(168c) Preparation of the Novel Pore Structure Catalysts

For heavy oil cracking ,the pore structure of catalyst should be accessible for primary crackling of the large hydrocarbon molecules so that the forming smaller molecules can transfer into zeolite channels and further crack into the gasoline on zeolite activity site. However, the pore size of current FCC catalyst is not large enough for heavy oil cracking. A large pore size REUSY/SiO2-Al2O3 FCC catalyst was prepared using polystyrene (PS) particles as template. The FCC catalyst contain 15%REUSY and 85% SiO2-Al2O3. The volume ratio of the PS template to the catalyst is 1:1 and the PS particles template has the diameter in the range of 20~150nm. BET and Scanning Electron Microscope (SEM) are used to characterize the novel pore structure catalysts. It is found that the novel pore structure catalysts have higher surface areas, larger pore size and more pore voids than that of the catalyst prepared without PS template. The surface areas increased by 180m2/g and pore volumes by 0.2cm3/g. According to microactivity test, the novel pore structure catalyst showed higher heavy oil cracking ability. The conversion of a heavy oil on the novel pore structure FCC catalyst was reached 95%, while the converstion was only 70% using the catalyst prepared without PS template at the same reaction conditions.

Keywords: Template; PS particles; Heavy oil cracking; Large pore catalysts