Rare Earth-Free FCC Catalyst Using Magnesium and Silica Sol
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Solution Overview
Problem
The petroleum refining industry faces challenges with high costs and reduced catalyst performance due to the scarcity of rare earth metals, leading to a need for rare earth-free catalytic cracking catalysts that maintain or exceed the activity and selectivity of conventional rare earth-containing catalysts.
Innovation Solution
The development of high matrix surface area catalytic cracking catalysts using an acidified silica sol binder and magnesium salt, which replaces rare earth metals, comprising zeolite, clay, and a matrix material, with a magnesium salt treatment to enhance catalytic activity and selectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rare earth metals are used in FCC catalyst formulations to enhance activity and stability, then catalyst activity and hydrothermal zeolite stability are improved, but catalyst cost increases significantly
Solution Approach 1:
The patent removes rare earth metals from the catalyst formulation entirely, extracting the problematic component that causes high cost while maintaining catalyst performance through alternative components (silica sol binder and magnesium salt)
Solution Approach 2:
The patent replaces expensive rare earth metals with cheaper alternative materials (silica sol and magnesium salt) that can achieve similar or better catalyst performance, significantly reducing raw material costs
2Ease of manufacture
If rare earth metal levels are reduced to offset raw material costs, then catalyst cost decreases, but catalyst activity, stability and yield performance are significantly reduced
Solution Approach 1:
The patent changes the chemical composition parameters of the catalyst by introducing silica sol binder and magnesium salt treatment, which fundamentally alters how activity and stability are achieved without relying on rare earth metals
Solution Approach 2:
The patent creates a composite catalyst system combining silica sol binder with magnesium salt treatment, where the synergistic interaction between these components replaces the function previously provided by rare earth metals
3Productivity
If high matrix surface area is used in catalyst composition to improve activity, then catalytic activity increases, but catalyst complexity increases
Solution Approach 1:
The silica sol binder serves multiple functions simultaneously: it binds the catalyst components together, provides high surface area for activity, and when combined with magnesium salt treatment, provides stabilization. This multi-functionality reduces the need for separate additives
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
These catalysts provide increased catalytic activity and selectivity for coke and hydrogen, offering cost savings while maintaining performance comparable to rare earth-containing catalysts, with improved hydrothermal stability and reduced dependence on rare earth metals.
Implementation Method 1
an acidified silica sol binder
Implementation Method 2
magnesium salt in certain catalytic cracking catalyst compositions
Implementation Method 3
at least one zeolite component having catalytic cracking activity under FCC conditions
Data Source
AI summary
A rare earth free particulate catalytic cracking catalyst which comprises a zeolite having catalytic cracking ability under catalytic cracking conditions, an acidified silica sol binder, magnesium salt, clay and a matrix material. The catalytic cracking catalyst has a high matrix surface area and is useful in a catalytic cracking process, in particularly, a fluid catalytic cracking process, to provide increased catalytic activity and improved hydrogen and coke selectivity without the need to incorporate rare earth metals.