Zeolite Beta Catalyst for Light Olefin Yield

The patent uses a composite catalyst system combining zeolite beta with metal components (Fe, Co, Ni, Cu, Mn, Zn, or Sn) and phosphorus modification. This composite structure integrates the shape-selective cracking ability of zeolite beta with the dehydrogenation activity of metals, while phosphorus modification suppresses excessive coke formation. The composite catalyst achieves both high light olefin production and reduced catalyst deactivation.

The patent modifies the catalyst's chemical composition by introducing phosphorus and specific metal oxides in controlled amounts. This changes the surface properties and active site distribution of the catalyst, optimizing the balance between dehydrogenation activity and coke resistance. The modified catalyst maintains high productivity while reducing harmful coke formation.

The patent employs a composite catalyst consisting of zeolite beta as the base material with added metal components and phosphorus modification. This composite structure provides both high light olefin selectivity (achieving over 15% yield) and maintains operational simplicity. The catalyst can be used in conventional fluidized bed or moving bed reactors without requiring complex process modifications.

The patent introduces specific metal components and phosphorus modification at localized active sites within the zeolite beta structure. This creates regions with enhanced dehydrogenation activity and shape-selective cracking capability, while the bulk catalyst structure remains stable and easy to handle. The local modification approach improves light olefin yield without complicating the overall process operation.

The patent uses a composite catalyst with zeolite beta as the framework, incorporating metal oxides (Fe, Co, Ni, Cu, Mn, Zn, or Sn) and phosphorus modification. This composite structure achieves high propylene and butylene yields through synergistic effects: zeolite beta provides shape-selective cracking, metals provide dehydrogenation activity, and phosphorus modification optimizes acid site distribution. The multi-component catalyst is prepared by conventional impregnation and calcination methods, maintaining reasonable complexity while achieving superior performance.

The composite catalyst performs multiple functions simultaneously: cracking of hydrocarbon feedstocks, dehydrogenation to form olefins, and shape-selective product distribution. The zeolite beta framework, metal components, and phosphorus modification work together to achieve high light olefin yield without requiring separate catalysts for each function, thus managing complexity while improving productivity.

The patent modifies the catalyst's chemical composition by introducing phosphorus and controlled amounts of metal oxides. This changes the surface chemistry and active site characteristics, optimizing the reaction rate while suppressing coke formation. The modified catalyst maintains high reaction speed for light olefin production but shows improved resistance to deactivation, enhancing long-term reliability.

The patent acknowledges that dehydrogenation activity inherently promotes coke formation, but converts this harmful effect into a benefit by using controlled metal components that provide moderate dehydrogenation activity. The phosphorus modification and zeolite beta structure work together to limit excessive coke formation while maintaining the desired reaction rate. The catalyst design accepts some coke formation as inevitable but manages it within acceptable limits to maintain reliability.