Fluid Catalytic Cracking Catalyst Blend for Coke Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional fluid catalytic cracking catalysts for hydrocarbon oil fail to achieve satisfactory low coke content and sufficient catalytic activity, particularly due to issues with hydrogen transfer reaction activities and hydrothermal resistance.
Innovation Solution
A fluid catalytic cracking catalyst blend comprising two types of catalysts with different hydrogen transfer reaction activities and specific pore distributions, each containing zeolites and matrix components, is developed. The catalysts are pseudo-equilibrated and blended in specific ratios to optimize coke reduction and high-value product yields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If conventional fluid catalytic cracking catalysts are used, then catalytic activity is maintained, but coke content remains high and selectivity is insufficient
Solution Approach 1:
The catalyst system is segmented into two distinct catalyst types with different pore size distributions. Catalyst (a) has a pore volume ratio (V1/V2) < 0.8 for small-to-large pores, while catalyst (b) has a pore volume ratio (V3/V4) < 0.2 for medium-to-large pores. This segmentation allows each catalyst to perform specialized functions: catalyst (a) primarily cracks heavy oil with low hydrogen transfer activity, while catalyst (b) controls coke formation with low medium-pore volume, achieving both low coke content and high selectivity simultaneously
Solution Approach 2:
Different regions of the catalyst system have different pore quality characteristics. Catalyst (a) is designed with specific small-to-large pore volume ratio < 0.8 for heavy oil access, while catalyst (b) is designed with specific medium-to-large pore volume ratio < 0.2 for coke control. This local quality differentiation enables each catalyst to optimize its function in specific reaction zones, reducing overall coke formation while maintaining high liquid yield
2Reliability
If catalysts with high hydrogen transfer reaction activity are used, then selectivity improves, but coke formation increases
Solution Approach 1:
Catalyst (a) acts as an intermediary that performs heavy oil cracking with controlled hydrogen transfer activity. By using a catalyst with specific pore distribution (V1/V2 < 0.8) and lower hydrogen transfer activity, the system allows heavy oil to be cracked into intermediate products that can then be further processed, reducing the need for high hydrogen transfer activity that would otherwise cause excessive coke formation
Solution Approach 2:
The invention changes the pore size distribution parameters of the catalysts to control hydrogen transfer reaction activity. By setting catalyst (a) with pore volume ratio V1/V2 < 0.8 and catalyst (b) with pore volume ratio V3/V4 < 0.2, the system optimizes the balance between hydrogen transfer activity and coke formation, achieving high selectivity without excessive coke
3Productivity
If catalysts with high bottom cracking capability are used, then heavy oil conversion improves, but coke depositing on catalyst surface increases
Solution Approach 1:
The catalyst system is segmented into two specialized catalysts: catalyst (a) with small-to-large pore volume ratio V1/V2 < 0.8 for heavy oil cracking, and catalyst (b) with medium-to-large pore volume ratio V3/V4 < 0.2 for coke control. This segmentation enables catalyst (a) to provide high bottom cracking capability while catalyst (b) suppresses coke deposition on the catalyst surface
Solution Approach 2:
The invention uses a composite catalyst system combining two different catalyst types with complementary pore structures. Catalyst (a) provides heavy oil cracking activity with its specific small-to-large pore distribution, while catalyst (b) provides coke control with its specific medium-to-large pore distribution. The composite system achieves both high bottom cracking capability and low surface coke deposition
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 blended catalysts effectively reduce coke formation and enhance selectivity and heavy oil cracking performance, achieving higher yields of gasoline and other high-value products while maintaining catalytic activity and resistance.
Implementation Method 1
fluid catalytic cracking catalyst for hydrocarbon oil that is a blend of two types of fluid catalytic cracking catalysts
Data Source
AI summary
A fluid catalytic cracking catalyst for hydrocarbon oil that is a blend of two types of fluid catalytic cracking catalysts each of which has a different hydrogen transfer reaction activity or has a pore distribution within a specific range after being pseudo-equilibrated. One catalyst is a catalyst containing a zeolite and matrix components, and the other catalyst is a catalyst containing a zeolite and matrix components. This catalyst is composed of the one catalyst and the other catalyst blended at a mass ratio within a range of 10:90 to 90:10.