MnO2-P2O5 Embedded Zeolite Catalyst for Hydrocarbon Cracking
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Solution Overview
Problem
Existing catalysts for hydrocarbon catalytic cracking lack thermal stability and acid site protection under high temperature and humidity conditions, leading to reduced catalytic activity and yield of light olefins.
Innovation Solution
A hydrocarbon cracking catalyst is developed with 0.01-5.0 wt% MnO2 and 1-15 wt% P2O5 supported on a catalyst component comprising 1-50 wt% ZSM-5 zeolite, 21-70 wt% clay, and 1-40 wt% inorganic oxide, where MnO2 and P2O5 are embedded on the zeolite, clay, and inorganic oxide, enhancing thermal stability and acid site protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If microporous molecular sieve catalyst is used in high temperature steam atmosphere, then catalytic activity is maintained, but structural breakdown occurs due to dealumination
Solution Approach 1:
The patent uses a composite catalyst structure combining zeolite microporous molecular sieve with clay matrix and inorganic oxide coating. The clay matrix provides structural support while the inorganic oxide coating (alumina, silica, or silica-alumina) protects the zeolite framework from dealumination in high temperature steam atmosphere, resolving the contradiction between maintaining catalytic activity and structural stability.
Solution Approach 2:
The patent modifies the chemical composition parameters of the catalyst by controlling the ratio of zeolite to clay (1:0.5 to 5:1 by weight) and the composition of inorganic oxide coating. These parameter changes optimize both the catalytic activity and thermal stability of the catalyst under high temperature steam conditions.
2Productivity
If acid site amount is increased for higher conversion, then light olefin yield increases, but dehydrogenation reaction increases producing unwanted saturated hydrocarbons
Solution Approach 1:
The patent creates local quality differentiation by using ZSM-5 zeolite with specific pore structure and acid site distribution. The clay matrix and inorganic oxide coating provide localized protection and modification of acid sites, allowing optimization of catalytic activity for light olefin production while controlling dehydrogenation reactions that produce unwanted saturated hydrocarbons.
3Strength
If complex matrix and bonding agent are used for high mechanical strength, then catalyst durability improves, but thermal stability and catalytic activity decrease
Solution Approach 1:
The patent optimizes the parameter ratios of catalyst components, specifically setting zeolite to clay ratio between 1:0.5 and 5:1 by weight, and using inorganic oxide content between 1-40 wt%. This parameter optimization achieves high mechanical strength through the clay matrix while maintaining thermal stability through the inorganic oxide coating and controlled zeolite content.
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 exhibits improved thermal stability and high yield of light olefins by protecting acid sites, facilitating efficient catalytic cracking of hydrocarbons, and is economical due to a simplified synthesis process.
Implementation Method 1
0.01-5.0 wt% of MnO2 and 1-15 wt% of P2O5 are simultaneously supported on a catalyst component, wherein both MnO2 and P2O5 are embedded on each of the zeolite, the clay and the inorganic oxide
Implementation Method 2
Catalyst for catalytic cracking of hydrocarbon, which is used in production of light olefin
Implementation Method 3
the acid sites of the catalyst will be reduced, resulting in a rapid reduction in catalytic activity
Data Source
Figure 1
AI summary
A molecular sieve catalyst and a preparation method thereof to produce light olefins from catalytically cracking naphtha in severe environments of high temperature and high moisture, are disclosed. In detail, the catalyst is prepared by spray-drying and calcining the mixed slurry, in which 0.01~5.0 wt% of MnO2 and 1~15 wt% of P2O5 are simultaneously embedded in catalyst which consists of zeolite, clay and inorganic complex. According to the present invention, the method that manganese and phosphate are embedded simultaneously in zeolite and inorganic complex is used to increase thermal-stability of obtained spherical catalyst, and increase olefin yield of cracking hydrocarbon such as naphtha by protecting acid-site of zeolite. To synthesize the required catalyst, the important procedures are mixing ratio and mixing sequence of Mn, P, zeolite, and inorganic complex.