determined. From earlier studies, it is known that the Al content per crystal of USY varied tremendously and that PTA preferentially is deposited on crystals with higher Al content due to ion-exchange with zeolite protons. Here, we show that this preferential deposition of PTA on Al-rich crystals led to a more constant value of n_Pt/n_A ratio from one zeolite crystal to another, which was beneficial for catalytic performance. Use of CPA led to a large variation of Pt loading independent of Al content, giving rise to larger variations of n_Pt/n_A ratio from crystal to crystal that negatively affected the catalytic performance. This study thus shows the impact of local metal loading variations at the zeolite crystal scale (nanoscale) caused by different interactions of metal precursors with the zeolite, which are essential to design and synthesize optimal catalysts, in particular at low noble metal loadings.

Shape selectivity effects in the hydroconversion of perhydrophenanthrene over bifunctional catalysts

The zeolite pore structure dictates the formation of isomers, which in turn influences the preferred ring opening products and the distribution of cracking products.

Hydrocracking of Fischer-Tropsch Paraffin Mixtures over Strong Acid Bifunctional Catalysts to Engine Fuels

Biomass-based Fischer-Tropsch paraffin mixtures, having C16-C46 and C11-C45 carbon number range, were hydrocracked over platinum-supported beta, ZSM-5, and mordenite catalysts. The aim of the study was to investigate the effects of the feedstock composition, the process parameters, and the catalyst properties (acidity and zeolite structure) on the C21+ conversions, the product yields, and the isoparaffin contents. It was stated that lower C21+ conversions and higher JET and diesel fuel yields can be obtained for feedstock comprising C11-C45 hydrocarbons. Under identical reaction conditions, the activity order of the catalysts was Pt/H-beta > Pt/H-ZSM-5 > Pt/H-mordenite. This order corresponds to the relative number of accessible acid sites. Among the tested catalysts, platinum-supported beta zeolite showed the highest hydroisomerization activity; meanwhile, in the pores of Pt/ZSM-5 and Pt/H-mordenite, diffusion constraints were observed. As the product of hydrocracking valuable gasoline, JET and diesel fuels having high hydrogen content and excellent burning properties were produced.

Hydrocracking of Light Diesel Oil over Catalysts with Industrially Modified Y Zeolites

Three industrially modified Y zeolites with a hierarchical structure were characterized by XRD, N2 adsorption–desorption, SEM, TEM, 27Al-/29Si-NMR, in situ pyridine-FTIR, and NH3-TPD techniques. The industrial hydrocracking catalyst of light diesel oil was prepared by kneading and extruding the mixture of 10 wt.% industrially modified zeolite, commercial alumina, nickel nitrate, and molybdenum oxide. The small amount of hierarchical Y zeolite in the hydrocracking catalyst plays a key role, resulting in selective hydrogenation of naphthalene and further ring-opening activity. The mesoporous structure of the zeolites provided an effective interface and improved the accessibility of acid sites to bulky reactants.

Bridging the gap between academic and industrial hydrocracking: on catalyst and operating conditions' effects

This work aims at bridging the knowledge gap between the well-studied Pt/zeolite catalysts and the industrially-employed NiMoS/(Al₂O₃ + zeolite) ones.

Citric Acid-Treated Zeolite Y (CY)/Zeolite Beta Composites as Supports for Vacuum Gas Oil Hydrocracking Catalysts: High Yield Production of Highly-Aromatic Heavy Naphtha and Low-BMCI Value Tail Oil

Citric acid-treated zeolite Y (CY) and zeolite beta were mechanically mixed to obtain composite zeolites (CY-Beta) with various zeolite beta contents. The composite zeolites were used as the acid components of hydrocracking catalyst supports. The physical and chemical properties of the supports and catalysts were analyzed by N₂ adsorption-desorption, XRD, SEM, and NH₃-TPD. The mechanical mixing of CY and zeolite beta does not destroy the textual properties of the original zeolites. However, the acidity of the composite zeolite does not fit the linearly calculated value of the two zeolites because some of the acid sites are covered or reacted with other acid sites during the mixing process. In addition, weak acid sites favor the high yield of tail oil with low BMCI value. Compared with the CY-based and beta-based catalysts, the conversion and light oil yield of the CY-Beta-based catalyst was increased. The conversion, light oil yield, and petrochemical yield of the Ni-W/20CY-Beta(20)/ASA catalyst are 78.15, 65.0, and 83.7%, respectively. The BMCI value of the tail oil is 4.7, and the aromatic potential content (APC) of heavy naphtha (boiling point 65–177°C) is 42%. The 1,500 h pilot plant test of Ni-W/20CY-Beta(20)/ASA at 350°C, 7.0 MPa, 2.0 h⁻¹ LHSV, and 800 H₂/oil (v/v) shows that the activity remains stable during the 1,500 h evaluation. The heavy naphtha (APC about 41.0) yield of 41.2 illustrates that the catalyst has the ability to aromatize and cyclize the light fractions. The yield of diesel is about 25% with a cetane index (CI) of 59.2; the frozen point is lower than −45°C, and the cold filter plugging point is −35°C, demonstrating the isomerization performance for middle distillations. The yield of tail oil is 14.9% with a BMCI of 4.4, showing the high hydrogenation performance of the catalyst to transform the un-cracked tail oil to saturated hydrocarbon in order to reduce the BMCI value.

Interplay of the adsorption of light and heavy paraffins in hydroisomerization over H-beta zeolite

Hydroisomerization: controlling selectivity by tuning the Pt/zeolite properties.

Density functional theory simulations of complex catalytic materials in reactive environments: beyond the ideal surface at low coverage

Advanced DFT models of complex catalysts, such as amorphous silica–alumina and supported subnanometric platinum particles, bridge the gap between the ideal surface model and the industrial catalyst.

Preparation of Mesoporous Silica-Supported Palladium Catalysts for Biofuel Upgrade

We report the preparation of two hydrocracking catalysts Pd/CoMoO4/silica and Pd/CNTs/CoMoO4/silica (CNTs, carbon nanotubes). The structure, morphologies, composition, and thermal stability of catalysts were studied by X-ray diffraction (XRD), scanning electron microscopy (SEM), Raman spectroscopy, transmission electron microscopy (TEM), energy-dispersive X-ray (EDX), and thermogravimetric analysis (TGA). The catalyst activity was measured in a Parr reactor with camelina fatty acid methyl esters (FAMEs) as the feed. The analysis shows that the palladium nanoparticles have been incorporated onto mesoporous silica in Pd/CoMoO4/silica or on the CNTs surface in Pd/CNTs/CoMoO4/silica catalysts. The different combinations of metals and supports have selective control cracking on heavy hydrocarbons.

Synthesis and characterization of activated carbon from sawdust of Algarroba wood. 1. Physical activation and pyrolysis

Synthesis of activated carbon (AC) from sawdust of Algarroba wood was performed as a function of the temperature under CO(2) and N(2) flow. Characterization was performed by adsorption-desorption N(2) isotherms, FTIR, XPS and SEM. Functional acid or basic groups were detected on the surface of AC. For both studied atmospheres, the maximum value of surface area was obtained at 800°C. A monotonic correlation between temperature and mean pore diameter was detected being the higher the activation temperature the lower the mean pore width of AC. Ultramicroporous AC with pore diameters of 6.7 Å and 5.3 Å were obtained at 900°C under CO(2) and N(2) flow, respectively. It can be concluded that pore diameter and the functionalization of the AC surface can be controlled easily controlling the temperature of activation, independently of the gas atmosphere. The present results suggest that waste biomass is a potential source for the synthesis of carbon materials with potential novel applications.