Modified ZSM-5 Catalyst for Steam-Enhanced Crude Oil Cracking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional refinery systems face challenges in producing high yields of light olefins and light aromatic compounds from crude oil, as existing steam enhanced catalytic cracking methods using ZSM-5 zeolites have lower selectivity and efficiency.
Innovation Solution
A cracking catalyst composition is developed, comprising a metal species impregnated on a ZSM-5 zeolite, such as chromium, vanadium, iron, platinum, molybdenum, or cerium, which enhances the dispersion of the metal species across the zeolite surfaces, improving the selectivity and yield of light olefins and aromatic compounds through steam catalytic cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional steam enhanced catalytic cracking methods using ZSM-5 zeolites are used, then crude oil can be converted to light olefins and aromatic compounds, but the selectivity and yield are lower
Solution Approach 1:
The patent applies local quality by impregnating metal species (such as Pt, Pd, Rh, Ru, Ir, Os, or their oxides) onto specific regions of the ZSM-5 zeolite catalyst. This creates localized active sites with enhanced catalytic properties, where the metal species are distributed throughout the zeolite structure to provide specific catalytic functions that improve both selectivity and yield of light olefins and aromatic compounds.
Solution Approach 2:
The patent employs composite materials by combining ZSM-5 zeolite with impregnated metal species to create a composite catalyst system. The ZSM-5 zeolite provides the structural framework and acid catalytic sites, while the impregnated metal species contribute additional catalytic functionality, resulting in a composite catalyst that achieves superior selectivity and productivity compared to conventional single-component catalysts.
2Productivity
If metal species are impregnated on ZSM-5 zeolite to improve selectivity and yield, then conversion to light olefins and aromatic compounds increases, but the catalyst composition becomes more complex
Solution Approach 1:
The patent applies merging by integrating multiple functional components into a single catalyst formulation. The ZSM-5 zeolite and metal species are combined through impregnation to create a unified catalyst system that performs multiple catalytic functions simultaneously, improving conversion efficiency while maintaining a practical and manufacturable catalyst structure.
Solution Approach 2:
The patent employs parameter changes by adjusting the impregnation conditions, metal loading amounts, and calcination parameters to optimize the catalyst performance. By carefully controlling these parameters, the patent achieves high conversion efficiency while managing the complexity of the catalyst composition through systematic optimization rather than arbitrary complexity.
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 increases the conversion of crude oil to light olefins and aromatic compounds by enhancing the dispersion of metal species on ZSM-5 zeolite surfaces, leading to improved selectivity and yield compared to conventional methods.
Implementation Method 1
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.