DEVELOPMENT OF CRACKING CATALYSTS

• Main Author: Yusuf Putra Hudaya, Farhansyah
• Format: Theses
• Language: Indonesia
• Online Access: https://digilib.itb.ac.id/gdl/view/83170
• Institution: Institut Teknologi Bandung

In 2022, fuel consumption in Indonesia reached 477 million barrels, with gasoline accounting for 48.7% of this total. The majority of gasoline demand is met through the cracking process, specifically fluid catalytic cracking (FCC). This is achieved with the assistance of a composite catalyst comprising zeolite Y, active matrix, filler, binder, and additives. The diffusional resistance of large hydrocarbon molecules to access active sites on the microporous structure of zeolite Y represents a significant obstacle in the FCC process. The utilisation of an active matrix represents a potential solution to this problem. Anggaswara and Hudaya (2023) have investigated the process of making an active matrix from kaolin with a surface area of 144.23 m²/g and cracking conversion of up to 70.0%-b/b. However, the development of an FCC catalyst composite with an active matrix has not been investigated. The objective of this research was to ascertain the ratio of zeolite to active matrix in an FCC catalyst, with the aim of achieving high conversion, high yields of gasoline, propylene, butylene, and diesel. The active matrix and zeolite Y were synthesised using hydrothermal method. Fumed silica and metakaolin were used as the binder and filler, respectively. The catalyst composite was synthesised using the dry mixing method. The composition of the zeolite and active matrix was varied in order to obtain a zeolite to active matrix ratio (Z/M) of between 0.20–1.00. Furthermore, the impact of incorporating ZSM-5 additive and implementing a regeneration treatment was also investigated. Subsequently, the catalysts were subjected to analysis via X-ray fluorescence, Brunauer-Emmet-Teller (BET), Barret-Joyner-Halenda (BJH), X-ray diffraction, and NH3-temperature programmed desorption in order to determine their composition, surface characteristics, crystal characteristics, and acidity. The intrinsic cracking activity was evaluated through a microactivity test. The resulting gas and liquid products were analysed using gas chromatography, while the coke was analysed using thermogravimetric analysis. The results demonstrated that the optimal cracking conversion can be attained within the Z/M ratio range of 0.71–1. Additionally, the optimal gasoline and diesel yield was observed at a Z/M ratio of 0.71 and 0.20 respectively. The highest propylene yield was achieved on a catalyst with a Z/M ratio of 0.71 and a ZSM-5 additive content of 5%-mass. The addition of ZSM-5 has been observed to increase the propylene yield by two times, while simultaneously decreasing the gasoline yield by half times. The one-time reaction and regeneration process has been demonstrated to affect the surface characteristics of the FCC catalyst, yet it does not impact the intrinsic cracking activity