Core–Shell Zeolite Y@γ‐Al2O3 Nanorod Composites: Optimized Fluid Catalytic Cracking Catalyst Assembly for Processing Heavy Oil

Abstract

AbstractCompositions, structures, and distributions of the active phases in fluid catalytic cracking (FCC) catalysts have an essentially important impact on their porosities, acidities, and thus cracking capabilities for processing heavy oil fractions. Here, we report a facile approach for fabrication of core–shell zeolite Y@γ‐Al2O3 nanorod composites by controlling the attachment of boehmite nanorods on the external surface of zeolite crystals, and thus regulating the dispersion and combination of the active alumina matrix on zeolite components in the FCC catalyst. The synthesized discrete boehmite nanorods possess a large quantity of positive charges and can directly electrostatically interact with the negative surface of zeolite crystals, leading to the formation of core–shell zeolite Y@γ‐Al2O3 nanorod composites (nY@Al2O3). The optimized 4Y@Al2O3 composite (Y/γ‐Al2O3 weight ratio of 4) with zeolite crystals fully embedded by alumina nanorods shows enhanced textural properties, acidity accessibilities, and improved cracking ability of 1,3,5‐triisopropyl benzene. Taking it as the main active component, the produced FCC catalyst shows better contaminant resistant ability and especially higher gasoline yield in the cracking of heavy oil, which could potentially bring practical economic profits for the oil‐refining industry.