Middle distillate hydrocracking catalyst containing zeolite beta with low OD acidity and large domain size
A hydrocracking catalyst is provided comprising: a. from 0.5 to 10 wt % zeolite beta having an OD acidity of 20 to 400 μmol/g and an average domain size from 800 to 1500 nm 2 ; b. from 0 to 5 wt % zeolite USY having an ASDI between 0.05 and 0.12; wherein a wt % of the zeolite beta is greater than the wt % of the zeolite USY; c. a catalyst support; and d. 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 the hydrocracking catalyst to produce middle distillates is provided. A method for making the hydrocracking catalyst is also provided.
1. A hydrocracking catalyst comprising:
a. from 0.5 to 10 wt % zeolite beta having an OD acidity of 20 to 400 μmol/g and an average domain size from 800 to 1500 nm 2 ;
b. from 0 to 5 wt % zeolite USY having an ASDI between 0.05 and 0.12; wherein a wt % of the zeolite beta is greater than the wt % of the zeolite USY;
c. a catalyst support; and
d. at least one metal selected from the group consisting of elements from Group 6 and Groups 8 through 10 of the Periodic Table.
2. The hydrocracking catalyst of claim 1 , wherein the zeolite beta has a SiO 2 /Al 2 O 3 mole ratio (SAR) from 50 to 200.
3. The hydrocracking catalyst of claim 1 , wherein the OD acidity is from 30 to 100 μmol/g.
4. The hydrocracking catalyst of claim 1 , wherein the average domain size is from 900 to 1250 nm 2 .
5. The hydrocracking catalyst of claim 1 , wherein the zeolite beta has more large domains that have a domain size from 1200 to 2000 nm 2 than small domains that have the domain size from 200 to 600 nm 2 .
6. The hydrocracking catalyst of claim 1 , wherein the zeolite beta has a standard deviation for domain sizes greater than 700 nm 2 .
7. The hydrocracking catalyst of claim 1 , wherein the wt % of the zeolite beta is from 1 to 5 wt % higher than the wt % of the zeolite USY.
8. The hydrocracking catalyst of claim 1 , wherein a weight ratio of the zeolite USY to the zeolite beta is 0 to 0.48.
9. The hydrocracking catalyst of claim 1 , wherein the zeolite USY has a total Brönsted acid sites determined by FTIR after H/D exchange of 0.080 to 0.200 mmol/g.
10. The hydrocracking catalyst of claim 1 , comprising at least one Group 6 metal and at least one metal selected from Groups 8 through 10 of the Periodic Table.
11. 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. from 0.5 to 10 wt % zeolite beta having an OD acidity of 20 to 400 μmol/g and an average domain size from 800 to 1500 nm 2 ;
b. from 0 to 5 wt % zeolite USY having an ASDI between 0.05 and 0.12; wherein the wt % of the zeolite beta is greater than the wt % of the zeolite USY;
c. a catalyst support; and
d. at least one metal selected from the group consisting of elements from Group 6 and Groups 8 through 10 of the Periodic Table.
12. The process of claim 11 , wherein the hydrocarbonaceous feedstock has a TBP range within 700 to 1200° F. (371 to 649° C.).
13. The process of claim 11 , wherein the zeolite beta has a SiO 2 /Al 2 O 3 mole ratio (SAR) from 50 to 200.
14. The process of claim 11 , wherein the OD acidity is from 30 to 100 μmol/g.
15. The process of claim 11 , wherein the average domain size is from 900 to 1250 nm 2 .
16. The process of claim 11 , wherein the zeolite beta has more large domains that have a domain size from 1200 to 2000 nm 2 than small domains that have the domain size from 200 to 600 nm 2 .
17. The process of claim 11 , wherein the zeolite beta has a standard deviation for domain sizes greater than 700 nm 2 .
18. The process of claim 11 , wherein the wt % of the zeolite beta is from 1 to 5 wt % higher than the wt % of the zeolite USY.
19. The process of claim 11 , wherein a weight ratio of the zeolite USY to the zeolite beta is 0 to 0.48.
20. The process of claim 11 , wherein the zeolite USY has a total Brönsted sites determined by FTIR after H/D exchange of 0.080 to 0.200 mmol/g.
21. The process of claim 11 , comprising at least one Group 6 metal and at least one metal selected from Groups 8 through 10 of the Periodic Table.
22. The process of claim 11 , wherein the hydrocracked effluent comprises from greater than 30 vol % to 50 vol % of a heavy middle distillate having a TBP of 380-700° F. (193-371° C.).
23. A method for making the hydrocracking catalyst of claim 1 , comprising:
a. mixing together a zeolite beta having an OD acidity of 20 to 400 μmol/g and an average domain size from 800 to 1500 nm 2 ; optionally, a zeolite USY having an ASDI between 0.05 and 0.12; a catalyst support; and enough liquid to form an extrudable paste; wherein a wt % of the zeolite beta is greater than a second wt % of the zeolite USY;
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; and
d. post-treating the metal-loaded extrudate by subjecting the metal-loaded extrudate to drying and calcination; wherein the hydrocracking catalyst has improved selectivity for producing a hydrocracked effluent having a TBP of 380-700° F. (193-371° C.).