Modified ZSM-5 for steam enhanced catalytic cracking of crude oil to light olefins and aromatics
A process for upgrading a hydrocarbon feed comprises contacting the hydrocarbon feed with steam in the presence of a cracking catalyst composition at reaction conditions sufficient to cause at least a portion of hydrocarbons in the hydrocarbon feed to undergo one or more cracking reactions to produce a steam catalytic cracking effluent comprising light olefins, light aromatic compounds, or both, where the cracking catalyst composition comprises a cracking additive comprising metal species impregnated on a ZSM-5 zeolite, where the metal species comprises a metal selected from the group consisting of chromium, vanadium, iron, platinum, molybdenum, cerium, and nickel.
1. A process for upgrading a hydrocarbon feed, the process comprising:
passing the hydrocarbon feed to a steam catalytic cracking reactor, where the hydrocarbon feed comprises a crude oil having an API gravity of from 25 to 50; and
contacting the hydrocarbon feed with steam in the presence of a cracking catalyst composition in the steam catalytic cracking reactor at reaction conditions sufficient to cause at least a portion of hydrocarbons in the hydrocarbon feed to undergo one or more cracking reactions to produce a steam catalytic cracking effluent comprising light olefins, light aromatic compounds, or both, where:
the cracking catalyst composition comprises a zeolite catalyst and a cracking additive;
the cracking additive consists of cerium oxide impregnated on a ZSM-5 zeolite;
the zeolite catalyst is different from the ZSM-5 zeolite of the cracking additive; and
the cracking additive comprises from 2 wt. % to 10 wt. % of the cerium oxide based on a total weight of the cracking additive.
2. The process of claim 1 , where the ZSM-5 zeolite of the cracking additive has a molar ratio of silica to alumina of from 20 to 300.
3. The process of claim 1 , where:
the ZSM-5 zeolite has a molar ratio of silica to alumina of 30.
4. The process of claim 1 , where the cracking additive has an average particle size of 300 micrometer (μm) to 2000 μm.
5. The process of claim 1 , where the cracking additive has a surface area of from 200 (square meter per gram) m 2 /g to 400 m 2 /g.
6. The process of claim 1 , where the cracking additive has an average pore diameter of from 3 nanometers (nm) to 10 nm.
7. The process of claim 1 , where the zeolite catalyst comprises an equilibrium catalyst.
8. The process of claim 1 , where an amount of the cracking additive in the cracking catalyst composition is from 20 wt. % to 30 wt. % based on the cracking catalyst composition.
9. The process of claim 1 , where the cracking additive is prepared by a method comprising:
preparing a zeolite mixture comprising the ZSM-5 zeolite and water;
while mixing the zeolite mixture, adding a cerium oxide precursor mixture to the zeolite mixture to produce a combined mixture, where the cerium oxide precursor mixture comprises a cerium oxide precursor and water;
stirring the combined mixture at a temperature of from 10 Celsius (° C.) to 30° C. for a mixing time of from 1 hour to 5 hours;
heating the combined mixture to an evaporation temperature of from 30° C. to 100° C. while stirring;
maintaining the combined mixture at the evaporation temperature for a period of time from 1 hours to 24 hours, while stirring, where:
maintaining the combined mixture at the evaporation temperature while mixing causes water to slowly evaporate from the combined mixture to produce solid particles; and
slowly evaporating the water from the combined mixture while mixing disperses the cerium oxide precursor over the surfaces of the ZSM-5 zeolite; and
calcining the solid particles at a temperature of from 400° C. to 800° C. for 1 hour to 12 hours to produce the cracking additive.
10. The process of claim 1 , wherein the cracking catalyst composition consists of:
from 70 wt. % to 80 wt. % of the zeolite catalyst; and
from 20 wt. % to 30 wt. % of the cracking additive based on the total weight of the cracking catalyst composition.
11. The process of claim 1 , where the crude oil has a density of greater than or equal to 0.80 grams per milliliter or an end boiling point of from 500° C. to 1000° C.
12. The process of claim 1 , wherein the cracking catalyst composition consists of the zeolite catalyst and the cracking additive.
13. A cracking catalyst composition for upgrading a hydrocarbon feed, wherein the cracking catalyst composition comprises:
a zeolite catalyst; and
a cracking additive consisting of cerium oxide impregnated on a ZSM-5 zeolite,
where the zeolite catalyst is different from the ZSM-5 zeolite of the cracking additive, and
where the cracking additive comprises from 2 wt. % to 10 wt. % of the cerium oxide based on a total weight of the cracking additive.