Fluid Catalytic Cracking Catalyst with Oxygenated Feedstock
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Solution Overview
Problem
Existing fluid catalytic cracking (FCC) processes face challenges in reducing coke and hydrogen formation, which limits efficiency and product yield.
Innovation Solution
The process involves contacting a fluid catalytic cracking catalyst composition with a feedstock containing oxygenated compounds and optionally a hydrocarbon feed, using a catalyst composition that includes Y-type zeolites, ZSM-5 zeolites, a rare earth component, a phosphorus component, and alumina, which reduces coke and hydrogen production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional fluid catalytic cracking processes are used with hydrocarbon feedstocks, then cracking conversion is achieved, but coke and hydrogen formation increases
Solution Approach 1:
The patent changes the chemical composition parameter of the feedstock by introducing oxygenated compounds (alcohols, esters, ethers, aldehydes, or ketones) comprising 1-50 wt% of the total feedstock. This parameter change fundamentally alters the cracking reaction pathways, reducing coke and hydrogen formation while maintaining cracking conversion through the unique reactivity of oxygenated compounds with the catalyst and hydrocarbon feedstock.
2Object-generated harmful factors
If oxygenated compounds are added to feedstock, then coke and hydrogen production decreases, but feedstock composition complexity increases
Solution Approach 1:
The patent defines specific parameter ranges for oxygenated compound addition (1-50 wt%) and specifies acceptable classes of oxygenated compounds (alcohols, esters, ethers, aldehydes, ketones). These parameter specifications manage the complexity by providing clear operational guidelines while achieving the benefit of reduced coke and hydrogen formation.
3Object-generated harmful factors
If catalyst composition is modified to reduce coke, then cracking activity may be affected, but product selectivity needs to be maintained
Solution Approach 1:
The oxygenated compounds act as intermediaries in the cracking process, facilitating reactions that produce fewer coke precursors. The oxygenated compounds interact with the catalyst and hydrocarbon feedstock to create alternative reaction pathways that maintain cracking activity while reducing harmful byproducts through this intermediary role.
Solution Approach 2:
The patent creates a composite feedstock system combining hydrocarbon feedstock with oxygenated compounds. This composite material approach allows the synergistic interaction between the two components, where the oxygenated compounds modify the overall reaction behavior to reduce coke formation while maintaining the cracking functionality provided by the hydrocarbon portion.
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 approach results in decreased coke and hydrogen production, along with improved yields of gasoline, propylene, and increased olefinicity, while allowing for higher catalyst to oil ratios and operational temperatures.
Implementation Method 1
contacting a fluid catalytic cracking catalyst composition with a feedstock comprising an oxygenated feed... The fluid catalytic cracking catalyst composition comprises one or more Y-type zeolites, one or more ZSM-5 zeolites, a rare earth component, a phosphorus component, and alumina comprising boehmite and/or pseudoboehmite
Data Source
AI summary
This invention provides a process for fluid catalytic cracking of a feedstock, which process comprises contacting a fluid catalytic cracking catalyst composition with a feedstock comprising an oxygenated feed and optionally a hydrocarbon feed, wherein the oxygenated feed comprises at least one oxygenated compound containing at least carbon, hydrogen, and oxygen.