Modified ZSM-5 Catalyst for Higher Light Olefin and Aromatic Yields
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Solution Overview
Problem
Conventional refinery systems face challenges in achieving high selectivity for light olefins and light aromatic compounds during the steam enhanced catalytic cracking of crude oil using ZSM-5 zeolites, as they often result in lower yields of these valuable products.
Innovation Solution
A cracking catalyst composition is developed that includes a metal species impregnated on a ZSM-5 zeolite, such as chromium, vanadium, iron, platinum, molybdenum, or cerium, which is prepared by a method involving mixing with water, evaporation, and calcination to enhance dispersion, thereby improving the conversion of crude oil to light olefins and aromatic compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional ZSM-5 zeolite is used for steam enhanced catalytic cracking, then the process is simple, but the yield of light olefins and light aromatic compounds is low
Solution Approach 1:
The patent applies composite materials by combining metal species (such as chromium, vanadium, iron, platinum, molybdenum, or cerium) with ZSM-5 zeolite to create a composite catalyst. This composite structure integrates the cracking activity of ZSM-5 with the selective properties of the metal species, thereby increasing the yield of light olefins and light aromatic compounds while managing the added complexity through systematic catalyst design
2Productivity
If metal species are impregnated on ZSM-5 zeolite to improve product yield, then the yield of light olefins and aromatic compounds increases, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by performing metal species impregnation on the ZSM-5 zeolite before the cracking reaction. The metal species are pre-loaded onto the zeolite support through impregnation followed by drying and calcination, creating a pre-assembled catalyst that is ready for use. This preliminary preparation ensures optimal distribution of metal species and activates the catalyst for enhanced cracking performance
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 significantly enhances the yield of light olefins and aromatic compounds, achieving yields of up to 40-60% and 15-45% respectively, compared to conventional methods, by ensuring greater dispersion of the metal species on the ZSM-5 zeolite surfaces.
Implementation Method 1
a cracking catalyst composition is developed that includes a metal species impregnated on a ZSM-5 zeolite
Implementation Method 2
which is prepared by a method involving mixing with water, evaporation, and calcination
Implementation Method 3
contacting the hydrocarbon feed with steam in the presence of a cracking catalyst composition at reaction conditions sufficient to cause at least a portion of hydrocarbons in the hydrocarbon feed to undergo one or more cracking reactions
Data Source
AI summary
A process for upgrading a hydrocarbon feed comprises contacting the hydrocarbon feed with steam in the presence of a cracking catalyst composition at reaction conditions sufficient to cause at least a portion of hydrocarbons in the hydrocarbon feed to undergo one or more cracking reactions to produce a steam catalytic cracking effluent comprising light olefins, light aromatic compounds, or both, where the cracking catalyst composition comprises a cracking additive comprising metal species impregnated on a ZSM-5 zeolite, where the metal species comprises a metal selected from the group consisting of chromium, vanadium, iron, platinum, molybdenum, cerium, and nickel.