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KR-20260065866-A - Catalytic pyrolysis of plastics to produce petrochemical feedstocks

KR20260065866AKR 20260065866 AKR20260065866 AKR 20260065866AKR-20260065866-A

Abstract

The present invention generally relates to a catalyst composition comprising a mesoporous active matrix and phosphorus-stabilized ZSM-5, a method for preparing such a composition, and a method for using such a composition in a fluidized bed or conical jet bed reactor for the catalytic pyrolysis of plastics into olefins and aromatic compounds. The method of using such a composition for the catalytic pyrolysis of plastics (e.g., waste plastics) provides petrochemical feedstocks such as ethylene, propylene, and butylene with high gasification rates and better selectivity.

Inventors

  • 위안 구앙
  • 션 위펑
  • 청 위-청
  • 후 루이종
  • 하딩 로버트 에이치

Assignees

  • 더블유.알. 그레이스 앤드 캄파니-콘.

Dates

Publication Date
20260511
Application Date
20240828
Priority Date
20230905

Claims (20)

  1. Mesoporous active matrix; and phosphorus-stabilized ZSM-5 A catalyst composition comprising
  2. A catalyst composition according to claim 1, wherein the mesoporous active matrix comprises one or more of kaolin clay and peptized alumina.
  3. A catalyst composition according to claim 1 or 2, wherein the catalyst composition comprises one or more of kaolin clay and peptided alumina, in an amount greater than about 30% based on the total weight of the catalyst composition.
  4. A catalyst composition according to any one of claims 1 to 3, wherein the catalyst composition comprises more than about 10% of peptided alumina based on the total weight of the catalyst composition.
  5. In claim 4, the catalyst composition comprises peptized alumina in an amount greater than about 30% based on the total weight of the catalyst composition.
  6. A catalyst composition according to any one of claims 1 to 5, wherein the catalyst composition comprises about 10% to about 70% of peptided alumina based on the total weight of the catalyst composition.
  7. A catalyst composition according to any one of claims 1 to 6, wherein the mesoporous active matrix comprises pores having a pore size of about 20 Å to about 600 Å or about 40 Å to about 600 Å.
  8. A catalyst composition according to any one of claims 1 to 6, wherein the mesoporous active matrix comprises pores having a pore size greater than about 600 Å.
  9. A catalyst composition according to any one of claims 1 to 7, wherein the mesoporous active matrix has a surface area of about 50 m² /g to about 250 m² /g before deactivation.
  10. A catalyst composition according to claim 9, wherein the mesoporous active matrix has a surface area of about 60 m² /g to about 200 m² /g, about 80 m² /g to about 150 m² /g, or about 90 m² /g to about 120 m² /g before deactivation.
  11. A catalyst composition according to any one of claims 1 to 10, wherein the mesoporous active matrix has a pore volume greater than about 0.01 cc/g.
  12. In claim 11, the catalyst composition wherein the mesoporous active matrix has a pore volume of about 0.1 cc/g to about 0.4 cc/g.
  13. A catalyst composition according to any one of claims 1 to 12, wherein the catalyst composition comprises phosphorus-stabilized ZSM-5 in an amount greater than about 5% w/w based on the total weight of the catalyst composition.
  14. In claim 13, the catalyst composition comprises about 5% to about 70% of phosphorus-stabilized ZSM-5 based on the total weight of the catalyst composition.
  15. A catalyst composition according to any one of claims 1 to 14, wherein the phosphorus-stabilized ZSM-5 further comprises one or more metals selected from iron, copper, zinc, nickel, titanium, vanadium, chromium, manganese, cobalt, gallium, and boron.
  16. A catalyst composition according to any one of claims 1 to 15, wherein the phosphorus-stabilized ZSM-5 has a crystallite size of about 0.05 microns to about 2 microns.
  17. A catalyst composition according to any one of claims 1 to 16, wherein the catalyst composition comprises about 0.5 weight% to about 15 weight% of P₂O₅ based on the total weight of the composition.
  18. A catalyst composition according to any one of claims 1 to 17, wherein the phosphorus-stabilized ZSM-5 and the mesoporous active matrix are separate particles within the catalyst composition.
  19. A process for preparing a catalyst composition comprising a mesoporous active matrix and phosphorus-stabilized pentasyl zeolite, (a) a step of providing an aqueous slurry A comprising solid particles of phosphorus-stabilized pentasyl zeolite; (b) a step of combining slurry A with peptided alumina, kaolin clay, and alumina sol to provide slurry B; (c) a step of spray-drying slurry B to form catalyst particles; and (d) a step of calcining the spray-dried catalyst particles at a temperature and for a time sufficient to remove volatile substances and recover the catalyst composition. A process including
  20. In claim 19, the process further comprises the step of washing the calcined catalyst particles with a water and ammonia solution at a pH of about 3 to about 7.5.

