Hydrocracking catalyst comprising coated cracking component part

Details Hydrocracking catalyst comprising coated cracking component part Hydrocracking catalyst comprising coated cracking component part

1996-11-21

1998-12-22

Griffin, Walter D.

Mineral oils: processes and products

Chemical conversion of hydrocarbons

Cracking

208108, 208109, 208110, 502 63, 502 64, 502 66, 502 67, 502 74, 502 77, 502325, 502305, 502313, 502332, C10G 4702, C10G 4718

Patent

active

058513787

DESCRIPTION:

BRIEF SUMMARY
BACKGROUND OF THE INVENTION

1. Field of the Invention
The invention pertains to a hydrocracking catalyst comprising coated particles of a cracking component, such as zeolite particles, or particles of an amorphous cracking component such as silica-alumina, or mixtures thereof, which are coated with an inorganic oxide.
2. Description of Related Art
The oil refining industry commonly employs hydrocracking processes to convert hydrocarbonaceous feedstocks to products of a lower boiling range. Such processes entail contacting the feedstock with hydrogen at elevated temperature and pressure under the influence of a catalyst, with the catalyst containing at least a hydrogenation component and an acidic component which effects the actual cracking. The catalyst generally also comprises a support or binder material. The acidic cracking component is generally either a zeolite or an amorphous cracking component, but may also be a combination of both.
Hydrocracking processes are generally carried out at a pressure in the range of about 100 to 250 bar and a temperature in the range of 230.degree. to 450.degree. C. In the context of this invention hydrocracking processes include all processes in which hydrocarbons are cracked in the presence of hydrogen, including, int. al., hydrodewaxing.
A more recent development is to carry out hydrocracking processes in reactors commonly employed for hydrodesulphurisation and/or hydrodenitrogenation. The cost of constructing "regular" hydrocracking reactors is substantial on account of the high pressures which occur during operation, and it has been found that even though reactors designed for hydrodesulphurisation and/or hydrodenitrogenation do not permit such high pressures, achieving a certain degree of hydrocracking, notably to middle distillate, at these lower pressures, say below 100 bar, is nevertheless becoming increasingly relevant. This type of hydrocracking is also referred to as "mild hydrocracking" (MHC).


SUMMARY OF THE INVENTION

There is a continuing need for hydrocracking catalysts with an improved activity, both in normal hydrocracking and in mild hydrocracking, and an improved selectivity, notably to middle distillates. The present invention provides such an improved hydrocracking catalyst. The hydrocracking catalyst according to the invention comprises hydrogenation metals and a cracking component, which is either a zeolitic cracking component, or an amorphous cracking component, or a mixture of both, which catalyst is characterised in that at least 50% of the outer surface of said cracking component has been coated with a layer of previously formed inorganic oxide, which layer has a thickness in the range of 10 nm to 5 .mu.m, more commonly in the range of 10 nm to 2 .mu.m. The oxide layer has been applied to the zeolite particles before the zeolite particles are incorporated into the hydrocracking catalyst.


DETAILED DESCRIPTION OF THE INVENTION

If in the framework of this invention reference is made to coated cracking component particles, what is meant is that at least 50% of the outer surface of said cracking component particles is coated with a layer of inorganic oxide, which layer has a thickness in the range of 10 nm to 5 .mu.m, generally in the range of 10 nm to 2 .mu.m. It is preferred for the outer surface of the cracking component particles to be coated to the fullest possible extent, up to 100%.
It is noted that within the framework of the invention the term zeolite refers not just to aluminosilicate zeolites but to all materials functioning as molecular sieves. Preferred zeolites for use in hydrocracking catalysts will be discussed in more detail below.
It is further noted that within the framework of this invention the term amorphous cracking component refers to all amorphous cracking components which are known for use in hydrocracking. These components will also be discussed in more detail below.
The use of coated zeolite particles instead of uncoated zeolite particles in hydrocracking catalysts has the advantage that the zeolite is protected fr

REFERENCES:
patent: 4023869 (1977-05-01), Rollmann
patent: 5082814 (1992-01-01), Stockwell et al.
Journal of Colloid and Interface Science, vol. 21 (1966) 405-414.
International Search Report, dated Oct. 4, 1995.

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