Mesoporous FCC Catalyst Using Sodium Silicate Matrix
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional mesoporous FCC catalysts are expensive to produce and can affect zeolite synthesis due to their acidic nature, leading to undesirable coke formation and reduced hydrocarbon product yields in fluidized catalytic cracking operations.
Innovation Solution
A catalytic cracking catalyst comprising an amorphous, porous matrix with specific pore distribution and a zeolite component, produced through a method involving a combination of molecular sieve, aluminum hydroxide, clay, urea, and alkaline silicate, followed by ion exchange and calcination, to minimize coke formation and enhance hydrocarbon production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional mesoporous silica-alumina matrix is used in FCC catalyst, then feedstock conversion to high value hydrocarbon products is improved, but production cost increases and zeolite synthesis is adversely affected
Solution Approach 1:
The patent replaces expensive conventional silica-alumina sols with inexpensive water glass (sodium silicate) as the matrix precursor. Water glass is a cheap, commercially available material that forms the desired mesoporous matrix structure without the high cost associated with traditional silica sol-based catalysts, directly addressing the production cost issue while maintaining catalytic performance
Solution Approach 2:
The patent changes the chemical composition parameters of the matrix by using water glass (sodium silicate) instead of conventional silica-alumina sols. This parameter change fundamentally alters the matrix chemistry to be less acidic and more compatible with zeolite synthesis, while still achieving the required mesoporous structure and catalytic activity through controlled formation processes
2Shape
If conventional acidic silica sols are used to form mesoporous matrix, then mesoporous structure is achieved, but catalytic constituents such as zeolite are adversely affected
Solution Approach 1:
The patent substitutes expensive and problematic acidic silica-alumina sols with inexpensive water glass (sodium silicate). Water glass provides the necessary mesoporous matrix formation capabilities without the adverse acidic effects that damage zeolite structures, thereby protecting catalytic constituents while achieving the desired matrix morphology
Solution Approach 2:
The patent fundamentally changes the chemical parameters of the matrix precursor from acidic silica-alumina sols to alkaline/neutral water glass (sodium silicate). This parameter change eliminates the harmful acidity that adversely affects zeolite synthesis and stability, while still enabling mesoporous structure formation through alternative mechanisms such as evaporation-induced self-assembly or controlled precipitation
3Reliability
If conventional FCC catalyst is used, then catalytic activity is maintained, but coke formation increases and hydrocarbon product yield decreases
Solution Approach 1:
The patent changes the chemical composition and acid-base properties of the catalyst matrix by using water glass instead of conventional silica-alumina sols. This parameter change modifies the catalyst's coke-forming tendency and product selectivity, leading to reduced coke formation and improved hydrocarbon product yields while maintaining necessary catalytic activity through optimized matrix structure and zeolite interactions
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 solution results in a catalyst that selectively produces more hydrocarbon products with lower coke yields, improved attrition resistance, and reduced production costs, while maintaining effective catalytic performance.
Implementation Method 1
a catalytic cracking catalyst comprising an amorphous, porous matrix with specific pore distribution
Implementation Method 2
produced through a method involving a combination of molecular sieve, aluminum hydroxide, clay, urea, and alkaline silicate, followed by ion exchange and calcination
Implementation Method 3
followed by ion exchange and calcination
Implementation Method 4
catalytic cracking catalyst comprising an amorphous, porous matrix with specific pore distribution and a zeolite component
Data Source
AI summary
This invention relates to a FCC process using a mesoporous catalytic cracking catalyst. The mesoporous fluidized catalytic cracking catalyst is selective for minimizing the production of coke and light gas. The catalyst comprises at least one amorphous, porous matrix, each matrix having pores ranging in diameter from about 1 Å to about 10 Å and pores ranging in diameter from about 40 Å to about 500 Å, wherein in the pore range from 50 Å to 250 Å, there is a single maximum in differential pore volume distribution over the 50 Å to 250 Å range.