Description

Catalytic pyrolysis of plastics to produce petrochemical feedstocks Cross-reference regarding related applications This application claims the advantage of priority to U.S. Provisional Application No. 63/580,579 filed on September 5, 2023, the entire contents of which are incorporated herein by reference. Technology field The present invention generally relates to the conversion of plastics into olefins and aromatics through pyrolysis. Specifically, the present invention relates to a catalytic composition comprising a mesoporous active matrix and phosphorus-stabilized ZSM-5, and a method for preparing and using such a composition in a fluidized bed or conical jet bed reactor to catalytically pyrolyze plastics into olefins and aromatic compounds. Catalytic pyrolysis, which involves the decomposition of polymeric materials by heating them in the absence of oxygen and in the presence of a catalyst, represents a useful method for recycling plastic waste. Silica-alumina, zeolites, and fluid catalytic cracking (FCC) catalysts are generally used to lower energy barriers, influence the composition of products through decomposition, and reduce process time. Although catalytic pyrolysis has been extensively studied, there remains a need to develop more efficient catalytic pyrolysis methods that maximize the yields of desirable products, such as light olefins and aromatic compounds, while minimizing the yields of undesirable products, such as methane and ethane. In particular, propylene is a specific light olefin in high demand as it is used in many of the world's largest and fastest-growing synthetic and thermoplastic materials. The present disclosure provides a catalyst composition comprising a mesoporous active matrix and phosphorus-stabilized ZSM-5, and a method for preparing and using such composition in a fluidized bed or conical jet bed reactor for the catalytic pyrolysis of plastics into olefins and aromatic compounds. A method for using such composition for the catalytic pyrolysis of plastics (e.g., waste plastics) provides petrochemical feedstocks such as ethylene, propylene, and butylene with a high gasification rate and better selectivity. In one aspect, Mesoporous active matrix; and Phosphor-stabilized ZSM-5 A catalyst composition comprising is provided. In some embodiments, the mesoporous active matrix comprises one or more of kaolin clay and peptized alumina. In some embodiments, the catalyst composition comprises one or more of kaolin clay and peptized alumina, in an amount greater than about 30% based on the total weight of the catalyst composition. In some embodiments, the catalyst composition comprises more than about 10% of peptided alumina based on the total weight of the catalyst composition. In some embodiments, the catalyst composition comprises more than about 30% of peptided alumina based on the total weight of the catalyst composition. In some embodiments, the catalyst composition comprises about 10% to about 70% of peptided alumina based on the total weight of the catalyst composition. In some embodiments, the mesoporous active matrix comprises pores having a pore size of about 20 Å to about 600 Å, or about 40 Å to about 600 Å. In some embodiments, the mesoporous active matrix comprises pores having a pore size greater than about 600 Å. In some embodiments, the mesoporous active matrix has a surface area of about 50 m² /g to about 250 m² /g before deactivation. In some embodiments, the mesoporous active matrix has a surface area of about 60 m² /g to about 200 m² /g, about 80 m² /g to about 150 m² /g, or about 90 m² /g to about 120 m² /g before deactivation. In some embodiments, the mesoporous active matrix has a pore volume greater than about 0.01 cc/g. In some embodiments, the mesoporous active matrix has a pore volume of about 0.1 cc/g to about 0.4 cc/g. In some embodiments, the catalyst composition comprises more than about 5% w/w of phosphorus-stabilized ZSM-5 based on the total weight of the catalyst composition. In some embodiments, the catalyst composition comprises about 5% to about 70% of phosphorus-stabilized ZSM-5 based on the total weight of the catalyst composition. In some embodiments, phosphorus-stabilized ZSM-5 further comprises one or more metals selected from iron, copper, zinc, nickel, titanium, vanadium, chromium, manganese, cobalt, gallium, and boron. In some embodiments, phosphorus-stabilized ZSM-5 has a crystallite size of about 0.05 microns to about 2 microns. In some embodiments, the catalyst composition comprises about 0.5% w/w to about 15% w/w of P₂O₅ based on the total weight of the composition. In some embodiments, the phosphorus-stabilized ZSM-5 and the mesoporous active matrix are distinct particles within the catalyst composition. In another aspect, a process for preparing a catalyst composition comprising a mesoporous active matrix and a phosphorus-stabilized pentasyl zeolite is provided, said process comprising: (a) a step of providing an aqueous slurry A c