Hierarchical zeolite Y and nano-sized zeolite beta composite
A method is provided for forming composite of nano-sized zeolite beta and hierarchical zeolite Y. The method includes synthesizing a hierarchical zeolite Y, synthesizing a gel of a nano-sized zeolite beta, forming a slurry of the nano-sized zeolite beta from the gel, and mixing the hierarchical zeolite Y with the slurry to form a composite. The composite is dried and an extrudable paste is formed from the dried composite. The extrudable paste is extruded to form extrudates, which are calcined to form calcined extrudates.
1. A method for directly hydroprocessing a crude oil to form petrochemicals, comprising:
flowing a feedstock comprising at least a portion of the crude oil into a hydroprocessing unit; and
hydroprocessing the feedstock using a catalyst comprising a composite of nano-sized zeolite beta and hierarchical zeolite Y to form a product stream, wherein the product stream is fed to a steam cracker.
2. The method of claim 1 , wherein the composite of nano-sized zeolite beta and hierarchical zeolite Y, is formed by method comprising:
synthesizing the hierarchical zeolite Y;
synthesizing a gel of nano-sized zeolite beta;
forming a slurry of the nano-sized zeolite beta;
mixing the hierarchical zeolite Y with the slurry to form a composite;
drying the composite to form a dried composite;
forming an extrudable paste from the dried composite;
extruding the extrudable paste to form extrudates; and
calcining the extrudates to form calcined extrudates.
3. The method of claim 2 , wherein forming the extrudable paste comprises incorporating molybdenum and nickel, and wherein treating the extrudable paste further comprises:
extruding the extrudable paste to form extrudates; and
calcining the extrudates to form calcined extrudates.
4. The method of claim 2 , wherein treatment of the extrudable paste comprises:
extruding the extrudable paste to form extrudates; and
calcining the extrudates to form calcined extrudates followed by impregnation of the calcined extrudates with nickel and tungsten.
5. The method of claim 1 , wherein the feedstock comprises greater than about 5% hydrocarbons with a boiling point of greater than about 540° C.; and the product stream comprises less than about 1% hydrocarbons with a boiling point of greater than about 540° C.
6. The method of claim 1 , wherein the catalyst comprises a composite of nano-sized zeolite beta and hierarchical zeolite Y, comprising:
particles of nano-sized zeolite beta of less than about 100 nm; and
particles of hierarchical zeolite Y of about 500 nm.
7. The method of claim 1 , comprising a ratio of the nano-sized zeolite beta to the hierarchical zeolite Y of about 20/80 by weight.
8. The method of claim 1 , comprising a ratio of the nano-sized zeolite beta to the hierarchical zeolite Y of about 40/60by weight.
9. The method of claim 1 , the catalyst comprising:
between about 14 weight percent and about 16 weight percent molybdenum oxide; and
about 4 weight percent and about 6 weight percent nickel oxide.
10. The method of claim 1 , wherein the composite is formed by:
synthesizing a hierarchical zeolite Y;
synthesizing a nano-sized zeolite beta gel;
forming a slurry of the nano-sized zeolite beta;
mixing the hierarchical zeolite Y with the slurry to form a composite;
drying the composite to form a dried composite;
forming an extrudable paste from the dried composite;
extruding the extrudable paste to form extrudates; and
calcining the extrudates to form calcined extrudates.
11. The method of claim 10 , wherein forming the extrudable paste comprises mixing the extrudable paste with molybdenum oxide and nickel nitrate.
12. The method of claim 10 , wherein the calcined extrudates are impregnated with tungsten and nickel.