阅读说明：本技术 流动催化裂化用结构体及其制造方法、以及具备该流动催化裂化用结构体的流动催化裂化用装置 (Fluid catalytic cracking structure, method for producing same, and fluid catalytic cracking apparatus provided with same ) 是由 增田隆夫 中坂佑太 吉川琢也 加藤祯宏 福岛将行 高桥寻子 马场祐一郎 关根可织 于 2018-05-31 设计创作，主要内容包括：本发明提供一种流动催化裂化用催化剂结构体、具有该流动催化裂化用催化剂结构体的流动催化裂化用装置以及流动催化裂化用催化剂结构体的制造方法,所述流动催化裂化用催化剂结构体具有优异的催化活性,通过抑制催化剂物质之间的凝聚,能实现长期良好的催化活性。一种流动催化裂化用催化剂结构体,其特征在于,具备：多孔质结构的载体,其由沸石型化合物构成：以及至少一种催化剂物质,其存在于所述载体内,所述载体具有相互连通的通道,所述催化剂物质是金属微粒或固体酸,存在于所述载体的至少所述通道,在所述催化剂物质是金属微粒的情况下,所述催化剂物质是选自由镍、钴、铁、铜、金、银、铂、钯、铑、铱、钌、锇以及钼构成的组中的至少一种金属的微粒。(The present invention provides a catalyst structure for fluid catalytic cracking, a device for fluid catalytic cracking having the same, and a method for manufacturing the catalyst structure for fluid catalytic cracking, wherein the catalyst structure for fluid catalytic cracking has excellent catalytic activity, and can realize good catalytic activity for a long period by suppressing aggregation of catalyst substances. A fluid catalytic cracking catalyst structure comprising: a porous support composed of a zeolite-type compound: and at least one catalyst substance present in the carrier, the carrier having channels communicating with each other, the catalyst substance being a metal particulate or a solid acid, the catalyst substance being present in at least the channels of the carrier, and in the case where the catalyst substance is a metal particulate, the catalyst substance being a particulate of at least one metal selected from the group consisting of nickel, cobalt, iron, copper, gold, silver, platinum, palladium, rhodium, iridium, ruthenium, osmium, and molybdenum.)

1. A fluid catalytic cracking catalyst structure comprising:

a porous support composed of a zeolite-type compound; and

at least one catalyst species present within the support,

the carrier has channels that are in communication with each other,

the catalyst material is a metal particulate or a solid acid, is present in at least the channels of the support,

in the case where the catalyst material is a metal fine particle, the catalyst material is a fine particle of at least one metal selected from the group consisting of nickel (Ni), cobalt (Co), iron (Fe), copper (Cu), gold (Au), silver (Ag), platinum (Pt), palladium (Pd), rhodium (Rd), iridium (Ir), ruthenium (Ru), osmium (Os), and molybdenum (Mo).

2. The fluid catalytic cracking catalyst structure according to claim 1, wherein,

the carrier is a zeolite Y type compound.

3. The fluid catalytic cracking catalyst structure according to claim 1 or 2,

the channel has: any one of one-dimensional pores, two-dimensional pores, and three-dimensional pores defined by the framework structure of the zeolite-type compound; and a diameter expanding portion different from any one of the one-dimensional hole, the two-dimensional hole, and the three-dimensional hole,

the catalyst substance is present in at least the enlarged diameter portion of the channel.

4. The fluid catalytic cracking catalyst structure according to claim 3,

the diameter expanding portion causes a plurality of holes constituting any one of the one-dimensional hole, the two-dimensional hole, and the three-dimensional hole to communicate with each other.

5. The fluid catalytic cracking catalyst structure according to claim 3 or 4,

when the catalyst material is a metal fine particle, the metal fine particle has an average particle diameter larger than the average inner diameter of the channel and equal to or smaller than the inner diameter of the enlarged diameter portion, and when the catalyst material is a solid acid, the solid acid is a fine particle, and the average particle diameter of the fine particle is larger than the average inner diameter of the channel and equal to or smaller than the inner diameter of the enlarged diameter portion.

6. The fluid catalytic cracking catalyst structure according to claim 5,

the metal fine particles or the metal element (M) of the solid acid is contained in an amount of 0.5 to 2.5 mass% based on the mass of the fluid catalytic cracking catalyst structure.

