Framework-Substituted Zeolite Catalyst for FCC Product Selectivity
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Solution Overview
Problem
The fluidized catalytic cracking (FCC) industry faces challenges in reducing the production of dry gas and coke while maximizing the production of gasoline and light olefins, as existing catalysts do not effectively balance these outcomes.
Innovation Solution
A catalyst comprising a framework-substituted ultra-stable Y-type zeolite with zirconium and/or hafnium atoms substituted for aluminum atoms, along with optional titanium substitution, is used to enhance cracking activity and reduce dry gas and coke production, characterized by specific crystal lattice constants, surface areas, and silica-alumina ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional FCC catalysts are used, then cracking activity is maintained, but production of dry gas and coke increases
Solution Approach 1:
The patent applies parameter changes by substituting aluminum atoms in the zeolite framework with zirconium and/or hafnium atoms. This atomic substitution modifies the chemical and physical parameters of the catalyst, including acid site density, pore structure, and thermal stability, thereby improving selectivity toward gasoline and light olefins while reducing dry gas and coke formation
Solution Approach 2:
The patent employs composite materials by creating a framework-substituted zeolite that combines multiple elements (aluminum, zirconium, hafnium, and optionally titanium) within the zeolite structure. This composite approach at the atomic level generates synergistic effects that enhance cracking activity for desired products while suppressing harmful byproducts
2Productivity
If framework-substituted ultra-stable Y-type zeolite with zirconium and/or hafnium substitution is used, then gasoline and light olefins production increases, but catalyst complexity increases
Solution Approach 1:
The patent applies local quality by introducing zirconium and/or hafnium atoms at specific locations within the zeolite framework rather than uniformly throughout. This localized substitution at atomic sites creates specific active centers that enhance gasoline and light olefins production while maintaining overall catalyst simplicity and avoiding excessive complexity
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 effectively increases the production of gasoline and light olefins while minimizing dry gas and coke formation, optimizing the product slate in FCC processes.
Implementation Method 1
a catalyst for fluidized catalytic cracking of hydrocarbon oil including as a support, the zeolite in which a part of aluminum atoms constituting the zeolite framework is replaced with zirconium atoms and/or hafnium atoms
Data Source
AI summary
The present invention relates to a catalyst for fluidized catalytic cracking of hydrocarbon oil containing a framework-substituted zeolite-1 in which zirconium atoms and/or hafnium atoms form a part of a framework of an ultra-stable Y-type zeolite.