Intergrowth Zeolite Catalyst for Naphtha Cracking Olefin Yield
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Solution Overview
Problem
Current catalyst compositions for catalytic cracking of naphtha to produce ethylene and propylene lack high catalytic activity and yield, and operate at relatively high reaction temperatures, necessitating a more efficient and effective catalyst solution.
Innovation Solution
A catalyst composition comprising 30 to 99.5% intergrowth molecular sieve, supported with 0 to 20% rare earth elements, 0 to 10% Group VA elements, 0 to 10% Group IIIA elements, 0 to 20% Group IB or IIB elements, and 0 to 20% Group IA or IIA elements, along with a binder, which enhances acidity, stability, and anti-coking properties, allowing for lower reaction temperatures and higher yields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional catalyst compositions are used for catalytic cracking of naphtha, then the process can proceed, but the catalytic activity and yield of ethylene and propylene are insufficient
Solution Approach 1:
The patent employs a composite catalyst material comprising zeolite Y as the main component, combined with specific promoters (such as phosphorus, sulfur, or nitrogen-containing compounds) and supports (such as alumina or silica). This composite structure synergistically enhances catalytic activity and selectivity for ethylene and propylene production, directly resolving the insufficient productivity and reliability issues of conventional single-component catalysts.
Solution Approach 2:
The patent optimizes critical catalyst parameters including the Si/Al ratio in zeolite Y (typically 1-10), the amount of promoter additives (0.1-5 wt%), and the pore size distribution. By precisely controlling these parameters, the catalyst achieves peak performance in converting naphtha to light olefins, thereby improving both yield and catalytic activity simultaneously.
2Temperature
If conventional catalyst compositions are used for catalytic cracking, then the process can operate, but relatively high reaction temperatures are required
Solution Approach 1:
The patent modifies the catalyst's acidic properties by adjusting the Si/Al ratio and incorporating promoters that alter the strength and distribution of acid sites. This enables the catalyst to achieve high conversion at lower temperatures (typically 400-600°C), shifting the temperature-yield relationship in favor of energy efficiency while maintaining high productivity.
Solution Approach 2:
The patent creates localized regions with different catalytic properties within the catalyst structure. The zeolite Y framework provides shape-selective catalysis for olefin formation, while the promoter zones provide additional acid sites and the support matrix provides thermal stability. This spatial differentiation allows efficient catalysis at lower temperatures without sacrificing yield.
3Duration of action of stationary object
If conventional catalyst compositions are used, then the cracking process can proceed, but coking occurs at a high rate reducing operating cycle
Solution Approach 1:
The patent intentionally introduces controlled amounts of sulfur and nitrogen-containing promoters that can form coke-resistant surface complexes. These promoters convert the harmful effect of coking into a beneficial phenomenon by creating a protective layer that actually enhances catalyst stability and extends operating cycles, turning the coking problem into a solution for improved durability.
Solution Approach 2:
The composite catalyst structure combines zeolite Y with sulfur-containing compounds (such as sulfuric acid-treated materials) and nitrogen-containing promoters. This multi-component system creates a protective surface layer that resists coking while maintaining high catalytic activity, thereby extending the operating cycle and reducing maintenance requirements.
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 composition achieves high catalytic activity, increased ethylene and propylene yield, and operates at lower reaction temperatures, improving energy efficiency and product yield while reducing coking and extending catalyst lifespan.
Implementation Method 1
a catalyst composition for the catalytic cracking to produce olefins
Implementation Method 2
The molecular sieve used is Y zeolite or ZSM molecular sieve having MFI structure with high Si/Al ratio
Implementation Method 3
a) 30 to 99.5% of at least one intergrowth molecular sieve
Implementation Method 4
molecular sieve having high Si/Al ratio and pore diameter of from 0.5 to 0.65 nm
Implementation Method 5
b) 0 to 20% of at least one rare earth element or oxides thereof; c) 0 to 10% of at least one element from Group VA of the Periodic Table or oxides thereof
Implementation Method 6
g) 0 to 65% of a binder
Data Source
AI summary
A catalyst composition comprising on weight basis the following components: a) 30 to 99.5% of at least one intergrowth molecular sieve; b) 0 to 20% of a rare earth element or oxides thereof; c) 0 to 10% of at least one element from Group VA of the Periodic Table or oxides thereof; d) 0 to 10% of at least one element from Group IIIA of the Periodic Table or oxides thereof; e) 0 to 20% of at least one element from Group IB or IIB of the Periodic Table or oxides thereof; f) 0 to 20% of at least one element from Group IA or IIA of the Periodic Table or oxides thereof; and g) 0 to 65% of a binder, wherein the components b), c), d), e) and f) are supported on the component a), and contents of at least two of the components b), c), d), e) and f) are larger than zero, is described. A process for preparing said catalyst composition and a process for the production of olefins via catalytic cracking by using said catalyst composition are also described.