7. The fluid catalytic cracking catalyst structure according to any one of claim 3 to claim 6,

the average inner diameter of the channel is 0.1 nm-1.5 nm,

the inner diameter of the diameter-expanded portion is 0.5nm to 50 nm.

8. The fluid catalytic cracking catalyst structure according to any one of claim 1 to claim 7,

the catalyst substance is a metal fine particle having an average particle diameter of 0.08 to 30 nm.

9. The fluid catalytic cracking catalyst structure according to claim 8,

the metal fine particles have an average particle diameter of 0.4 to 11.0 nm.

10. The fluid catalytic cracking catalyst structure according to any one of claim 1 to claim 9,

the catalyst material is a metal fine particle, and the ratio of the average particle diameter of the metal fine particle to the average inner diameter of the channel is 0.05 to 300.

11. The fluid catalytic cracking catalyst structure according to any one of claim 1 to claim 10,

the catalyst material is a metal fine particle, and the ratio of the average particle diameter of the metal fine particle to the average inner diameter of the channel is 0.1 to 30.

12. The fluid catalytic cracking catalyst structure according to any one of claim 1 to claim 11,

the catalyst material is a metal fine particle, and the ratio of the average particle diameter of the metal fine particle to the average inner diameter of the channel is 1.4 to 3.6.

13. The fluid catalytic cracking catalyst structure according to any one of claim 1 to claim 12,

a catalyst material is also retained on the outer surface of the support.

14. The fluid catalytic cracking catalyst structure according to claim 13,

the content of the catalyst substance present in the carrier is more than the content of the catalyst substance remaining on the outer surface of the carrier.

15. The fluid catalytic cracking catalyst structure according to any one of claim 1 to claim 14,

the zeolite-type compound is a silicate compound.

16. The fluid catalytic cracking catalyst structure according to any one of claim 1 to claim 15,

has the shape of cylindrical, leaf-shaped, dumbbell-shaped or annular particles.

17. An apparatus for fluid catalytic cracking, comprising the catalyst structure for fluid catalytic cracking according to any one of claims 1 to 16.

18. A method for producing a catalyst structure for fluid catalytic cracking, comprising:

a firing step of firing a precursor material (B) obtained by impregnating a precursor material (a) for obtaining a framework having a porous structure composed of a zeolite-type compound with a metal-containing solution of a metal including fine metal particles or a metal of a solid acid;

a hydrothermal treatment step of subjecting a precursor material (C) obtained by firing the precursor material (B) to hydrothermal treatment; and

and a step of subjecting the precursor material (C) after the hydrothermal treatment to a reduction treatment.

19. The method for producing a catalyst structure for fluid catalytic cracking according to claim 18,

before the firing step, 50 to 500 mass% of a nonionic surfactant is added to the precursor material (a).

20. The method for producing a catalyst structure for fluid catalytic cracking according to claim 18 or 19,

the metal-containing solution is impregnated into the precursor material (a) by adding the metal-containing solution to the precursor material (a) a plurality of times before the firing step.

21. The method for producing a catalyst structure for fluid catalytic cracking according to any one of claims 18 to 20,

when the precursor material (A) is immersed in the metal-containing solution before the firing step, the amount of the metal-containing solution added to the precursor material (A) is adjusted so that the atomic ratio Si/M, which is the ratio of silicon (Si) constituting the precursor material (A) to the metal element (M) contained in the metal-containing solution added to the precursor material (A), is 10 to 1000.

22. The method for producing a catalyst structure for fluid catalytic cracking according to claim 18,

in the hydrothermal treatment step, the precursor material (C) is mixed with a structure-directing agent.

23. The method for producing a catalyst structure for fluid catalytic cracking according to claim 18,

the hydrothermal treatment step is performed in an alkaline environment.

Technical Field

The present invention relates to a structure for fluid catalytic cracking, a method for producing the same, and an apparatus for fluid catalytic cracking provided with the structure for fluid catalytic cracking.

Background

As one of the main processes of petroleum refining, a Fluid Catalytic Cracking (FCC) process is known, and developed as the following process: cracking high boiling point hydrocarbons such as vacuum gas oil and atmospheric residual oil at 500-550 ℃ in the presence of a catalyst to produce high octane gasoline. As a catalyst used in the FCC process, a solid acid mainly composed of zeolite is mainly used. In recent years, the FCC process has been an important place as a technology for upgrading heavy oil, and has been used for increasing the production of petrochemical base products such as propylene, while producing gasoline. Therefore, in order to cope with such diverse purposes, various catalysts have been developed and studied. Among them, a catalyst mainly composed of so-called REUSY, which is obtained by imparting UltraStable Y Type Zeolite (USY) and Rare Earth metal (RE Earth) is known.

