Bimetallic Cracking Additive for Steam Catalytic Cracking
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Solution Overview
Problem
There is a need for improved cracking catalysts and processes to enhance the production of light olefins and light aromatic compounds from crude oil through steam enhanced catalytic cracking, as conventional methods have limitations in selectivity and yield.
Innovation Solution
A bimetallic cracking additive comprising a ZSM-5 zeolite with first and second metal species, such as chromium, iron, platinum, molybdenum, cerium, or zinc, impregnated onto the zeolite, is used in conjunction with steam to enhance catalytic cracking reactions, increasing the dispersion of metals and improving the conversion of crude oil into light olefins and aromatic compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional cracking catalysts are used for steam enhanced catalytic cracking of crude oil, then the process can produce light olefins and aromatic compounds, but the selectivity and yield of these valuable products are limited
Solution Approach 1:
The patent applies composite materials by combining ZSM-5 zeolite with multiple metal species (chromium, iron, platinum, molybdenum, cerium, or zinc) to create a bimetallic cracking additive. This composite catalyst structure integrates the shape-selective properties of ZSM-5 zeolite with the catalytic activity of metal species, achieving both high selectivity for light olefins and aromatic compounds and improved overall productivity in steam enhanced catalytic cracking of crude oil
Solution Approach 2:
The patent applies local quality by impregnating specific metal species onto specific regions of the ZSM-5 zeolite structure. The metal species are distributed within the zeolite matrix to create localized catalytic sites with optimized properties for cracking reactions, allowing different regions of the catalyst to perform specialized functions that enhance both selectivity and yield
2Productivity
If metal species are impregnated onto ZSM-5 zeolite using conventional methods, then the catalyst can be prepared, but the metal dispersion is insufficient to maximize catalytic efficiency
Solution Approach 1:
The patent applies parameter changes by modifying the impregnation process parameters to achieve optimal metal dispersion on ZSM-5 zeolite. The modified wet impregnation method adjusts conditions such as metal precursor concentration, impregnation time, drying rate, and calcination temperature to maximize the dispersion of metal species throughout the zeolite matrix, thereby enhancing catalytic cracking efficiency
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 process achieves higher yields of light olefins and aromatic compounds, surpassing the selectivity and efficiency of conventional methods, by utilizing a modified wet impregnation method that disperses metal species more effectively across the ZSM-5 zeolite, thereby improving the catalytic cracking efficiency.
Implementation Method 1
contacting the hydrocarbon feed with steam in the presence of a cracking catalyst composition at reaction conditions sufficient to cause at least a portion of hydrocarbons in the hydrocarbon feed to undergo one or more cracking reactions
Implementation Method 2
The first metal species and the second metal species are impregnated onto the ZSM-5 zeolite
Data Source
AI summary
A process for upgrading a hydrocarbon feed comprises contacting the hydrocarbon feed with steam in the presence of a cracking catalyst composition at reaction conditions sufficient to cause at least a portion of hydrocarbons in the hydrocarbon feed to undergo one or more cracking reactions to produce a steam catalytic cracking effluent comprising light olefins, light aromatic compounds, or both, where: the cracking catalyst composition comprises a cracking additive comprising a ZSM-5 zeolite, a first metal species, and a second metal species, where the first metal species and the second metal species are impregnated onto the ZSM-5 zeolite, the first metal species comprises a metal or metal oxide comprising a first metal, the second metal species comprises a metal or metal oxide comprising a second metal, and the second metal is different from the first metal.