Matrix Effects in a Fluid Catalytic Cracking Catalyst Particle: Influence on Structure, Acidity, and Accessibility

Matrix effects in a fluid catalytic cracking (FCC) catalyst have been studied in terms of structure, accessibility, and acidity. An extensive characterization study into the structural and acidic properties of a FCC catalyst, its individual components (i.e., zeolite H-Y, binder (boehmite/silica) and kaolin clay), and two model FCC catalyst samples containing only two components (i.e., zeolite-binder and binder-clay) was performed at relevant conditions. This allowed the drawing of conclusions about the role of each individual component, describing their mutual physicochemical interactions, establishing structure-acidity relationships, and determining matrix effects in FCC catalyst materials. This has been made possible by using a wide variety of characterization techniques, including temperature-programmed desorption of ammonia, infrared spectroscopy in combination with CO as probe molecule, transmission electron microscopy, X-ray diffraction, Ar physisorption, and advanced nuclear magnetic resonance. By doing so it was, for example, revealed that a freshly prepared spray-dried FCC catalyst appears as a physical mixture of its individual components, but under typical riser reactor conditions, the interaction between zeolite H-Y and binder material is significant and mobile aluminum migrates and inserts from the binder into the defects of the zeolite framework, thereby creating additional Brønsted acid sites and restoring the framework structure