Zeolite catalysts generally have characteristics of high catalytic activity, high stability, and the like based on their microporous structure. On the other hand, however, there are also the following disadvantages due to their steric hindrance: the accessibility of the volume of the zeolite micropores is reduced during the action of the catalyst and moreover, the zeolite crystals cannot always be used effectively.

In order to improve such a drawback, various attempts have been made.

For example, patent document 1 discloses a catalyst composition for hydrocarbon cracking, which contains: a first zeolite component such as ITQ-7 zeolite exchanged with a rare earth element; and a second zeolite component such as faujasite exchanged with a rare earth element. Patent document 1 describes: by the catalyst composition, the octane number of the prepared gasoline is enabled to be a good value, the yields of C3 olefin and C4 olefin are good, and the yield of the obtained gasoline is also good.

Disclosure of Invention

Problems to be solved by the invention

However, in the above-described catalyst, since the catalyst metal is present on the surface of the zeolite or in the vicinity of the surface thereof, the catalyst metal is moved by external force or heat, and as a result, the catalyst particles are likely to be aggregated (sintered). When the agglomeration between catalyst particles occurs, the effective surface area as a catalyst decreases, whereby the catalytic activity decreases. Even if the zeolite has a structure in which predetermined grids connected to each other are formed, there is room for improvement in the following respects: in zeolite catalysts, the accessibility of the active sites to the reactant or product molecules is sufficiently ensured to maximize the effectiveness of the catalyst.

Accordingly, an object of the present invention is to provide a catalytic cracking catalyst structure having excellent catalytic activity and capable of realizing good catalytic activity over a long period of time by suppressing aggregation of catalyst substances, a method for producing the same, and an apparatus for dynamic catalytic cracking having the catalytic cracking catalyst structure.

Technical scheme

The present invention is as follows.

[1] A fluid catalytic cracking catalyst structure comprising: a porous support composed of a zeolite-type compound; and at least one catalyst substance present in the carrier, the carrier having channels communicating with each other, the catalyst substance being a metal particulate or a solid acid, the catalyst substance being present in at least the channels of the carrier, and in the case where the catalyst substance is a metal particulate, the catalyst substance being a particulate of at least one metal selected from the group consisting of nickel (Ni), cobalt (Co), iron (Fe), copper (Cu), gold (Au), silver (Ag), platinum (Pt), palladium (Pd), rhodium (Rd), iridium (Ir), ruthenium (Ru), osmium (Os), and molybdenum (Mo).

[2] The fluid catalytic cracking catalyst structure according to [1], wherein the carrier is a zeolite Y-type compound.

[3] The catalyst structure for fluid catalytic cracking according to [1] or [2], wherein the channel has: any one of one-dimensional pores, two-dimensional pores, and three-dimensional pores defined by the framework structure of the zeolite-type compound; and an expanded diameter portion different from any of the one-dimensional hole, the two-dimensional hole, and the three-dimensional hole, wherein the catalyst substance is present in at least the expanded diameter portion of the channel.

[4] The fluid catalytic cracking catalyst structure according to [3], wherein the diameter-enlarged portion connects a plurality of holes constituting any one of the one-dimensional holes, the two-dimensional holes, and the three-dimensional holes.

[5] The catalyst structure for fluid catalytic cracking according to [3] or [4], characterized in that,

when the catalyst material is a metal fine particle, the metal fine particle has an average particle diameter larger than the average inner diameter of the channel and equal to or smaller than the inner diameter of the enlarged diameter portion, and when the catalyst material is a solid acid, the solid acid is a fine particle, and the average particle diameter of the fine particle is larger than the average inner diameter of the channel and equal to or smaller than the inner diameter of the enlarged diameter portion.

[6] The fluid catalytic cracking catalyst structure according to [5], wherein the metal fine particles or the metal element (M) of the solid acid is contained in an amount of 0.5 to 2.5 mass% based on the fluid catalytic cracking catalyst structure.

[7] The structure of any one of [3] to [6], wherein the average inner diameter of the channel is 0.1nm to 1.5nm, and the inner diameter of the enlarged diameter portion is 0.5nm to 50 nm.

