Recycling of Spent FCC Catalysts: Conversion of Leached Residues to Zeolite ZSM-5.

The commercial recycling of spent FCC catalyst typically focuses on recovering only 1-3 % of rare-earth elements, with the remaining residues often disposed of in landfills. Here, we present a novel method to close a recycling loop for spent FCC catalyst. The method involves a series of leaching steps: Firstly, the spent catalyst material is leached with HNO3 to remove rare-earth elements such as La; second, solvothermal leaching with HCl removes most of Al and impurities like Fe, Ni and V; finally, a third leaching with H2SO4 removes Ti. The solid residues are then used to synthesize ZSM-5 without the addition of any extra silicon or aluminum sources after mild activation. The impurities in the synthesis gel strongly modify the properties of the zeolite, with ZSM-5 crystals containing higher levels of impurities exhibiting lower crystallinities, surface areas, acidities, cracking activities, as well as larger particle sizes.

Crucial Role of Silica-Alumina Binder Mixtures for Hydrocarbon Cracking with ZSM-5 Additives.

Alumina-containing binders are widely used for the binding of catalyst particles by spray drying and calcination. As a part of the active matrix, they contribute to the catalytic performance of the resulting catalyst grain during hydrocarbon cracking. In this study, correlations are investigated using different compositions of Al- and Si-based binders (AlCl3 and colloidal silica) together with kaolin as a filler and ZSM-5 zeolite as an active compound. It was demonstrated that the conversion of a 50:50 hexane mixture, the selectivity toward unsaturated hydrocarbons, and the shape-selective conversion of the hexane feed are highly dependent on the amount and distribution of alumina in binder formulations. While silica species are distributed near the outer shell of catalyst grains, the alumina species are distributed evenly as an adhesive between the catalyst compounds ZSM-5 and kaolin. An optimum amount of alumina in binder formulations results in an increasing conversion of hydrocarbon feedstock due to optimum in active-site accessibility but only a slight decrease in shape-selective properties compared to pure ZSM-5, resulting in an optimum yield of light olefins, especially propylene.