Novel composite material with a wide pore distribution was synthesized by an in situ technique using spent FCC catalyst as raw material. The characterization results indicated that the composite material contained 56.7% of zeolite Y and exhibited a much larger specific surface area and pore volume as well as strong hydrothermal stability. Fluid catalytic cracking(FCC) catalyst was prepared based on the composite material. The results indicated that the as-prepared catalyst possessed a unique pore structure that was advantageous to the diffusion-controlled reactions. In addition, the attrition resistance, activity and hydrothermal stability of the studied catalyst were superior to those of the reference catalyst. The catalyst also exhibited excellent nickel and vanadium passivation performance, strong bottoms upgrading selectivity, and better gasoline and coke selectivity. In comparison to the reference catalyst, the yields of the gasoline and light oil increased by 1.61 and 1.31 percentage points, respectively, and the coke yield decreased by 0.22 percentage points, and the olefin content in the produced gasoline reduced by 2.51 percentage points, with the research octane number increased by 0.7 unit.
This paper has provided an effective method to utilize the flter residue. A Y zeolite-containing composite and a fuid catalytic cracking （FCC） catalyst had been successfully prepared by an in-situ crystallization technology using flter residue and kaolin as raw materials. The samples were characterized by XRD, FT-IR, SEM, and N2 adsorption-desorption techniques and evaluated in a bench FCC unit. In comparison to the reference samples synthesized from single kaolin, the silica/alumina molar ratio, the external surface area, and the total pore volume of the composite increased by 16.2%, 14.5%, and 16.2%, respectively. The catalyst possessed more meso- and macro-pores and more acid sites than the reference catalyst, and exhibited better coke selectivity. The prepared catalyst had the optimum isomerization and aromatization performance. The olefn content in the cracked gasoline obtained over this catalyst was reduced by 5.05 percentage points with the research octane number of gasoline increased by 0.5 units.
In this paper,the kaolin/urea intercalation composites prepared by direct intercalation method and the catalysis composites containing ZSM-5 molecular sieve synthesized based on the kaolin/urea intercalation composites by an in-situ crystallization technique were investigated.The effects of the intercalation ratios and de-intercalation rate and the amounts of added kaolin/urea intercalation composite on the synthesis of the catalysis composites containing the ZSM-5 molecular sieve were studied.The samples were characterized by X-ray diffraction,FT-IR,TG-DTA,N2 adsorption-desorption,and SEM,respectively.The results showed that the structure of the samples prepared by kaolin/urea intercalation composite was pure ZSM-5 molecular sieve.The crystallinity of ZSM-5 molecular sieve increased at first and then decreased with the increase of intercalation ratio of kaolin/urea intercalation composite.When the intercalation ratio was 62%,the crystallinity of ZSM-5 molecular sieve was lower.When the amount of added kaolin/urea intercalation composite with an intercalation ratio of 22%was 3%,the crystallinity of ZSM-5 zeolite was improved to reach 65%.Compared to the crystallization product formed without adding kaolin/urea intercalation composite,the crystallinity of ZSM-5 molecular sieve has increased by 54.8%.The catalytic composites containing ZSM-5 molecular sieve had better thermal stability with a wide pore structure,featuring a particle diameter of about 2.5μm,a BET specific surface area of 236 m^2/g,and a pore size of 10.6 nm.