[8] The catalytic cracking catalyst structure for fluid catalytic cracking according to any one of [1] to [7], wherein the catalyst substance is a metal fine particle having an average particle diameter of 0.08nm to 30 nm.

[9] The catalytic cracking catalyst structure according to [8], wherein the metal fine particles have an average particle diameter of 0.4nm to 11.0 nm.

[10] The structure of any one of [1] to [9], wherein the catalyst material is fine metal particles, and the ratio of the average particle diameter of the fine metal particles to the average inner diameter of the channels is 0.05 to 300.

[11] The structure of any one of [1] to [10], wherein the catalyst material is fine metal particles, and a ratio of an average particle diameter of the fine metal particles to an average inner diameter of the channels is 0.1 to 30.

[12] The catalytic cracking catalyst structure according to any one of [11], wherein the catalytic material is fine metal particles, and a ratio of an average particle diameter of the fine metal particles to an average inner diameter of the channels is 1.4 to 3.6.

[13] The catalytic cracking catalyst structure according to any one of [12], wherein a catalyst substance is further held on an outer surface of the carrier.

[14] The fluid catalytic cracking catalyst structure according to [13], wherein the content of the catalyst substance present in the carrier is larger than the content of the catalyst substance held on the outer surface of the carrier.

[15] The catalyst structure for fluid catalytic cracking according to any one of [1] to [14], characterized in that the zeolite-type compound is a silicate compound.

[16] The catalytic cracking catalyst structure for fluid catalytic cracking according to any one of [1] to [15], which has a particle shape of a cylindrical shape, a leaf shape, a dumbbell column shape or a ring shape.

[17] An apparatus for fluid catalytic cracking, comprising the catalyst structure for fluid catalytic cracking according to any one of [1] to [16 ].

[18] A method for producing a catalyst structure for fluid catalytic cracking, comprising: a firing step of firing a precursor material (B) obtained by impregnating a precursor material (a) for obtaining a framework body having a porous structure composed of a zeolite-type compound with a metal-containing solution of a metal including fine metal particles or a metal of a solid acid; a hydrothermal treatment step of subjecting a precursor material (C) obtained by firing the precursor material (B) to hydrothermal treatment; and a step of subjecting the precursor material (C) after the hydrothermal treatment to a reduction treatment.

[19] The method for producing a catalytic cracking catalyst structure according to item [18], wherein 50 to 500 mass% of a nonionic surfactant is added to the precursor material (A) before the firing step.

[20] The method for producing a catalyst structure for fluid catalytic cracking according to any one of [18] and [19], wherein the metal-containing solution is impregnated into the precursor material (A) by adding the metal-containing solution to the precursor material (A) a plurality of times before the firing step.

[21] The method for producing a catalyst structure for fluid catalytic cracking according to any one of [18] to [20], wherein, when the metal-containing solution is impregnated into the precursor material (A) before the firing step, the amount of the metal-containing solution added to the precursor material (A) is adjusted so that the ratio (atomic ratio Si/M) of silicon (Si) constituting the precursor material (A) to a metal element (M) contained in the metal-containing solution added to the precursor material (A) is 10 to 1000 in terms of the ratio.

[22] The method for producing a catalyst structure for fluid catalytic cracking according to item [18], wherein the precursor material (C) is mixed with a structure-directing agent in the hydrothermal treatment step.

[23] The method for producing a catalyst structure for fluid catalytic cracking according to item [18], wherein the hydrothermal treatment step is performed in an alkaline environment.

Advantageous effects

According to the present invention, it is possible to provide a catalyst structure for fluid catalytic cracking, which has excellent catalytic activity and can realize good catalytic activity over a long period of time by suppressing aggregation of catalyst substances, a method for producing the same, and an apparatus for fluid catalytic cracking having the catalyst structure for fluid catalytic cracking.

Drawings

Fig. 1 is a view schematically showing the internal structure of a fluid catalytic cracking catalyst structure according to an embodiment of the present invention, fig. 1(a) is a perspective view (partially shown in cross section), and fig. 1(b) is a partially enlarged sectional view.

Fig. 2 is a partially enlarged cross-sectional view for explaining an example of the function of the fluid catalytic cracking catalyst structure of fig. 1, fig. 2(a) is a view for explaining a sieve function, and fig. 2(b) is a view for explaining a catalytic function.

