Heterogeneous catalyst engineering ⇒ from stable and deactivation resistant to viable technical catalyst

Problem statement

Advances in heterogeneous catalyst “structure” are driven to improve their “function” or performance, i.e., activity, selectivity, and stability. Cooperative research is required to understand the structure and function relationships: developing new synthesis protocols for heterogeneous catalysts with unique surface properties, defined porosity, identification and understanding of catalytically active sites, reaction mechanisms, and finally, prediction and analysis of the processes using various computational tools.

Our group focuses on developing new catalyst formulations using innovative synthesis routes for various important heterogeneous catalysts. That includes thermal, electro, and bio-electro catalysis.

The active phase cannot be used directly in its final application or reactor for various reasons, including poor mechanical resistance, heat or mass transport, and fluidization features. We must mix the active phase with other ingredients in a matrix of binder and filler, while we shape it into a technical catalyst. We investigate new synthetic protocols for technical catalysis using spray drying and fluidized beds to cover the whole range of sizes. At the same time, we incorporate additional (unconventional) ingredients such as SiC to improve some features even further.

Goals

  • Technical catalyst I ⇒ spray drying and extrusion
  • Technical catalyst II ⇒ spray fluidized bed reactor
  • Technical catalyst III ⇒ electrospinning
  • Zeolite catalysts ⇒ with defined structure/porosity
  • Multi-metal (high entropy) alloy catalysts
  • MXene catalysts ⇒ single and multi-dimensional
  • Perovskite catalysts
  • Metal-organic framework (MOFs) catalysts
  • Supported metal/metal-oxide catalysts
  • Aerogel catalyst

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Effect of the Catalyst Properties in Polypropylene Pyrolysis Waxes Cracking under FCC Conditions

by Arandes, Torre, Azkoiti, Castaño, Bilbao, De Lasa
Catal. Today Year: 2008

Abstract

The catalytic cracking of polyolefin pyrolysis waxes has been studied under conditions that mimic the operation of a catalytic cracking unit (FCC). Two commercial catalysts of different properties were used. Yields and compositions of the lumps (dry gases, LPG, gasoline and coke) were compared with those corresponding to the actual feed in the refinery (vacuum gas-oil). The effect of process operating conditions (temperature and contact time) is significant. Catalyst acidity has a significant effect on conversion (at a temperature around 525 °C) and on yields and compositions of lumps (in the 500–550 °C range). The main effect of increasing catalyst acidity is an increase in coke content on the catalyst by decreasing the yield to dry gases. Due to the higher hydrogen transfer capacity, the gasoline obtained using the catalyst with higher acidity has a higher aromatic (especially C6–C8) and paraffinic content, and lower olefin content, being these two latter fractions less branched. An increase in catalyst acidity leads to a lower yield of light olefins and to an increase in the yield of paraffins.

Keywords

FCC W2C HCE