Mesoporous FCC Catalyst with Alkaline Earth Matrix
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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 diameter distribution and a zeolite component, produced through a method involving molecular sieves, aluminum hydroxide, clay, urea, and alkaline silicate, with ion exchange and calcination steps 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 into high value hydrocarbon products is effective, but production cost increases and zeolite synthesis is adversely affected
Solution Approach 1:
The patent changes the chemical composition parameters of the matrix by replacing conventional acidic silica-alumina with an alkaline earth metal-containing matrix (such as calcium, strontium, or barium aluminosilicate). This parameter change maintains the mesoporous structure needed for feedstock conversion while eliminating the acidity that causes harmful effects, and uses more abundant, cheaper materials to reduce production cost.
Solution Approach 2:
The patent creates a composite catalyst system combining zeolite crystallites with an alkaline earth metal-containing amorphous matrix. This composite structure allows the zeolite to perform its primary catalytic function while the alkaline earth metal matrix provides structural support, additional catalytic activity, and prevents the harmful acidic effects, achieving multiple functions simultaneously.
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 inverts the conventional approach by using an alkaline or neutral matrix composition instead of an acidic one. The alkaline earth metal-containing matrix has basic or neutral properties that counteract the harmful acidic effects on zeolite while still forming the required mesoporous structure through controlled hydrolysis and condensation of aluminosilicate precursors in alkaline conditions.
3Reliability
If conventional FCC catalyst is used, then catalytic cracking activity is maintained, but coke formation increases and hydrocarbon product yield decreases
Solution Approach 1:
The patent changes the acid-base properties parameter of the catalyst system by introducing alkaline earth metals into the matrix. This parameter change reduces the overall acidity and modifies the catalytic pathway to favor hydrocarbon product formation over coke formation, while maintaining the cracking activity through the zeolite component and the modified matrix structure.
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 the effectiveness of zeolite catalytic activity.
Implementation Method 1
combining water, at least one molecular sieve, at least one aluminum hydroxide or aluminum oxyhydroxide, at least one clay, at least one urea compound having the formula (I), and at least one phosphate to form a first mixture; combining the first mixture with sufficient aqueous alkaline silicate solution to form a slurry
Implementation Method 2
combining the first solid with water and an ion exchange composition comprising one or more of sulfuric acid, aluminum sulfate, and/or ammonium sulfate, to form the catalyst precursor
Implementation Method 3
catalytic cracking, notably fluidized catalytic cracking (FCC), is a conventional process for converting higher average molecular weight, higher boiling hydrocarbons to more valuable, lower average molecular weight, lower boiling hydrocarbons
Implementation Method 4
Stripped deactivated catalyst contains a carbonaceous residue, called coke. Stripped catalyst recovered from the stripper is conducted to a regenerator, e.g., a fluidized bed regenerator, and contacted with a combusting gas, e.g., air, at elevated temperature to burn off the coke and reactivate the catalyst
Data Source
AI summary
This invention relates to a mesoporous catalytic cracking catalyst, a process for the production of such catalysts, and a process utilizing such catalysts in cracking operations. The mesoporous fluidized catalytic cracking catalyst is selective for minimizing the production of coke and light gas. The catalyst comprises an amorphous, porous matrix having pores ranging in diameter from about 1 Å to about 10 Å and ranging in diameter from about 40 Å to about 500 Å, but substantially free of pores ranging in diameter from about 10 Å to about 40 Å.