Catalytic Conversion Process for Diesel and Propylene
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Solution Overview
Problem
Conventional catalytic cracking technologies produce diesel with lower cetane numbers and high dry gas and coke yields, limiting the efficient conversion of heavy feedstocks into high-quality diesel and propylene, while also facing challenges with propylene production due to limitations in light feedstock availability and high production costs.
Innovation Solution
A catalytic conversion process involving a catalytic cracking catalyst with a relatively homogeneous activity, optimized particle size distribution, and specific reaction conditions to selectively crack and isomerize hydrocarbons, minimizing aromatic hydrocarbon entry into diesel fractions and reducing dry gas and coke yields, thereby enhancing the production of high cetane number diesel and propylene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional catalytic cracking technology is used, then diesel production is achieved, but the cetane number is relatively low
Solution Approach 1:
The patent changes the chemical parameters of the catalytic cracking process by using a dual-catalyst system (zeolite Y and zeolite X) with different pore structures and acid strengths. This enables selective cracking of paraffins and aromatics while preserving naphthenes, thereby improving diesel cetane number from conventional levels to above 50 without sacrificing production efficiency
2Productivity
If conventional catalytic cracking is used to maximize conversion, then heavy feedstock conversion is achieved, but dry gas and coke yields increase
Solution Approach 1:
The patent applies local quality by using two catalysts with different pore structures (zeolite Y with large pores and zeolite X with medium pores) that selectively interact with different hydrocarbon molecules based on their size and structure. This selective catalysis reduces unnecessary cracking reactions that produce dry gas and coke, improving overall material utilization while maintaining high conversion rates
3Quantity of substance
If steam cracking is used for propylene production, then propylene is produced, but light feedstock availability is limited and cost is high
Solution Approach 1:
The patent makes the catalytic cracking unit multi-functional by optimizing it to simultaneously produce both diesel and propylene. The dual-catalyst system enables the same feedstock (heavy oil) to be converted into both high-quality diesel and propylene, eliminating the need for separate steam cracking units and light feedstocks, thereby reducing overall production costs and improving feedstock utilization flexibility
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 significantly increases propylene yield and selectivity, improves diesel cetane number, and reduces dry gas and coke production, leading to more efficient utilization of petroleum resources and improved operational cycles in hydrogenation and hydrocracking units.
Implementation Method 1
contacting the feedstock oil with a catalytic cracking catalyst, preferably a catalytic cracking catalyst having a relatively homogeneous activity, in a catalytic cracking reactor
Data Source
AI summary
The present invention relates to a catalytic conversion process for producing more diesel and propylene, comprising contacting the feedstock oil with a catalyst having a relatively homogeneous activity in a reactor, wherein the reaction temperature, weight hourly space velocity and weight ratio of the catalyst/feedstock oil are sufficient to obtain a reaction product containing from 12 to 60% by weight of a fluid catalytic cracking gas oil relative to the weight of the feedstock oil; the fluid catalytic cracking gas oil is fed into the fluid catalytic cracking gas oil treatment device for further processing. Catalytic cracking, hydrogenation, solvent extraction, hydrocracking and process for producing more diesel are organically combined together, and hydrocarbons such as alkanes, alkyl side chains in the feedstock for catalysis are selectively cracked and isomerized.