FCC Catalyst Attrition Resistance via Poly Aluminum Chloride
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Solution Overview
Problem
Existing fluid catalytic cracking (FCC) catalysts lack sufficient attrition resistance, which is crucial for their performance in fluidized beds.
Innovation Solution
A process involving the spray-drying of an aqueous slurry comprising zeolite, clay, and poly aluminum chloride with a specific OH/Al ratio (greater than 1 and less than 2) followed by calcination, where the poly aluminum chloride has the formula [Al2(OH)yCl6-y] with y ranging from 2.2 to 3.6, is used to enhance attrition resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional poly aluminum chloride with OH/Al ratio of 2 to 2.67 is used in the spray-dried slurry, then the catalyst can be prepared with standard properties, but the attrition resistance of the catalyst particles is insufficient
Solution Approach 1:
The patent applies parameter changes by adjusting the OH/Al ratio of poly aluminum chloride from the conventional range of 2 to 2.67 to a specific range of 1.5 to 2.0. This parameter modification fundamentally alters the properties of the catalyst particles, significantly improving attrition resistance while maintaining manufacturability through standard spray-drying and calcination processes.
Solution Approach 2:
The patent uses composite materials by combining zeolite, clay, and specifically formulated poly aluminum chloride with optimized OH/Al ratio in a spray-dried slurry. This composite approach creates synergistic effects where the poly aluminum chloride with modified parameters provides enhanced mechanical strength and attrition resistance to the overall catalyst structure.
2Strength
If poly aluminum chloride with higher OH/Al ratio is used to improve attrition resistance, then catalyst particle strength increases, but the manufacturing process becomes more complex and less controllable
Solution Approach 1:
The patent resolves this contradiction by changing the parameter range of OH/Al ratio from conventional high values (2-2.67) to an optimized range (1.5-2.0). This parameter adjustment achieves sufficient particle strength without requiring complex process modifications, as the spray-drying and calcination steps remain standard industrial processes.
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 significantly improves the attrition resistance of the resulting FCC catalysts, as demonstrated by lower attrition indices in experimental tests, indicating more durable catalyst particles.
Implementation Method 1
spray-drying an aqueous slurry
Implementation Method 2
spray-drying an aqueous slurry
Implementation Method 3
subsequently calcined
Data Source
AI summary
This invention relates to a process for the preparation of a fluid catalytic cracking catalyst with improved attrition resistance. According to this preparation process, an aqueous slurry comprising a zeolite, day, and poly aluminum chloride is spray-dried and subsequently calcined, the poly aluminum chloride having the formula [Al2(OH)yCl6-y]x, wherein x is at least 1 and y is greater than 2 and smaller than 4.