Boron Oxide FCC Catalysts for Resid Cracking
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Solution Overview
Problem
Current fluid catalytic cracking (FCC) catalysts face challenges in minimizing coke and hydrogen yields, especially when processing resid feeds containing high levels of contaminant metals like nickel and vanadium, which lead to decreased gasoline production and increased operational costs due to heat imbalance and compressor expenses.
Innovation Solution
Incorporating FCC compatible inorganic particles containing one or more boron oxide components into the catalyst composition to reduce coke and hydrogen yields by passivating deleterious metals, thereby maintaining catalyst selectivity and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional FCC catalysts are used to process resid feeds, then cracking activity is maintained, but coke and hydrogen yields increase due to metal contaminants
Solution Approach 1:
Boron oxide serves as an intermediary substance that selectively interacts with contaminant metals (Ni, V, Fe) to form stable borates, preventing these metals from catalyzing unwanted dehydrogenation reactions. The boron oxide acts as a passivating agent that mediates between the harmful metals and the hydrocarbon feed, eliminating their detrimental effects on coke and hydrogen formation while preserving zeolite cracking activity
Solution Approach 2:
The invention converts the harmful effect of metal contaminants into a beneficial outcome by using boron oxide to selectively trap these metals. The metals that would normally increase coke and hydrogen yields are instead captured by boron oxide to form stable borates, transforming a harmful catalytic effect into a beneficial passivation mechanism that protects the zeolite from metal-induced deactivation
2Productivity
If catalyst activity is increased to improve gasoline yield, then conversion efficiency improves, but selectivity decreases with higher coke and gas production
Solution Approach 1:
The catalyst composition exhibits local quality differentiation where boron oxide is strategically positioned to provide selective passivation at metal contamination sites, while the zeolite maintains its inherent gasoline-selective cracking activity in uncontaminated regions. This spatial differentiation of functions allows high activity and high selectivity to coexist by localizing the protective effect where metals are present
3Productivity
If resid feeds are processed to maximize heavy hydrocarbon conversion, then feed utilization improves, but contaminant metal effects increase coke and hydrogen formation
Solution Approach 1:
Boron oxide is incorporated into the catalyst composition in advance to provide preliminary protection against metal contaminants before they can cause harm. The boron oxide is pre-positioned on the catalyst surface to intercept and passivate metals as they are introduced with the resid feed, preventing the subsequent formation of unwanted coke and hydrogen that would occur without this preliminary protective action
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 use of boron oxide components in the FCC catalyst composition effectively lowers hydrogen and coke yields, enhancing gasoline production and reducing operational costs by preventing metal-induced dehydrogenation reactions and maintaining catalyst performance under varying hydrocarbon feed conditions.
Implementation Method 1
Incorporating FCC compatible inorganic particles containing one or more boron oxide components into the catalyst composition to reduce coke and hydrogen yields by passivating deleterious metals
Implementation Method 2
Catalytic cracking in current FCC catalysts is attributable to both the zeolite and non-zeolite (e.g. matrix) components
Data Source
AI summary
Described are fluid catalytic cracking (FCC) compositions, methods of manufacture and use. FCC catalyst compositions comprise particles containing a non-zeolitic component and one or more boron oxide components. In embodiments, the FCC catalyst composition contains a zeolite component and optionally a rare earth component and a transition alumina. FCC catalytic compositions may comprise a first particle type containing one or more boron oxide components and a first matrix component mixed with a second particle type containing a second matrix component, and a zeolite. The FCC catalyst compositions can be used to crack hydrocarbon feeds, particularly resid feeds containing high V and Ni, resulting in lower hydrogen and coke yields.