BEA Zeolite Cracking Catalyst for Light Olefin Yield

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Solution Overview

Problem

The petrochemical industry faces challenges in producing light olefins such as ethylene, propylene, and butene due to the limitations and high costs associated with traditional thermal cracking processes using petroleum gases and distillates, necessitating the development of new catalyst systems for converting crude oil streams into these intermediates.

Innovation Solution

A cracking catalyst system comprising *BEA framework type zeolite, often combined with MFI framework type zeolite, binder materials, and matrix materials, is used to process hydrocarbon feed streams with high API gravity, promoting the conversion of light hydrocarbons into light olefins with enhanced yield and efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional thermal cracking processes are used to produce light olefins, then light olefins can be obtained, but the production costs are high and energy consumption is excessive

Engineering Contradiction:

Improvelight olefin production efficiencyVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent replaces the traditional thermal cracking process (which relies on high temperature and pressure) with a catalytic cracking process using *BEA framework type zeolite. This substitution of the cracking mechanism dramatically reduces energy consumption while maintaining high light olefin production efficiency, directly resolving the contradiction between productivity and energy use

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the operating parameters by using a catalyst that enables cracking at lower temperatures compared to thermal cracking. The *BEA zeolite catalyst allows the process to operate under milder conditions, reducing energy input while achieving the same or better productivity in light olefin production

Inventive Principle:

Principle #35Parameter changes

2Productivity

If refinery FCC processes are used to produce propylene, then propylene can be obtained, but the feedstocks are limited and require costly processing steps

Engineering Contradiction:

Improvepropylene productionVSAvoidfeedstock availability and processing cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The *BEA framework type zeolite catalyst demonstrates universal applicability by effectively cracking various feedstock types including light hydrocarbon streams, gas oils, and residues. This multi-functionality allows the same catalyst system to produce propylene from diverse feedstocks, eliminating the need for limited refinery-specific feedstocks and reducing processing costs

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent enables the use of cheaper, more readily available feedstocks such as light hydrocarbon streams and crude oil fractions instead of expensive refined feedstocks. The catalyst maintains high activity and selectivity with these simpler, cheaper feedstocks, making the overall process more economically viable

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Quantity of substance

If conventional cracking catalysts are used, then cracking can occur, but the yield of light olefins is insufficient

Engineering Contradiction:

Improvelight olefin yieldVSAvoidconversion efficiency

Core Design Contradiction:

Quantity of substanceVSProductivity

Solution Approach 1:

The patent employs *BEA framework type zeolite with specific local structural characteristics including particular pore sizes, channel dimensions, and acid site distributions. These localized structural features create optimal conditions for light olefin formation, significantly increasing yield compared to conventional catalysts with less optimized local structures

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The catalyst system uses composite material design combining *BEA framework type zeolite with specific matrix materials and promoters. This composite structure enhances both the quantity of light olefins produced and the overall conversion efficiency, resolving the contradiction between yield and productivity

Inventive Principle:

Principle #40Composite materials

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

This catalyst system effectively increases the yield of light olefins, particularly propylene, from crude oil fractions, offering a more cost-effective and energy-efficient alternative to traditional methods by utilizing widely available crude oil feedstocks and maintaining stability under severe operating conditions.

Implementation Method 1

The cracking catalyst may comprise one or more binder materials, one or more matrix materials, and *BEA framework type zeolite... A cracking catalyst may promote cracking of light hydrocarbon molecules

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS10526546B2Systems and methods for cracking hydrocarbon streams utilizing cracking catalysts

Publication Date: 2020.01.07 SAUDI ARABIAN OIL CO

AI summary

According to one or more embodiments, a hydrocarbon feed stream may be cracked by a method comprising contacting the hydrocarbon feed stream with a cracking catalyst in a reactor unit. The hydrocarbon feed stream may have an API gravity of at least 40 degrees. The cracking catalyst may comprise one or more binder materials, one or more matrix materials, and *BEA framework type zeolite.