Phosphorus-Metal Modified Zeolite Beta Catalyst for Light Olefin Yield
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Solution Overview
Problem
Current hydrocarbon conversion catalysts for producing light olefins, such as C2-C4 olefins, have limitations in yield and selectivity, particularly for propylene production, due to coke formation and restricted feedstock boiling ranges, which are not adequately addressed by existing zeolite-based catalysts.
Innovation Solution
A hydrocarbon conversion catalyst comprising a zeolite mixture with modified zeolite beta, a thermotolerant inorganic oxide, and clay, where the zeolite beta is modified with phosphorus and a metal (Fe, Co, Ni, Mn, or Sn), enhancing hydrothermal stability and olefin selectivity, thereby increasing the yield of C2-C12 olefins for further cracking into C2-C4 olefins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If metal-supported catalysts with dehydrogenation activity are used, then light olefin production is accelerated, but coke formation increases and feedstock boiling range is restricted
Solution Approach 1:
The patent uses a composite catalyst system combining zeolite beta (providing cracking activity and shape selectivity) with modified MFI structure zeolite (enhancing olefin production). This composite approach allows the catalyst to achieve high light olefin yield without excessive coke formation, as the zeolite components work synergistically to balance dehydrogenation and cracking functions while maintaining feedstock versatility.
2Quantity of substance
If conventional catalytic cracking is used for gasoline and light diesel production, then these products are obtained, but light olefin yield is limited to less than 15 wt%
Solution Approach 1:
The patent modifies the MFI structure zeolite with specific metals (Fe, Co, Ni, Mn, or Zn) to create local active sites with enhanced dehydrogenation activity. This local modification allows the catalyst to selectively promote light olefin formation from diesel oil and heavy oil cracking, achieving over 15 wt% light olefin yield while maintaining acceptable gasoline and light diesel production.
3Quantity of substance
If zeolite beta is used to enhance hydrothermal stability and olefin selectivity, then C2-C12 olefin yield increases, but catalyst complexity increases
Solution Approach 1:
The patent optimizes the SiO2/Al2O3 ratio in zeolite beta to specific ranges (20-100:1) and controls the content of modifying metals (0.1-5.0 wt% each) to achieve the desired balance between olefin yield and catalyst complexity. By carefully adjusting these parameters, the catalyst achieves high C2-C12 olefin yield while maintaining manageable composition complexity and manufacturing feasibility.
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 significantly improves the selectivity and yield of light olefins, particularly propylene, by enhancing the cracking of diesel oil and heavy oil, while maintaining high hydrothermal stability and reducing coke formation.
Implementation Method 1
the zeolite beta has both acid catalytic property and structural selectivity due to its structural particularity
Implementation Method 2
said zeolite beta modified with phosphorus and the metal M simultaneously, it not only enhances the hydrothermal stability of said zeolite beta
Implementation Method 3
the catalyst provides a higher yield of C 2 -C 12 olefins, which are just the effective precursors for the production of C 2 -C 4 olefins by further cracking
Data Source
AI summary
A hydrocarbon conversion catalyst, which comprises, based on the total weight of the catalyst, 1-60 wt% of a zeolite mixture, 5-99 wt% of a thermotolerant inorganic oxide and 0-70 wt% of clay, wherein said zeolite mixture comprises, based on the total weight of said zeolite mixture, 1-75 wt% of a zeolite beta modified with phosphorus and a transition metal M, 25-99 wt% of a zeolite having a MFI structure and 0-74 wt% of a large pore zeolite, wherein the anhydrous chemical formula of the zeolite beta modified with phosphorus and the transition metal M is represented in the mass percent of the oxides as (0-0.3)Na2O·(0.5-10)Al2O3·(1.3-10)P2O5·(0.7-15)MxOy·(64-97)SiO2, in which the transition metal M is one or more selected from the group consisting of Fe, Co, Ni, Cu, Mn, Zn and Sn; x represents the atom number of the transition metal M, and y represents a number needed for satisfying the oxidation state of the transition metal M. The catalysts provided in the present invention have higher ability to convert petroleum hydrocarbons and higher yields for light olefins, particularly for propylene. The catalysts can be used for the selectively producing light olefins.