Methods of producing catalyst compositions, and methods of cracking hydrocarbon feed streams using such catalyst compositions
This disclosure generally relates to methods for producing catalyst compositions, which may include forming a precursor solution comprising a silicon-containing material, an aluminum-containing material, and a quaternary amine, hydrothermally treating the precursor solution at a first temperature to form an intermediate mixture, hydrothermally treating the intermediate mixture at a second temperature to form beta zeolite, wherein the first temperature is less than the second temperature by at least 200° C., forming an extrudable mixture comprising the beta zeolite, alumina, a metal precursor, and a binder, extruding the extrudable mixture to form extrudates, and calcining the extrudates to form the catalyst composition.
1. A method for producing a catalyst composition, the method comprising:
forming a precursor solution comprising a silicon-containing material, an aluminum-containing material, and a quaternary amine;
hydrothermally treating the precursor solution at a first temperature to form an intermediate mixture;
hydrothermally treating the intermediate mixture at a second temperature to form beta zeolite, wherein the first temperature is less than the second temperature by at least 200° C.;
forming an extrudable mixture comprising the beta zeolite, alumina, a metal precursor, and a binder;
extruding the extrudable mixture to form extrudates; and
calcining the extrudates to form the catalyst composition.
2. The method of claim 1 , wherein the beta zeolite is not calcined before extruding the extrudable mixture.
3. The method of claim 1 , wherein the intermediate mixture is not dried before forming the beta zeolite.
4. The method of claim 1 , wherein the silicon-containing material comprises SiO 2 , sodium silicate, tetramethylsiloxane, tetraethylsiloxane, silicon salt, silicon alkoxide, fumed silica, or combinations thereof.
5. The method of claim 1 , wherein the aluminum-containing material comprises aluminum nitrate, aluminum sulfate, aluminum alkoxide, other aluminum salts, or combinations thereof.
6. The method of claim 1 , wherein the quaternary amine comprises tetraethylammonium hydroxide, tetraethylammonium bromide, or combinations thereof.
7. The method of claim 1 , wherein the first temperature is of from 100° C. to 150° C.
8. The method of claim 1 , wherein the second temperature is of from 500° C. to 650° C.
9. The method of claim 1 , further comprising cooling the intermediate mixture before hydrothermally treating the intermediate mixture.
10. The method of claim 1 , further comprising washing the intermediate mixture before hydrothermally treating the zeolite intermediate.
11. The method of claim 1 , wherein the metal precursor comprises molybdenum, nickel, tungsten, or combinations of two or more thereof.
12. The method of claim 1 , wherein the extrudable mixture further comprises a zeolite Y.
13. The method of claim 1 , wherein the beta zeolite has a surface area of greater than or equal to 400 cm 2 /g.
14. The method of claim 1 , wherein one or more of:
the beta zeolite has a mesopore volume of greater than 0.5 mL/g;
the beta zeolite has a micropore volume of greater than 0.1 mL/g;
the beta zeolite has an average pore size of greater than 3 nanometers;
the beta zeolite has a crystallinity of at least 70% as measured using x-ray diffraction;
the catalyst composition has a surface area of greater than or equal to 250 cm 2 /g;
the catalyst composition has a mesopore volume of greater than 0.4 mL/g; or
the catalyst composition has an average pore size of greater than 3 nanometers.
15. A method of cracking a hydrocarbon feed stream comprising contacting the hydrocarbon feed stream with the catalyst composition of claim 1 to crack at least a portion of the hydrocarbon feed stream to form a product effluent.
16. The method of claim 15 , wherein the hydrocarbon feed stream is crude oil.
17. The method of claim 15 , wherein the hydrocarbon feed stream is hydrotreated before the contacting.
18. The method of claim 15 , wherein the product effluent comprises at least 40 wt. % naphtha.
19. A method for producing a catalyst composition, the method comprising:
forming a precursor solution comprising a silicon-containing material, an aluminum-containing material, and a quaternary amine;
hydrothermally treating the precursor solution at a first temperature to form an intermediate mixture;
hydrothermally treating the intermediate mixture at a second temperature to form beta zeolite, wherein the first temperature is less than the second temperature by at least 200° C.;
forming an extrudable mixture comprising the beta zeolite, alumina, a metal precursor, and a binder;
extruding the extrudable mixture to form extrudates; and
calcining the extrudates to form the catalyst composition;
wherein:
the beta zeolite is not calcined before extruding the extrudable mixture;
the silicon-containing material comprises fumed silica;
the quaternary amine comprises tetraethylammonium hydroxide;
the first temperature is of from 100° C. to 150° C.;
the second temperature is of from 500° C. to 650° C.; and
the metal precursor comprises molybdenum and nickel.
20. The method of claim 19 , wherein the extrudable mixture further comprises a zeolite Y.