Noble metal zeolite catalyst for second-stage hydrocracking to make middle distillate

Abstract

A second-stage hydrocracking catalyst is provided, comprising: a) a zeolite beta having an OD acidity of 20 to 400 μmol/g and an average domain size from 800 to 1500 nm2; b) a zeolite USY having an ASDI between 0.05 and 0.12; c) a catalyst support; and d) 0.1 to 10 wt % noble metal; wherein the second-stage hydrocracking catalyst provides a hydrogen consumption less than 350 SCFB across a range of synthetic conversions up to 37 wt % when used to hydrocrack hydrocarbonaceous feeds having an initial boiling point greater than 380° F. (193° C.). A second-stage hydrocracking process using the second-stage hydrocracking process is provided. A method to make the second-stage hydrocracking catalyst is also provided.

It is claimed: 
     
         1 . A second-stage hydrocracking process, comprising:
 hydrocracking a hydrocarbonaceous feed having an initial boiling point greater than 380° F. (193° C.) in a second-stage hydrocracking reactor using a second-stage hydrocracking catalyst, wherein greater than 70 wt % of an effluent from the second-stage hydrocracking reactor has a hydrocracked boiling point greater than 380° F. (193° C.) and wherein the second-stage hydrocracking catalyst provides a hydrogen consumption less than 350 SCFB across a range of synthetic conversions up to 37 wt %; wherein the second-stage hydrocracking catalyst comprises:   a. a zeolite beta having an OD acidity of 20 to 400 μmol/g and an average domain size from 800 to 1500 nm 2 ;   b. a zeolite USY having an ASDI between 0.05 and 0.12;   c. a catalyst support; and   d. 0.1 to 10 wt % noble metal.   
     
     
         2 . The process of  claim 1 , wherein a wt % of the zeolite beta is greater than the wt % of the zeolite USY in the second-stage hydrocracking catalyst. 
     
     
         3 . The process of  claim 1 , wherein the zeolite beta has the OD acidity from 30 to 100 μmol/g. 
     
     
         4 . The process of  claim 1 , wherein the zeolite beta has the average domain size from 900 to 1250 nm 2 . 
     
     
         5 . The process of  claim 1 , wherein the zeolite USY has a total Bronsted acid sites determined by FTIR after H/D exchange of 0.080 to 0.200 mmol/g. 
     
     
         6 . The process of  claim 1 , wherein the second-stage hydrocracking catalyst has the hydrogen consumption between 250 and 350 SCFB over the range of synthetic conversion <625° F. (329° C.) from 23 to 37 wt %. 
     
     
         7 . The process of  claim 1 , wherein the second-stage hydrocracking catalyst has a compacted bulk density from 420 to 620 g/l. 
     
     
         8 . The process of  claim 1 , wherein the second-stage hydrocracking catalyst has a LOT (1000° F[538° C.]) less than 12 wt %. 
     
     
         9 . The process of  claim 1 , wherein the noble metal comprises platinum, platinum, or mixture thereof.