Cracking Catalyst Composition for High-Octane Gasoline Yield
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Solution Overview
Problem
Current catalytic cracking catalysts for hydrocarbon oils face challenges in achieving high cracking activity while maintaining gasoline yield and octane number, with existing methods either reducing yield or increasing coke deposition.
Innovation Solution
A catalyst comprising crystalline aluminosilicate, a binder, and a clay mineral with controlled sodium, potassium, and rare earth metal content, specifically regulating the [RE2O3 + Na2O + K2O]/crystalline aluminosilicate ratio and xenon adsorption amount, to enhance cracking activity and produce high-octane FCC gasoline without yield reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a high-silica zeolite with high acidity (e.g., ZSM-5) is added to the catalyst, then the octane number of FCC gasoline is improved, but the yield of FCC gasoline decreases
Solution Approach 1:
The invention changes the chemical composition parameters of the catalyst by precisely controlling the content of sodium, potassium, and rare earth metals, and regulating the [RE2O3 + Na2O + K2O]/crystalline aluminosilicate ratio. This parameter optimization enables the catalyst to achieve high cracking activity while maintaining high gasoline yield and improved octane number, resolving the contradiction between quality improvement and yield maintenance
2Measurement precision
If a method is used to convert heavy oil to light olefin fraction to increase octane number, then the octane number is improved, but coke deposits on the catalyst in increased amount
Solution Approach 1:
The invention optimizes the chemical composition parameters of the catalyst, specifically controlling the content of sodium, potassium, and rare earth metals, and regulating the [RE2O3 + Na2O + K2O]/crystalline aluminosilicate ratio to not larger than 0.1. This parameter optimization enables the catalyst to promote olefin production for high octane number while simultaneously suppressing excessive coke deposition through balanced acidity control
Solution Approach 2:
The invention uses a composite catalyst system comprising crystalline aluminosilicate, binder, and clay mineral with controlled metal content. This composite structure combines the cracking activity of aluminosilicate with the properties of binder and clay mineral, creating a balanced catalyst that achieves high octane number through olefin production while limiting coke formation
3Productivity
If a catalyst with high cracking activity is used to efficiently produce FCC gasoline, then the productivity is improved, but it is difficult to maintain both high gasoline yield and high octane number simultaneously
Solution Approach 1:
The invention optimizes multiple composition parameters simultaneously: controlling sodium and potassium content, controlling rare earth metal content, and regulating the [RE2O3 + Na2O + K2O]/crystalline aluminosilicate ratio. This multi-parameter optimization enables the catalyst to achieve high cracking activity while maintaining the ability to produce high-yield, high-octane gasoline, resolving the contradiction between productivity and product quality
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 catalyst achieves high cracking activity and high-octane FCC gasoline production efficiently, reducing operational costs and improving gasoline quality, thus being economically and environmentally beneficial.
Implementation Method 1
a catalyst for the catalytic cracking of a hydrocarbon oil
Implementation Method 2
the catalyst has a regulated xenon adsorption amount
Data Source
AI summary
A catalytic cracking catalyst is provided which has high cracking activity and with which the production of FCC gasoline having a high octane number can efficiently proceed without lowering a gasoline yield. Also provided are a process for producing the catalyst and a method of the catalytic cracking of a hydrocarbon oil with the catalyst. The catalyst for catalytic cracking of a hydrocarbon oil comprises a crystalline aluminosilicate, a binder, and a clay mineral in a certain proportion, wherein the content of sodium and potassium therein is 0.5% by mass or lower in terms of oxide (Na2O and K2O) amount, the content of at least one rare earth metal therein is 3.0% by mass or lower in terms of oxide (RE2O3, wherein RE is a rare earth element) amount, the [RE2O3 + Na2O + K2O]/[crystalline aluminosilicate] ratio by mass is 0.1 or lower, and the catalyst has a xenon adsorption amount, as measured at an adsorption temperature of 25°C and a partial xenon pressure of 650 torr, of 2.20×1020 molecules or more per g of the catalyst. Also provided are a process for producing the catalyst and a method of catalytic cracking of a hydrocarbon oil with the catalyst.