IP Library › Granted Patent US 12,409,445
Granted Patent B2
US 12,409,445 · App. 18/151,892 · Granted Sep 9, 2025

Hierarchically ordered crystalline microporous materials with long-range mesoporous order having cubic symmetry

Inventors: Rajesh Kumar Parsapur (Thuwal, SA); Robert Peter Hodgkins (Dhahran, SA); Omer Refa Koseoglu (Dhahran, SA); Kuo-Wei Huang (Thuwal, SA); Anissa Bendjeriou Sedjerari (Thuwal, SA)
Assignees: Saudi Arabian Oil Company; King Abdullah University of Science and Technology
B01J29/084B01J21/04B01J23/881C01B39/026C01B39/24C10G47/20C01P2002/72C01P2002/76C01P2002/77C01P2002/88C01P2004/04C10G2300/1074
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Quick Facts
Patent No.
US 12,409,445
App. No.
18/151,892
Granted
Sep 9, 2025
Kind
B2
Abstract

A composition of matter is provided comprising hierarchically ordered crystalline microporous material having well-defined long-range mesoporous ordering of cubic symmetry. The composition possesses mesopores having walls of crystalline microporous material and a mass of mesostructure between mesopores of crystalline microporous material. Long-range ordering is defined by presence of secondary peaks in an X-ray diffraction (XRD) pattern and/or cubic symmetry observable by microscopy.

Claims (26)

1. A composition of matter comprising hierarchically ordered crystalline microporous material having well-defined long-range mesoporous ordering of cubic symmetry comprising mesopores having walls of crystalline microporous material and a mass of mesostructure between mesopores of crystalline microporous material, wherein at least a portion of the mesopores contain micelles of supramolecular templates shaped to induce mesoporous ordering of cubic symmetry, and wherein the supramolecular templates possess one or more dimensions larger than dimensions of micropores of the crystalline microporous material to constrain diffusion into micropores of the crystalline microporous material, wherein the dimensions relate to a head group of a supramolecular template that constrains diffusion into micropores of the crystalline microporous material,

wherein the supramolecular template is characterized by a surfactant packing parameter g in the range of about 0.4-0.8, wherein

g=V/a 0 l

wherein

V=total volume of surfactant tails of the supramolecular template,

a 0 =area of the head group of the supramolecular template, and

l=length of surfactant tail of the supramolecular template.

2. The composition of matter as in claim 1 , further comprising an ionic co-solute.

3. The composition of matter as in claim 2 , wherein the ionic co-solute comprises NO 3 − .

4. The composition of matter as in claim 3 , wherein a molar ratio of supramolecular template to co-solute is in the range of about 0.8-1.3.

5. The composition of matter as in claim 2 , wherein a molar ratio of supramolecular template to co-solute is in the range of about 0.8-1.3.

6. The composition of matter as in claim 1 , wherein the mesoporous ordering possess Ia-3d, Fm-3m, Pm-3n, Pn-3m or Im-3m symmetry.

7. The composition of matter as in claim 1 , wherein the mesoporous ordering possess Ia-3d symmetry and secondary peaks in XRD are present at one or more of (220), (321), (400), (420) or (332) reflections.

8. The composition of matter as in any claim 1 , wherein the mesoporous ordering possess Ia-3d symmetry and long-range ordering is observable by microscopy viewing an electron beam down a [311], [111] or [110] zone axis.

9. The composition of matter as in claim 1 , wherein the mesoporous ordering possess Fm-3m symmetry and long-range ordering is observable by microscopy viewing an electron beam down a [001] or [110] zone axis.

10. The composition of matter as in claim 1 , wherein said crystalline microporous material comprises a zeolite or zeolite-type material.

11. A hydrocracking catalyst comprising the hierarchically ordered crystalline microporous material as in claim 10 , an inorganic oxide component as a binder, and an active metal component.

12. The hydrocracking catalyst as in claim 11 , wherein the hierarchically ordered crystalline microporous material comprises about 0.1-99, 0.1-90, 0.1-80, 0.1-70, 0.1-50, 0.1-40, 2-99, 2-90, 2-80, 2-70, 2-50, 2-40, 20-100, 20-90, 20-80, 20-70, 20-50, or 20-40 wt % of the hydrocracking catalyst.

13. The hydrocracking catalyst as in claim 11 , wherein the inorganic oxide component is selected from the group consisting of alumina, silica, titania, silica-alumina, alumina-titania, alumina-zirconia, alumina-boria, phosphorus-alumina, silica-alumina-boria, phosphorus-alumina-boria, phosphorus-alumina-silica, silica-alumina-titania, silica-alumina-zirconia, alumina-zirconia-titania, phosphorous-alumina-zirconia, alumina-zirconia-titania and phosphorus-alumina-titania.

14. The hydrocracking catalyst as in claim 11 , wherein the inorganic oxide component comprises alumina.

15. The hydrocracking catalyst as in claim 14 , wherein the crystalline microporous material comprises FAU zeolite and wherein the active metal component comprises one or more of Mo, W, Co or Ni (oxides or sulfides).

16. The hydrocracking catalyst as in claim 11 , wherein the active metal component comprises one or more metals selected from the Periodic Table of the Elements IUPAC Groups 6, 7, 8, 9 or 10.

17. A method for hydrocracking hydrocarbon oil, comprising: hydrocracking hydrocarbon oil with a hydrocracking catalyst as in claim 11 .

18. The method as in claim 17 , wherein the hydrocarbon oil comprises a recycle stream obtained from hydrocracking of VGO, straight run VGO or pre-treated straight run VGO, with selectivity to naphtha and middle distillates tailored as a function of the cubic symmetry mesophase.

19. The composition of matter as in claim 1 , wherein said crystalline microporous material is a zeolite having a framework selected from the group consisting of AEI, *BEA, CHA, FAU, MFI, MOR, LTL, LTA and MWW.

20. The composition of matter as in claim 1 , wherein said crystalline microporous material is a zeolite having FAU framework.

Assignments (2)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jan 9, 2023
From: HODGKINS, ROBERT PETER; KOSEOGLU, OMER REFA
To: SAUDI ARABIAN OIL COMPANY
Reel/Frame 062315/0839 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jan 9, 2023
From: PARSAPUR, RAJESH KUMAR; HUANG, KUO-WEI; SEDJERARI, ANISSA BENDJERIOU
To: KING ABDULLAH UNIVERSITY OF SCIENCE AND TECHNOLOGY
Reel/Frame 062316/0050 →
Continuity (2)
Continuation In Part 17857447 · Jul 5, 2022
Related Publication 20240009656A1 · Jan 11, 2024
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