FCC Catalyst Additive Phosphate Removal for Propylene Selectivity
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Solution Overview
Problem
Current FCC catalysts face challenges in maintaining catalytic activity while preserving attrition resistance and apparent bulk density, particularly due to the sensitivity of Y zeolites to extreme pH conditions and the detrimental effect of excess phosphate on active components.
Innovation Solution
A process involving the removal of excess phosphate from the FCC catalyst additive by slurring in demineralized water, followed by metal exchange with bivalent metals from Group IIA or IB to create moderate acid sites, enhancing selectivity towards high-value components like propylene and gasoline while suppressing low-value components like dry gas and bottoms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If basic phosphate source is used to improve catalytic activity of Y zeolites, then catalytic activity is improved, but attrition resistance is sacrificed
Solution Approach 1:
The patent removes excess phosphate from the catalyst system through washing with demineralized water, extracting the harmful component while preserving the beneficial catalytic activity of the Y zeolite structure
Solution Approach 2:
The patent optimizes the phosphate content parameter to a specific range (0.1-5 wt%) rather than using high amounts, and adjusts the SiO2/Al2O3 ratio to 2.5-5.0, transforming the system from high-phosphate to controlled-low-phosphate configuration
2Reliability
If extreme pH conditions are applied during catalyst preparation, then catalytic activity can be enhanced, but Y zeolites are damaged
Solution Approach 1:
The patent maintains pH within a moderate range (2-7) during preparation steps, avoiding extreme pH conditions that would damage the Y zeolite structure while still achieving the desired catalytic activity through controlled phosphate content and metal exchange
3Strength
If excess phosphate is present in the catalyst, then binder strength is improved, but selectivity towards high-value components decreases
Solution Approach 1:
The patent extracts excess phosphate through washing with demineralized water, removing the component that harms selectivity while maintaining sufficient phosphate for binder functionality
Solution Approach 2:
The patent creates a composite catalyst system combining Y zeolite, controlled-phosphate binder, and metal exchange components (Ca, Mg, Zn, or Cu) that work synergistically to provide both binder strength and high selectivity
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 results in an FCC catalyst additive with improved catalytic activity, attrition resistance, and selectivity towards high-value hydrocarbons, reducing the production of low-value components and maintaining adequate apparent bulk density.
Implementation Method 1
Catalytic cracking is widely used today to reduce heavy hydrocarbons into lighter and more useful products. One commonly used cracking catalyst is a type of crystalline inorganic synthetic products called 'Y zeolites.'
Implementation Method 2
the Y zeolites also have higher surface area and acidity as compared to other types of catalyst
Implementation Method 3
exchanging of the FCC catalyst additive of step (d) with the solution of bivalent metals from group consisting of Group IIA or Group IB
Data Source
AI summary
The present invention relates to a catalyst product for cracking of heavy hydrocarbon feed stocks predominantly in to light olefins and processes for preparing the catalyst. More specifically the present invention relates to a process of preparing Fluidic Catalytic Cracking (FCC) catalyst additive composition. The FCC catalyst additive composition of the present invention is a LPG selective catalyst particles comprising a medium pore zeolite bonded with clay-phosphate-silica-alumina binder. The catalyst of the present invention exhibits improved selectivity towards high value components like propylene and gasoline and suppressing low value components like dry gas and bottoms.