Value-Added Spent FCC Catalyst for Metal-Tolerant RFCC
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Solution Overview
Problem
Current Fluid Catalytic Cracking (FCC) catalysts are not cost-effective for processing heavy metal-laden feeds, leading to catalyst deactivation and the production of undesired products like coke and dry gas, necessitating the development of a more robust and metal-tolerant catalyst for Resid Fluid Catalytic Cracking (RFCC) operations.
Innovation Solution
A value-added spent FCC catalyst composition is created by introducing a rare earth or aluminum component as an activity enhancer, which provides simultaneous metal passivation and catalytic activity enhancement, improving thermal and metal stability, and increasing crystallinity and surface area, allowing for its reuse in RFCC processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional FCC catalysts are used for processing heavy metal-laden feeds, then catalyst cost is reduced, but catalyst deactivation increases and undesired products are produced
Solution Approach 1:
The patent modifies the catalyst composition by changing parameters such as adding metal passivators (antimony, arsenic, bismuth compounds) and adjusting the ratio of active components to create a catalyst that resists deactivation by nickel and vanadium while maintaining cost-effectiveness
Solution Approach 2:
The invention creates a composite catalyst material combining conventional FCC catalyst components with metal passivators and specific ratios of active components, resulting in a catalyst that simultaneously achieves cost-effectiveness and resistance to metal contamination deactivation
2Adaptability or versatility
If high metal tolerance catalysts are developed for RFCC, then processing capability improves, but catalyst complexity increases
Solution Approach 1:
The patent develops a catalyst composition that performs multiple functions simultaneously: it provides catalytic activity for cracking, passivates metals (nickel and vanadium), and maintains thermal stability, thereby achieving metal tolerance without requiring separate additives or complex multi-component systems
Solution Approach 2:
The invention merges the functions of catalytic activity and metal passivation into a single integrated catalyst composition, combining active components with metal passivators in specific ratios to create a unified material that addresses multiple requirements without increasing operational complexity
3Ease of manufacture
If spent FCC catalyst is reused for RFCC, then cost is reduced, but thermal stability and metal tolerance are insufficient
Solution Approach 1:
The patent applies preliminary treatment to spent FCC catalyst by introducing metal passivators and active components before reuse in RFCC, preparing the catalyst in advance to withstand thermal conditions and metal contamination that would otherwise cause deactivation
Solution Approach 2:
The invention changes the compositional parameters of spent catalyst by adding specific metal passivators (antimony, arsenic, bismuth compounds) and adjusting the ratio of active components, transforming the catalyst properties to achieve thermal stability and metal tolerance suitable for RFCC operation
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 value-added catalyst composition effectively enhances metal tolerance and catalytic activity, improving thermal stability and selectivity, enabling efficient processing of heavy metal-laden feeds and reducing catalyst deactivation rates, thus optimizing RFCC operations and reducing make-up rates.
Implementation Method 1
introducing a rare earth or aluminum component as an activity enhancer, which provides simultaneous metal passivation and catalytic activity enhancement
Implementation Method 2
provides simultaneous metal passivation and catalytic activity enhancement
Data Source
AI summary
A composition of a value added RFCC catalyst and a process of preparation of a composition for a dual function additive catalyst from a spent catalyst are disclosed. The value added spent FCC catalyst offers improved performance, options such as either employing as an additive for passivation of both vanadium and nickel and enhancing catalytic activity, for initial start-up or make-up for attrition losses. The value addition process does not harm any of physical properties of starting material with respect to ABD, attrition index, surface area and particle size distribution. Value added catalyst can be used in a range from 1-99 wt % in fluid catalytic cracking process in which, feeds may have higher metals and carbon.