Stabilized Zeolite Beta Catalyst for FCC Hydrothermal Degradation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Zeolite Beta catalysts used in fluid catalytic cracking processes face degradation under hydrothermal conditions due to coke accumulation and steam exposure, leading to reduced stability and efficiency.
Innovation Solution
Hydrothermally stabilized zeolite Beta is modified with 0.5 wt% or more of lanthanide series elements, phosphorus, or a combination thereof, such as lanthanum, to enhance structural stability and maintain catalytic activity under harsh processing conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If zeolite Beta is used as a catalyst in fluid catalytic cracking, then catalytic activity is achieved, but structural stability deteriorates under hydrothermal conditions
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition of zeolite Beta through incorporation of heteroatoms (gallium, germanium, tin, titanium, or zinc) at specific levels (0.1-5.0 mmol per mole of framework Al). This compositional parameter change enhances the zeolite's resistance to hydrothermal degradation while maintaining its catalytic framework structure and 12-ring pore channels.
Solution Approach 2:
The patent creates a composite material by integrating heteroatom-modified zeolite Beta into a catalyst system containing binder materials and optional additives. This composite structure combines the catalytically active zeolite component with supportive binder materials, creating a more robust catalyst that maintains structural integrity under hydrothermal cracking conditions.
2Reliability
If coke accumulation occurs on the catalyst, then catalytic activity decreases, but regeneration exposes the catalyst to harsh steam conditions
Solution Approach 1:
The patent applies preliminary action by pre-modifying the zeolite Beta framework with heteroatoms before the catalyst is subjected to hydrothermal conditions during regeneration. This advance structural reinforcement prevents framework collapse and aluminum leaching that would otherwise occur during high-temperature steam exposure, allowing the catalyst to withstand repeated regeneration cycles.
3Ease of manufacture
If zeolite Beta is synthesized without organic structure directing agent, then production cost and complexity are reduced, but hydrothermal stability is insufficient
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition of template-free synthesized zeolite Beta through heteroatom incorporation. This compositional modification compensates for the reduced structural order inherent in template-free synthesis, enhancing hydrothermal stability to levels suitable for FCC applications while maintaining the synthesis advantages of no organic template required.
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 modified zeolite Beta exhibits improved structural stability and catalytic activity, retaining a higher percentage of aluminum in tetrahedral positions and maintaining high Alpha values even after exposure to hydrothermal processing conditions, making it suitable for sustained use in fluid catalytic cracking environments.
Implementation Method 1
The catalyst can include hydrothermally stabilized zeolite Beta that has been modified with 0.5 wt % or more of a lanthanide series element, phosphorus, or a combination thereof
Data Source
AI summary
Methods are provided for performing fluid catalytic cracking (and/or other hydrothermal processing for cracking of hydrocarbons) on a feedstock containing hydrocarbons in the presence of a catalyst that includes zeolite Beta that is stabilized toward hydrothermal conditions. The hydrothermally stabilized zeolite Beta (including any of the various polymorphs) corresponds to zeolite Beta that is formed without the use of an organic structure directing agent, and that is further stabilized by addition of one or more stabilizers, such as lanthanide series elements or phosphorus.