Composite Zeolite Catalysts for Light Olefin Yield
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Solution Overview
Problem
Existing catalysts for hydrocarbon-related processes, such as cracking hydro-treated atmospheric residue (HT AR) and hydro-treated vacuum gas oil (HT VGO), face challenges in achieving high conversions and selectivity to light olefins.
Innovation Solution
The catalysts comprise a first zeolite selected from ZSM-5 and Y zeolite impregnated with P2O5, and a second zeolite different from the first zeolite selected from ZSM-5 and Y zeolite impregnated with La2O3, along with alumina, clay, and silica.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing catalysts are used for hydrocarbon cracking, then the process can proceed, but conversions and yields of light olefins are insufficient
Solution Approach 1:
The patent employs a composite catalyst system comprising multiple zeolite types (ZSM-5 and Y zeolite) with distinct pore structures and acid properties, combined with matrix materials (alumina, silica, clay). This composite structure synergistically enhances both conversion rate and light olefin selectivity, resolving the contradiction between productivity and reliability by integrating materials with complementary functions.
Solution Approach 2:
The catalyst design incorporates local quality differentiation through the use of ZSM-5 zeolite with its specific channel structure for light olefin formation and Y zeolite with larger pores for heavy hydrocarbon cracking. Each component is strategically positioned and sized to perform its specialized function, thereby achieving high conversion and selective light olefin production simultaneously.
2Reliability
If a single zeolite type is used in the catalyst, then the catalyst structure is simple, but activity and selectivity to light olefins are limited
Solution Approach 1:
The patent combines multiple zeolite types (ZSM-5 and Y zeolite) with different pore structures and acid characteristics in a composite catalyst system. This composite approach enhances both activity and selectivity to light olefins while managing the increased complexity through optimized formulation and preparation methods, thereby resolving the contradiction between performance and structural simplicity.
Solution Approach 2:
The catalyst is segmented into distinct functional components: ZSM-5 for light olefin formation through its specific channel structure, Y zeolite for heavy hydrocarbon cracking with its larger pores, and matrix materials for structural support. This segmentation allows each component to perform its specialized function optimally, achieving high activity and selectivity despite the increased compositional complexity.
3Productivity
If conventional cracking processes are used, then the process is straightforward, but light olefin yield is not maximized
Solution Approach 1:
The catalyst undergoes preliminary impregnation with phosphorus and lanthanum during manufacturing, which modifies the acid sites and pore structure before the cracking process begins. This preliminary treatment enhances the catalyst's ability to produce light olefins while the standardized preparation steps keep the manufacturing process manageable, resolving the contradiction between maximizing yield and maintaining ease of manufacture.
Solution Approach 2:
The patent optimizes key parameters including the ratio of ZSM-5 to Y zeolite, phosphorus and lanthanum impregnation levels, and calcination temperature to maximize light olefin yield. By carefully controlling these parameters within specific ranges, the catalyst achieves high productivity while the preparation process remains practical and manufacturable, balancing performance enhancement with 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
These catalysts provide high conversions and yields of total light olefins, with enhanced activity and selectivity relative to other catalysts, thereby maximizing light olefin yield in hydrocarbon cracking processes.
Implementation Method 1
a first zeolite selected from ZSM-5 and Y zeolite impregnated with P2O5 and a second zeolite different from the first zeolite selected from ZSM-5 and Y zeolite impregnated with La2O3
Data Source
AI summary
The disclosure relates to catalysts that include a first zeolite selected from ZSM-5 and Y zeolite impregnated with P2O5 and a second zeolite different from the first zeolite selected from ZSM-5 and Y zeolite impregnated with La2O3. The catalysts can also include alumina, clay, and silica. The catalysts can be used for various hydrocarbon-related processes, such as cracking hydro-treated atmospheric residue (HT AR) and hydro-treated vacuum gas oil (HT VGO).