Catalysts for Improving Pyrolysis Oil Quality

FAU-Y type zeolite-supported multi-component transition metal catalyst for oil shale pyrolysis that reduces pyrolysis temperature and improves oil and gas recovery. The catalyst is prepared by mixing aluminum powder, bismuth nitrate, zinc chloride, sodium citrate, and sodium hydroxide solution to form a clear solution. This solution is added to a FAU-Y zeolite carrier and heated to crystallize the zeolite around the metal clusters. The resulting catalyst contains Bi, Zn, and FAU-Y zeolite for pyrolyzing oil shale at lower temperatures compared to conventional catalysts.

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Acid-modified H-Beta zeolite catalyst for catalytic pyrolysis of lignin to produce bio-oil. The catalyst is prepared by treating H-Beta zeolite with acid to create aluminum vacancies, then exchanging metal ions into the vacancies through a solid-state ion exchange process. This acid modification allows controlling the acidity of the zeolite catalyst. The modified zeolite is then used to catalyze lignin pyrolysis at 600°C to generate high-quality bio-oil with reduced oxygen content.

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Rare earth mesoporous molecular sieve catalyst for improving oil shale cracking efficiency. The catalyst is a rare earth mesoporous molecular sieve with enlarged mesopores. The sieve is prepared by loading a quaternary ammonium base, metal nano-alumina, cyclohexane ethyl acetate, and surfactant onto a mesoporous material like quartz. The enlarged mesopores allow larger oil shale molecules to enter and react with the catalyst's acidic sites. This improves selectivity for lighter oil products, reduces gas and coke formation, and lowers cracking temperatures compared to conventional catalysts.

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A multifunctional catalyst for upgrading pyrolysis oils using heteropolyacids as metal precursors instead of conventional metal precursors. The catalyst is prepared by impregnating a zeolite support with a solution containing the heteropolyacid-based metal precursors. This deposits the catalyst metals onto the zeolite surface. The catalyst enables higher yields of valuable aromatics like benzene, toluene, xylene from pyrolysis oils at lower reaction pressures compared to existing catalysts.

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A method for producing high-quality oil from waste tires that involves crushing the tires, pyrolyzing them in an ammonia atmosphere under pressure, separating the pyrolysis liquid, and then refining it using hydrogen and catalysts. The pyrolysis in ammonia improves the oil quality compared to regular pyrolysis. The crushing step allows better pyrolysis. The refining step using hydrogen and catalysts further improves the oil quality.

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Multifunctional catalyst for upgrading pyrolysis oil that provides higher yield of valuable aromatic compounds like benzene, toluene, ethylbenzene, and xylenes from pyrolysis oil at lower reaction pressures compared to existing catalysts. The catalyst is made by depositing metal catalysts onto a hierarchical mesoporous zeolite support using heteropolyacids as precursors. The zeolite's larger pore size allows access of larger multi-ring aromatics. The heteropolyacid precursors enable higher aromatic yields at lower pressures.

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Preparation of a high-activity catalyst for biomass pyrolysis using metal-doped hierarchical pore ZSM-5 zeolite. The catalyst is made by etching HZSM-5 with HF acid to create hierarchical porosity, then doping the etched zeolite with nickel to increase cracking and hydrogen transfer activity. This enhances aromatics yield in biomass pyrolysis compared to conventional zeolites.

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Multifunctional catalyst for upgrading pyrolysis oil with improved yield and lower reaction pressure compared to existing catalysts. The catalyst is made by depositing metal catalysts onto a hierarchical mesoporous zeolite support using heteropolyacids as precursors. The zeolite support has an average pore size of 2-40 nm. This enables conversion of larger aromatics in pyrolysis oil. The heteropolyacid precursors increase yield at lower pressures. The catalyst composition is a mixture of metal catalysts supported on the zeolite.

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Preparing liquid fuel oil from biomass by catalytic cracking using a novel alkaline MNC-13 mesoporous molecular sieve catalyst. The MNC-13 sieve is synthesized using an acid-functionalized ionic liquid as a template. The MNC-13 sieve has high acidity, stability, and larger pore size compared to traditional microporous sieves, allowing wider molecular weight distribution of the pyrolysis oil products. This enables higher liquid fuel yields and better quality compared to other catalysts.

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High-temperature water vapor stable waste treatment catalyst for converting bio-oil and waste streams into higher quality fuels. The catalyst is a modified zeolite B with high water vapor resistance. It contains cobalt along with active components like iron, nickel, and ruthenium. The cobalt reduces crystal grain size and allows embedding in zeolite pores. This prevents water molecules entering the catalyst during high-temperature treatment of bio-oil or waste streams containing water vapor. The catalyst can withstand the high-temperature, high-water environment without deactivation.

