A selective octane-enhancing FCC catalyst using ZRP zeolite as an active component

A hetero-crystalline seeding method used to prepare a unique MFI type zeolite with a mesopores of about 4 nm dia designated as the ZRP zeolite was developed. ZRP zeolite, which is used as a component of FCC catalysts to produce high-octane gasoline and light olefins, had high stability and selectivity. Using DOCR and DOCP octane-enhancing catalysts containing the ZRP zeolite, the commercial trial was carried out in a 0.8 million ton/yr residue FCC unit with a feedstock composed of Daqing atmospheric residue. ZRP zeolite with a lower SiO₂Al₂O₃ ratio contained in the DOCR catalyst showed selectivity for C₅ and C₆ cracking. The ZRP zeolite with a higher SiO₂Al₂O₃ ratio contained in the DOCP catalyst had the selectivity for paraffin isomerization. The LPG yield could be adjustable along with increase in gasoline octane number.