Porous Acidic Clay Catalyst for Thermal Coking Liquid Yield
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Solution Overview
Problem
Current coking processes face challenges in achieving higher liquid yields while minimizing coke production, particularly in sustaining endothermic cracking reactions and providing adequate acid sites for cracking bulkier hydrocarbons, with limitations in heat transfer and acid site strength in continuous processes like Fluid and Flexi coking.
Innovation Solution
A catalyst comprising porous acidic clay material and a binder matrix, specifically designed to enhance the crackability of heavy feed materials, with a surface area of 100-200 m2/g, heat capacity of 0.9-1, and average pore diameter of 630-680 Å, which provides weak acid sites and improved heat transfer for thermal cracking, while maintaining attrition resistance and integrity during fluidization and transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a catalyst is introduced to enhance cracking of heavy hydrocarbons, then liquid yield increases, but catalyst attrition and loss of physical integrity occur during fluidization and transport
Solution Approach 1:
The patent employs a composite catalyst structure consisting of porous acidic clay material (providing cracking activity) bound with a binder matrix (providing mechanical strength). This composite approach allows the catalyst to simultaneously deliver high liquid yield through effective cracking while maintaining attrition resistance through the structural support of the binder, directly resolving the contradiction between productivity and reliability.
Solution Approach 2:
The catalyst utilizes porous acidic clay material with controlled pore structure (surface area 100-200 m2/g, pore diameter 630-680 Å) that provides both high cracking activity for liquid yield enhancement and structural framework for maintaining physical integrity during fluidization, addressing the contradiction between catalytic performance and mechanical stability.
2Power
If hot particles are used to supply heat for endothermic cracking reactions, then cracking efficiency improves, but heat transfer limitations reduce overall process effectiveness
Solution Approach 1:
The patent modifies the thermal parameters of the catalyst by selecting materials with optimized heat capacity (0.9-1.0 J/g·K) and pore structure, enabling more effective heat storage and transfer from hot particles to the heavy hydrocarbon feed, thereby improving both cracking reaction rate and heat transfer efficiency simultaneously.
3Productivity
If acid sites are increased to enhance cracking of bulkier hydrocarbons, then liquid yield improves, but coke formation increases
Solution Approach 1:
The patent applies local quality by creating specific pore size distributions (630-680 Å) and distributing acid sites selectively within the catalyst structure, providing adequate acid catalysis for cracking bulkier hydrocarbons to increase liquid yield while controlling the local environment to minimize conditions that promote excessive coke formation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The catalyst effectively increases liquid yields and reduces coke production by providing the necessary heat and acid sites for cracking heavy hydrocarbons, while maintaining physical integrity and attrition resistance, thus enhancing the efficiency of thermal cracking processes.
Implementation Method 1
A catalyst comprising porous acidic clay material and a binder matrix, specifically designed to enhance the crackability of heavy feed materials
Implementation Method 2
Heat for the endothermic cracking reactions is supplied by the hot particles, this permits the cracking and coking reactions to be conducted at higher temperatures
Implementation Method 3
porous acidic clay material... average pore diameter in the range of 630 to 680 A°
Data Source
AI summary
The present invention provides a catalyst product comprising of (a) porous acidic clay material and (b) binder and matrix to shape the catalyst to either microspheres, pellet, tablet, extrudate and ring and suitable for enhancing the crack-ability of heavy feed material derived from atmospheric and vacuum distillation bottoms; FCC bottoms, coker bottoms and hydrocracker bottoms. The invention particularly relates to a catalyst cum heat supply product suitable for thermal coking process either in a batch mode or continuous coking process.