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A catalyst for efficiently converting waste plastics into fuel oil with high yield and selectivity. The catalyst is made by modifying pillared clay from smectite or kaolin families. The clay is intercalated with metal compounds and has a particle size of 20 microns or less and an average pore diameter of 50 nanometers or more. This modified clay supports a metal catalyst to crack the waste plastics into fuel oil. The clay modification allows efficient decomposition of a wide range of waste plastics into fuel oil with high yield and selectivity to diesel fractions compared to other catalysts.

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Catalyst for cracking and deoxygenation of biomass liquefied oil to improve its quality and suitability as a fuel. The catalyst is composed of specific amounts of nickel, zirconia, and zeolite. This catalyst enables efficient catalytic cracking of biomass oil at mild conditions to remove oxygen as CO2 or water, leaving hydrocarbons. It provides high deoxygenation rate and good anti-coking performance for biomass oil refining.

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A method to effectively neutralize and reduce the environmental impacts of oily sludge generated in the oil industry. The method involves treating the sludge with solvents to separate the organic and inorganic components, then subjecting the organic portion to thermocatalytic pyrolysis using nanostructured catalysts. This process breaks down the complex organic molecules into smaller hydrocarbons like diesel fuel, while the inorganic portion is safely disposed of. The nanocatalysts have porosities in the 2-50 nm range to selectively convert the bulky hydrocarbons into desired products.

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A two-stage catalytic process to improve the quality of bio-oil from biomass pyrolysis. The first stage uses a mineral catalyst to pyrolyze the biomass at lower temperatures to increase the hydrogen-to-carbon ratio of the pyrolysis gas. This reduces the oxygen content and improves the yield of hydrocarbons in the pyrolysis oil. The second stage uses a zeolite catalyst to further reform the pyrolysis oil and remove oxygen. The zeolite also selectively separates the hydrocarbons, improving the oil quality. The first stage gas is directly fed to the second stage to provide hydrogen for reforming. This avoids coking the zeolite catalyst and extends its life.

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Obtaining light hydrocarbons through thermo-catalytic cracking of bio-oil derived from animal or vegetable fats using nanocrystalline zeolite catalysts. The process involves adding the nanocrystalline zeolite catalyst to a reactor, followed by addition of the bio-oil and heating. The catalyst's nanoscale dimensions enhance diffusivity and contact area, allowing efficient conversion of bio-oil into light hydrocarbons like pentanes, hexanes, heptanes, and octanes.

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A method to increase the yield of light fractions from heavy oils like high-sulfur crude oil. The method involves a two-step process. First, a light catalytic hydropyrolysis step using hydrogen and catalyst at high pressure and temperature to convert the heavy oil into light fractions like gasoline, kerosene, diesel, and vacuum gas oil. Second, plasma gasification of the heavy residue from the first step using a mixed plasma of water vapor and synthesis gas to further convert it into synthesis gas, hydrogen sulfide, and metal concentrate. This second step reduces the metal content of the heavy residue, preventing catalyst poisoning in further processing steps.

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A method to recycle waste tires and rubber by co-processing with carbon to produce synthetic oils and storable heat energy products. The method involves mixing crushed waste tires, carbon, and optionally a Fe catalyst. The mixture is heated at 400-600°C for 1-2 hours to convert the rubber and carbon into oils, gases, and solid residues. The oils can be fractionated for use as fuels or chemicals, and the solid residues have medium and high caloric value for energy storage. The Fe catalyst helps fix oxygenates and sulfur.

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Recycling rubber waste into useful fuel oil and gas without causing pollution. The method involves mixing rubber waste with a catalyst and cracking it at high temperature and low pressure in a reactor to produce gas. The gas is then catalytically reacted and condensed to separate oil and gas. The recovered gas is recycled back into the reactor and catalytic tube. This closed loop allows processing rubber waste into saleable products without environmental harm.

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A process for efficiently converting waste rubber into fuel oil and gas by cracking the rubber using a specific catalyst composition. The catalyst contains calcium oxide (CaO), nickel (Ni), XT-10 (a mixture of minerals), and trace amounts of niobium and titanium. The catalyst is reacted with waste rubber at temperatures around 280°C under pressure. The resulting products are filtered, condensed, and fractionated into light oil, heavy oil, and gas for storage. The catalyst allows rapid cracking of the rubber into fuels in just 2 hours.

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Recycling rubber waste into fuel oil, gas, and carbon black by cracking the rubber with a specific catalyst and process. The catalyst is a mixture of calcium oxide (CaO), nickel (Ni), XT-10, niobium, and titanium. The rubber waste is heated in a sealed reactor with the catalyst to soften and melt, then cracked at high temperatures to produce flammable gases and oils. The gases are separated and stored, while the carbon black and remaining solids are collected. The process converts rubber waste into useful resources instead of landfilling.

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