Modified ultra-stable Y (USY) zeolite catalyst for improving cold flow properties of distillates

1. A process for improving cold flow properties of distillates, the process comprising the step of contacting a hydrocarbon feedstock with a framework-substituted ultra-stable Y (USY)-type zeolite catalyst in which a portion of aluminum atoms constituting a zeolite framework thereof is substituted with zirconium atoms and/or titanium atoms and/or hafnium atoms, thereby producing a dewaxed distillate product having improved cold flow properties,

wherein the hydrocarbon feedstock has a boiling point range of 150° C. to 350° C.

2. The process of claim 1 , wherein the dewaxed distillate product has a cold flow property that is less than a corresponding cold flow property of the hydrocarbon feedstock, the cold flow property comprising one or more of a cloud point, a pour point, and a cold filter plugging point.

3. The process of claim 2 , wherein the cold flow property of the dewaxed distillate product is at least about 5° C. less than a corresponding cold flow property of the hydrocarbon feedstock.

4. The process according to claim 2 , wherein the cold flow property of the dewaxed distillate product comprises cloud point and is at least about 5° C. less than a corresponding cold point of the hydrocarbon feedstock.

5. The process according to claim 2 , wherein the cold flow property of the dewaxed distillate product comprises pour point and is at least about 5° C. less than a corresponding pour point of the hydrocarbon feedstock.

6. The process according to claim 2 , wherein the cold flow property of the dewaxed distillate product comprises filter plugging point and is at least about 5° C. less than a corresponding filter plugging point of the hydrocarbon feedstock.

7. The process according to claim 1 , wherein the framework-substituted USY-type zeolite catalyst comprises from about 0.1 to about 5% by mass zirconium and/or titanium atoms and/or hafnium atoms, calculated as the oxide basis.

8. The process according to claim 1 , wherein the framework-substituted USY-type zeolite in the catalyst further includes a support comprising inorganic oxides selected from the group consisting of alumina, silica-alumina and combinations thereof.

9. The process according to claim 1 , wherein the hydrocarbon feedstock and the framework-substituted USY-type zeolite catalyst are contacted in at least one dewaxing stage, which is operated at reaction temperature range of about 300° C. to about 420° C., a pressure of about 20 to about 90 Kg/cm2 and a liquid hourly space velocity (LHSV) of about 0.5 to about 5 h-1 and a hydrogen to hydrocarbon ratio of about 100 SLt/Lt to about 500 SLt/Lt.

10. The process according to claim 1 , wherein the framework-substituted USY-type zeolite catalyst contains amorphous silica-alumina as a dewaxing component.

11. The process according to claim 1 , wherein the framework-substituted USY-type zeolite catalyst contains alumina as a binder.

12. The process according to claim 1 , wherein the dewaxed distillate product contains less than about 500 ppm sulfur.

13. The process according to claim 1 , wherein the dewaxed distillate product contains less than about 100 ppm nitrogen.

14. The process according to claim 1 , wherein the dewaxed distillate product comprises a diesel fuel.

15. A process for making a diesel fuel product, comprising the steps of:

contacting a hydrocarbon feedstock with a hydrotreating catalyst under effective hydrotreating conditions in a hydrotreatment reactor to produce a hydrotreated effluent, wherein the hydrocarbon feedstock has a boiling point range of 150° C. to 350° C.;

separating the hydrotreated effluent into at least a hydrotreated liquid product and a gas-phase product, the hydrotreated liquid product having a cloud point;

mixing the hydrotreated liquid product with a hydrogen-containing stream and at least a portion of the gas-phase product to produce a hydrotreated dewaxing input stream; and

contacting the hydrotreated dewaxing input stream with a dewaxing catalyst under effective catalytic dewaxing conditions in a dewaxing reactor to form a dewaxed effluent that includes a dewaxed distillate product, the dewaxed effluent having a cold flow property that is at least about 5° C. less than a corresponding cold flow property of the feedstock, the cold flow property comprising one or more of a cloud point, a pour point, and a cold filter plugging point;

wherein the dewaxing catalyst comprises a framework-substituted ultra-stable Y (USY)-type zeolite in which a portion of aluminum atoms constituting a zeolite framework thereof is substituted with zirconium atoms and/or titanium atoms and/or hafnium.

16. The process of claim 15 , wherein the hydrotreating catalyst is free of any zeolite.

17. The process of claim 15 , wherein the framework-substituted USY-type comprises from about 0.1 to about 5% by mass zirconium and/or titanium atoms and/or hafnium atoms, each calculated as the oxide basis.

18. The process according to claim 15 , wherein the framework-substituted USY-type zeolite in the catalyst further includes a support comprising inorganic oxides selected from the group consisting of alumina, silica-alumina and combinations thereof.

19. The process according to claim 15 , wherein the effective catalytic dewaxing conditions comprise a reaction temperature range of about 300° C. to about 420° C., a pressure of about 20 to about 90 Kg/cm2 bars and a liquid hourly space velocity (LHSV) of about 0.5 to about 5 h-1 and a hydrogen to hydrocarbon ratio of about 100 SLt/Lt to about 500 SLt/Lt.

20. The process according to claim 15 , wherein the cold flow property of the dewaxed effluent is at least about 10° C. less than the corresponding cold flow property of the feedstock.

21. The process according to claim 15 , wherein the cold flow property of the dewaxed effluent is at least about 20° C. less than the corresponding cold flow property of the feedstock.

22. The process according to claim 15 , wherein the cold flow property of the dewaxed effluent is at least about 30° C. less than the corresponding cold flow property of the feedstock.