Different binders in FCC catalyst preparation: impact on catalytic performance in VGO cracking

In the present study, four different binders including two synthesized alumina-silica sol and two commercially available binders comprising LUDOX AS-30 colloidal silica and LUDOX AS-40 colloidal silica have been applied for preparation of FCC catalyst. Other catalyst components were included such as USY zeolite, kaolin, alumina, ZSM-5 zeolite and cerium nitrate. Four catalysts have been synthesized through spray drying of aqueous slurries of the components. The influence of different binders on the cracking performance and product distribution of FCC catalysts as well as their morphology has been investigated. Fourier transform infrared spectroscopy, scanning electron microscopy, X-ray powder diffraction, ammonia temperature-programmed desorption, inductive coupled plasma, Brunauer-Emmett-Teller and Barrett-Joyner-Halenda analysis have been operated to characterize the prepared catalysts. The reasonable spherical shaped particles of 40-50m size were obtained applying the synthesized alumina-silica sol and LUDOX-AS-40 colloidal silica as binder. The cracking activity of the prepared FCC catalysts was investigated in catalytic cracking of vacuum gas oil in a microactivity test unit and compared with the commercially available FCC catalyst. The results indicated that the synthesized catalysts have excellent activity with respect to the commercial one in terms of maximizing gasoline yields along with less alkanes production. The reusability of the catalysts was examined in four repeated cycles.