Rare Earth Oxophosphorus Catalyst for Vanadium Trapping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Vanadium contamination in fluid catalytic cracking (FCC) catalysts is detrimental, and existing vanadium traps using rare earth metals like lanthanum are not sufficient, affecting catalyst performance and requiring improved solutions.
Innovation Solution
Incorporating rare earth oxophosphorus components, particularly lanthanum phosphate, into the catalyst composition to minimize vanadium's detrimental effects and enhance catalyst performance, including the use of zeolites, silica, and aluminum-containing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If rare earth metals like lanthanum are used as vanadium traps, then vanadium contamination is reduced, but catalyst performance is adversely affected
Solution Approach 1:
The patent uses composite materials by combining rare earth metals with phosphorus-containing compounds to form rare earth oxophosphorus components. This composite approach allows the material to simultaneously trap vanadium and maintain catalytic activity, resolving the contradiction between vanadium trapping capability and catalyst performance.
Solution Approach 2:
The patent modifies the chemical composition parameters by introducing phosphorus to the rare earth metal system, creating rare earth oxophosphorus components with specific compositional ratios. This parameter change enables the material to achieve both effective vanadium trapping and preserved catalytic function.
2Object-affected harmful factors
If rare earth metals are used to trap vanadium, then vanadium effects are minimized, but the complexity of catalyst composition increases
Solution Approach 1:
The patent merges the vanadium trapping function with the catalytic function by integrating rare earth oxophosphorus components into the catalyst composition. This combining approach allows a single material system to perform multiple functions, reducing overall composition complexity while maintaining effectiveness.
Solution Approach 2:
The rare earth oxophosphorus components serve multiple functions: they act as vanadium traps, maintain catalytic activity, and stabilize the catalyst structure. This multi-functionality reduces the need for separate additives, thereby simplifying the overall catalyst composition.
3Object-affected harmful factors
If conventional vanadium traps are used, then vanadium contamination is addressed, but propylene yield is reduced and coke formation increases
Solution Approach 1:
The patent changes the chemical parameters of the vanadium trap by using rare earth oxophosphorus components instead of conventional rare earth metals. This parameter change results in improved catalytic properties that increase propylene yield and reduce coke formation while maintaining vanadium trapping capability.
Solution Approach 2:
The use of composite rare earth oxophosphorus materials provides superior catalytic performance compared to simple rare earth metal compounds. The composite structure enables better mass transfer and active site accessibility, leading to improved propylene yield and reduced coke formation.
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 effectively traps vanadium, maintains catalyst performance, and increases propylene yield while reducing coke and dry gas formation during fluid catalytic cracking.
Implementation Method 1
The vanadium trapping or passivation mechanism is believed to involve binding of vanadium to the rare earth metal
Data Source
AI summary
This invention is directed to a catalyst composition comprising one or more rare earth oxophosphorus components, and process for making such.