In 2017 the global demand for oil has reached more than 97 million barrels/day and a major portion of the gasoline/LPG blending stock, manufactured in the world, is produced by fluid catalytic cracking process. The primary component for all FCC catalysts is synthetic Faujasite zeolite or Y-zeolite which is dispersed in an amorphous matrix containing different functionalities. In FCC unit, catalyst come into continuous contact with a variety of hydrocarbons feed molecules at elevated temperature and pressure for only a few seconds in order to produce the key petrochemical products, including majority of transportation fuels, LPG and light olefins. Hence diffusion of hydrocarbon molecule is a critical parameter in this process and maximizing diffusion of feed into and products out of an FCC catalyst is crucial for unlocking the full value potential of a FCC unit.<br/>To address this key issue, Rive Technology has developed and commercialized Molecular Highway™ Technology which contains a precise series of mesopores engineered into the Y zeolite, promoting improved diffusion of FCC feed molecules into, and products out of the zeolite crystals of the FCC catalyst. Through a collaborative effort between W.R. Grace & Co. (Grace), and Rive Technology (Rive), an innovative catalyst solution incorporating Rive’s mesoporous zeolite was designed and have been successfully tested in the lab and out in the field. Detail studies have been conducted using Davison circulating riser and fixed fluidized bed reactor to understand the shift in product selectivity for FCC catalysts containing RIVE Zeolite. Improved diffusion results in a significant decrease in over-cracking to undesirable products, resulting in lowering undesirable coke and dry gas formation, and thereby boosting the C<sub>3</sub> + Total Liquid Volume yield. In addition, improved diffusivity reduces the secondary cracking reaction and lower hydrogen transfer, thus enhancing LPG and gasoline olefinicity.

Development and application of FCC catalyst integrating innovative Rive’s mesoporous Y zeolite

255th National Meeting (2018)

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