Fundamental Study of the Preparation Method and Functions of Supported Metal Catalysts and Catalytic Matrices for Petroleum Refining

Our studies of catalytic cracking catalysts investigated the preparation and function of novel matrices to develop various hierarchical catalysts. The introduction of mesoporous components of matrix into the catalyst increased the activity and modified the function of zeolite. The gel skeletal reinforcement method was effective to produce zeolite-containing hierarchical catalysts, with increased activity and product selectivity. The Curie point pyrolyzer was effective to evaluate the catalysts by analyzing the catalytic cracking of huge molecules of vacuum gas oil (VGO), soybean oil (SBO) and low-density polyethylene (LDPE). Simultaneous generation of zeolite and mesoporous silica generated uniform hierarchical catalysts, which were effective for the selective formation of valuable products such as p-xylene in catalytic cracking of LDPE. As a combined process for hydrocracking and catalytic reforming, dehydrocyclization-cracking of SBO and fatty acid methyl ester (FAME) was developed to form hydrogen and aromatics under low pressure of less than 1.0 MPa using zeolite-Al2O3 composite catalysts-supported PtNiMo hydrocracking catalysts. Both PtNiMo and PtCoMo catalysts could form liquid fuels at H2 pressure of lower than 1 MPa. Zn- or Ga-exchanged H-ZSM-5 and matrix Al2O3 composite catalytic reforming catalysts were prepared to make aromatics through dehydrocyclization of n-pentane. The presence of matrix Al2O3 increased the selectivity for aromatics and dimerization of C2-C4 olefins by the Diels_Alder reaction on reduced Zn and Ga species and subsequent dehydrogenation formed benzene, toluene and xylene.