Bimodal Pore Catalyst Additive for Gasoline Sulfur Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for reducing sulfur content in gasoline from fluid catalytic cracking units (FCC) face challenges such as high operating and capital costs, significant loss of research octane number (RON), and limited sulfur reduction efficiency, particularly when processing heavier hydrocarbon feedstocks.
Innovation Solution
A bi-modal pore size catalyst additive composition comprising copper aluminate spinel, large pore acidic alumina matrix, and clay is used, which provides effective sulfur reduction and maintains high RON while cracking heavier hydrocarbons, utilizing a co-precipitation method and spray drying process to achieve optimal pore distribution and activity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If post-treatment of gasoline product is used to reduce sulfur content, then sulfur content is reduced, but research octane number (RON) and yield are significantly lost
Solution Approach 1:
The invention applies preliminary action by incorporating the sulfur reduction additive into the FCC catalyst system before the cracking process. The additive pre-positions the necessary functional components (copper aluminate spinel and acidic alumina) within the catalyst structure, enabling sulfur removal to occur during the primary cracking operation rather than requiring subsequent post-treatment. This prevents RON loss because the sulfur reduction happens concurrently with cracking under conditions that preserve octane-enhancing olefins and aromatics.
Solution Approach 2:
The copper aluminate spinel and acidic alumina act as intermediaries within the FCC catalyst system. These components mediate between the hydrocarbon feedstock and the desired products by providing selective sulfur removal pathways. The acidic alumina matrix supports the copper aluminate spinel particles, creating an intermediary structure that facilitates sulfur hydrogenation and removal while maintaining the catalytic environment necessary for high-RON product formation.
2Quantity of substance
If FCC feed hydrotreater is used to remove sulfur, then sulfur content is reduced, but operating and capital costs increase significantly
Solution Approach 1:
The invention merges the sulfur reduction function with the existing FCC cracking process by incorporating the copper aluminate spinel and acidic alumina additive directly into the FCC catalyst system. This consolidation eliminates the need for separate pre-treatment hydrotreater units, their associated high-pressure hydrogen systems, and separate reaction/separation trains. The sulfur removal function is combined with the primary cracking operation, significantly reducing both capital investment and operating costs while achieving the same sulfur reduction objective.
Solution Approach 2:
The FCC catalyst additive performs multiple functions simultaneously: it provides sulfur removal activity through copper aluminate spinel, maintains catalytic cracking activity through acidic alumina, and integrates seamlessly with the existing FCC process conditions. This multi-functionality eliminates the need for dedicated sulfur removal equipment and allows the same catalyst system to handle both cracking and desulfurization, reducing overall process complexity and cost.
3Productivity
If conventional FCC catalyst is used, then cracking activity is maintained, but sulfur reduction efficiency is limited
Solution Approach 1:
The invention employs composite materials by combining copper aluminate spinel particles with acidic alumina matrix to create a multifunctional additive. The copper aluminate spinel provides sulfur reduction activity through its copper component, while the acidic alumina matrix provides cracking activity and structural support. This composite structure allows simultaneous achievement of sulfur removal and hydrocarbon cracking functions that conventional single-material catalysts cannot provide.
Solution Approach 2:
The additive applies local quality by concentrating sulfur removal functionality in specific copper aluminate spinel particles dispersed within the acidic alumina matrix. Rather than requiring the entire catalyst system to be modified for sulfur removal, the invention locally introduces sulfur-active components at strategic positions within the catalyst structure. This localized approach maintains overall cracking activity while providing enhanced sulfur reduction at specific active sites.
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 additive achieves 24-33% sulfur reduction in gasoline with minimal impact on RON, while maintaining high gasoline selectivity and metal tolerance, effectively addressing the limitations of existing FCC processes.
Implementation Method 1
copper aluminate spinel, acidic alumina matrix... gasoline sulfur removal activity... cracking heavier hydrocarbon feedstocks
Implementation Method 2
bimodal pore distribution... large pore diameter in the range of >200 to 400 Å and 25-45% of total pore is mesoporous pore diameter in the range of 20-200 Å
Data Source
AI summary
The present invention relates to an improved CuAl2O4 spinel based catalyst additive composition having bi-modal pore size for improving gasoline sulfur removal activity by maintaining high gasoline selectivity and maintaining research octane number (RON) while cracking heavier hydrocarbon feedstocks in the fluid catalytic cracking unit. More particularly, present invention relates to a gasoline sulfur reduction (GSR) additive comprising copper aluminate spinel, acidic alumina matrix; and clay, wherein the additive having bimodal pore distribution. Present invention also relates to a process for preparing the gasoline sulfur reduction (GSR) additive.