Octane-Enhancing FCC Catalyst

The first octane-enhancing FCC catalysts were introduced by catalyst manufacturers in the United States in the mid-1970s. Since about one-third of marketable gasoline in North America and Europe originates in FCC units, any increase in the octane number of FCC gasoline is important for refineries. Moreover, the use of octane-enhancing FCC catalysts is cost-effective; therefore beginning in the mid-1980s there was a worldwide trend away from originally gasoline oriented catalysts toward catalysts oriented to high-octane plus high yield of light products (‘octane tons’). 

Similar to gasoline FCC catalysts, octane FCC catalysts consist primarily of two major components: zeolite and matrix. Some octane catalysts contain a third component—octane-enhancing additives which are either incorporated into the catalyst matrix or added as separate particles. Although both the zeolite and matrix affect the antiknock quality of FCC gasoline, zeolite plays the leading role. 
According to their composition, most octane FCC catalysts can be classified as follows:

• Catalysts containing an octane-enhancing Y zeolite in a catalytically inert matrix.
• Catalysts containing an octane-enhancing Y zeolite in a catalytically active matrix.
• Catalysts containing an octane-enhancing or conventional rare earth-containing Y zeolite and octane additives, such as zeolite ZSM-5.

Catalysts of the first and second category can also contain, besides octane-enhancing Y zeolite, the usual rare earth-containing Y zeolite (RE, HY). The presence of rare earth-metal ions in Y zeolite enhances its stability and catalytic activity.

In recent years, the number of octane catalysts developed by various manufacturers to meet the specific requirements of individual refiners has increased. However, maximizing octane tons remains the main trend. The current market trend shows that in the foreseeable future octane FCC catalysts along with octane additives will continue to play an important role. 
The wide range of KNT Group products also includes catalysts with octane-enhancing additives (cracking catalyst microspheres).