Insights into Si/Al ratios for enhanced performance of β-zeolites in thermocatalytic cracking of crude oil to light olefins

The escalating demand for key petrochemicals, particularly ethylene and propylene, underscores the critical need for proficient catalysts in crude oil conversion processes. Attaining high propylene selectivity necessitates catalysts with superior adsorption capacity, thermal stability, moderate surface acidity, and pores large enough to facilitate the diffusion of larger crude oil molecules. In the present study, three different BEA Zeolites (β-zeolite) catalysts were successfully synthesized by hydrothermal method and used for catalytic cracking of Arabian Light crude oil to produce valuable petrochemical products, such as propylene, ethylene, and naphtha. The catalysts were characterized using ²⁷Al and ²⁹Si NMR, NH₃-TPD, BET, XRD, TGA, FTIR, XRF, and FE-SEM. The thermocatalytic cracking of Arabian Light crude oil was evaluated in a fixed-bed microactivity test (MAT) unit between 550 and 600 °C. The as-prepared β-zeolite with a Si/Al ratio of 50 exhibited better catalytic activity in the catalytic cracking of Arabian Light crude oil compared to counterparts with Si/Al ratios of 35 and 65, This superiority can be attributed to its optimal combination of surface acid site distribution, textural properties, surface morphology, and high adsorption capacity. The highest feed conversion (83.4 %) and selectivity to propylene (16.11 %) were attained using β-zeolite with a Si/Al ratio of 50 at 600 °C. Importantly, our findings suggest that these catalysts hold significant potential, rivalling primary MFI catalysts like ZSM-5 commonly employed in similar reactions. This underscores their promise as catalysts of choice in the realm of catalytic cracking processes, paving the way for advancements in petrochemical production.