FCC Catalyst Composition for Light Olefins and Aromatic Gasoline
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Solution Overview
Problem
Existing catalytic cracking processes struggle to simultaneously increase the yield of light olefins and aromatic gasoline while maintaining high gasoline yields, as they focus on propylene production, leading to undesirable high aromatics concentrations and inefficiencies in hydrogen distribution.
Innovation Solution
A catalytic cracking process utilizing a catalyst composition with 0 wt % to 15 wt % Y-type zeolite, greater than 30 wt % ZSM-5, and a ZSM-5 to Y-type zeolite weight ratio greater than 3, operating at a weight hourly space velocity (WHSV) from 40 h−1 to 120 h−1, and a temperature of 530° C. to 600° C., redistributes hydrogen content to enhance light olefin and aromatic gasoline production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If existing catalytic cracking processes focus on propylene production, then propylene yield is improved, but aromatic gasoline concentration becomes excessively high and hydrogen distribution becomes inefficient
Solution Approach 1:
The patent changes the catalyst composition parameters by increasing ZSM-5 content to greater than 30 wt% and adjusting the ZSM-5 to Y-type zeolite weight ratio to greater than 3, along with modifying operating conditions (WHSV: 40-120 h−1, temperature: 530-600° C.) to simultaneously improve propylene yield and control aromatic gasoline concentration
Solution Approach 2:
The patent uses a composite catalyst system comprising ZSM-5 zeolite and Y-type zeolite with specific weight ratios, where ZSM-5 provides propylene production activity while Y-type zeolite moderates the cracking behavior to control aromatic formation, creating a synergistic effect
2Quantity of substance
If existing catalytic cracking processes focus on propylene production, then propylene yield is improved, but hydrogen distribution becomes inefficient
Solution Approach 1:
The patent optimizes operating parameters including WHSV (40-120 h−1) and temperature (530-600° C.) along with catalyst composition to achieve efficient hydrogen distribution to the C4− fraction while maintaining high propylene yield, with up to 60% of feed hydrogen shifted to the C4− fraction
3Quantity of substance
If a single riser reactor is used with the specified catalyst composition, then light olefin and aromatic gasoline production is improved, but process complexity increases
Solution Approach 1:
The patent employs a single riser reactor that performs multiple functions: cracking of petroleum-based feedstock, production of light olefins, and formation of aromatic gasoline, all within one reactor unit using a multi-component catalyst system, thereby simplifying the overall process configuration
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
This process achieves high yields of light olefins and aromatics in gasoline, with up to 60% of feed hydrogen shifted to the C4− fraction, atomic H:C ratio ≤ 1.46:1 in aromatic gasoline, and flexibility to produce LCO and fuel oil, suitable for petrochemical industry feedstocks.
Implementation Method 1
contacting a petroleum-based feedstock with a catalyst in a single riser reactor at a temperature and a weight hourly space velocity (WHSV) to convert at least a portion of the petroleum-based feedstock into light olefins and aromatic gasoline
Implementation Method 2
the temperature is from about 530° C. to about 600° C.
Data Source
AI summary
A catalytic cracking process for producing light olefins and aromatic gasoline includes contacting a petroleum-based feedstock with a catalyst in a single riser reactor, where the catalyst includes 0 wt % to about 15 wt % of a Y-type zeolite and greater than 30 wt % of a pentasil zeolite, a weight ratio of pentasil zeolite to Y-type zeolite greater than 3; and a weight hourly space velocity (WHSV) is about 40 h−1 to about 120 h−1.