FCC Catalyst Composition for Gasoline Yield and Coke Reduction
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Solution Overview
Problem
Existing fluid catalytic cracking catalysts face challenges in achieving high gasoline yield and high LPG olefinicity, such as propylene and butenes, while minimizing coke production and maintaining catalyst activity and wear resistance.
Innovation Solution
A fluid catalytic cracking catalyst comprising faujasite-type zeolite, boehmite, and clay minerals, with specific X-ray diffraction intensity ratios and physical properties, is formulated and produced through a spray-drying process to enhance gasoline yield and LPG olefinicity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional FCC catalysts are used to increase gasoline yield, then cracking ability of heavy fractions is improved, but coke production increases and gasoline yield in catalytic cracking decreases
Solution Approach 1:
The patent employs a composite catalyst system comprising faujasite-type zeolite, boehmite, and clay minerals. This composite structure combines the high cracking activity of zeolite with the coke-resistant properties of boehmite and the structural stability of clay minerals, achieving high gasoline yield while suppressing coke formation through synergistic material interaction
Solution Approach 2:
The patent optimizes the local distribution and interaction of different catalyst components. By controlling the ratio and spatial arrangement of faujasite-type zeolite, boehmite, and clay minerals, the catalyst creates localized active sites that promote selective cracking while maintaining overall coke resistance and structural integrity
2Productivity
If catalyst activity is increased to improve cracking performance, then gasoline yield increases, but wear resistance decreases
Solution Approach 1:
The composite catalyst structure distributes mechanical stress across multiple materials with different properties. Faujasite-type zeolite provides high cracking activity, while boehmite and clay minerals contribute to structural strength and wear resistance, creating a balanced catalyst that maintains both high activity and durability under reactive conditions
Solution Approach 2:
The patent optimizes critical parameters including the ratios of different catalyst components, particle size distribution, and physical properties such as surface area and porosity. These parameter adjustments balance the conflicting requirements of high cracking activity and adequate wear resistance by fine-tuning the catalyst's physical and chemical characteristics
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 gasoline yield and LPG olefinicity, with improved diffusibility and reduced coke selectivity, while maintaining catalyst activity and wear resistance.
Implementation Method 1
fluid catalytic cracking catalyst... cracking ability of heavy fractions... gasoline yield... LPG olefinicity
Implementation Method 2
spray-drying process
Implementation Method 3
spray-drying process
Data Source
AI summary
Provided is a fluid catalytic cracking catalyst including faujasite-type zeolite, boehmite, a binder, and clay minerals, and satisfying the following formulas (1) and (2) in powder X-ray diffraction analysis:A/B≤1.2(1)A/C≥0.8(2)in the formulas (1) and (2), A is an integrated intensity of a diffraction peak attributed to (020) plane of the boehmite, B is an integrated intensity of a diffraction peak attributed to (120) plane of the boehmite, and C is an integrated intensity of a diffraction peak attributed to (331) plane of the faujasite-type zeolite.