Fig. 3 is a flowchart showing an example of the method for producing the fluid catalytic cracking catalyst structure shown in fig. 1.

Fig. 4 is a schematic diagram showing a modification of the fluid catalytic cracking catalyst structure of fig. 1.

Detailed Description

The catalyst structure for fluid catalytic cracking of the present invention is characterized by comprising: a porous support composed of a zeolite-type compound; and at least one catalyst substance present in the carrier, the carrier having channels communicating with each other, the catalyst substance being a metal fine particle or a solid acid, at least the channels present in the carrier, preferably channels held at least in a preceding carrier, and in the case where the catalyst substance is a metal fine particle, the catalyst substance being a fine particle of at least one metal selected from the group consisting of nickel (Ni), cobalt (Co), iron (Fe), copper (Cu), gold (Au), silver (Ag), platinum (Pt), palladium (Pd), rhodium (Rd), iridium (Ir), ruthenium (Ru), osmium (Os), and molybdenum (Mo).

With the above configuration, the catalyst substance as the predetermined metal fine particles is present at least in the channels of the support having the porous structure made of the zeolite-type compound, and therefore, the movement by heat or force from the outside of the support is suppressed, and further, the aggregation between the catalyst substances is suppressed. As a result, a decrease in catalytic activity due to a decrease in the effective surface area of the catalyst can be avoided, and the stability of catalytic activity as an FCC structure can be improved.

This provides excellent catalytic activity, and suppresses agglomeration of catalyst substances, thereby realizing good catalytic activity over a long period of time.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

[ constitution of catalyst Structure ]

Fig. 1 is a view schematically showing the structure of a catalyst structure for Fluid Catalytic Cracking (FCC) (hereinafter, simply referred to as "catalyst structure") according to an embodiment of the present invention, fig. 1(a) is a perspective view (partially shown in cross section), and fig. 1(b) is a partially enlarged cross-sectional view. The catalyst structure in fig. 1 is an example thereof, and the shape, size, and the like of each component of the present invention are not limited to fig. 1.

As shown in fig. 1(a), the catalyst structure 1 includes: a porous support 10 made of a zeolite-type compound; and at least one catalyst material 20 present within the support 10.

In the catalyst structure 1, the plurality of catalyst substances 20, … … are present inside the porous structure of the support 10, and are preferably included inside the porous structure of the support 10. The catalyst substance 20 is a metal fine particle or a solid acid having a catalytic function (catalytic activity). The metal fine particles will be described in detail later.

The solid acid is a substance that performs one or more functions alone or by being coordinated with the carrier 10. Specific examples of the functions include: a catalytic function, a light (or fluorescence) function, a light absorbing function, a recognition function, and the like. The solid acid is, for example, a catalyst substance having a catalytic function, and is preferably a fine particle. When the solid acid is a catalyst substance, the carrier 10 is a carrier on which the catalyst substance is supported.

The carrier 10 has a porous structure, and preferably has channels 11 communicating with each other by forming a plurality of holes 11a, … …, as shown in fig. 1 (b). Here, the catalyst substance 20 is present in at least the channels 11 of the carrier 10, and is preferably held in at least the channels 11 of the carrier 10.

With this configuration, the movement of the catalyst substance 20 in the carrier 10 is restricted, and the agglomeration of the catalyst substances 20 and 20 is effectively prevented. As a result, the decrease in the effective surface area of the catalyst material 20 can be effectively suppressed, and the catalytic activity of the catalyst material 20 can be maintained for a long period of time. That is, according to the catalyst structure 1, it is possible to suppress a decrease in catalytic activity due to aggregation of the catalyst substance 20, and to extend the life of the catalyst structure 1. Furthermore, by extending the life of catalyst structure 1, the frequency of replacement of catalyst structure 1 can be reduced, the amount of used catalyst structure 1 to be discarded can be greatly reduced, and resources can be saved.

In general, when a catalyst structure is used in a fluid (e.g., heavy oil), an external force may be applied from the fluid. In this case, if the catalyst substance is held only on the outer surface of the carrier 10 in an adhered state, there is a problem that the catalyst substance is easily detached from the outer surface of the carrier 10 under the influence of an external force from the fluid. In contrast, in the catalyst structure 1, the catalyst substance 20 is held at least in the channels 11 of the carrier 10, and therefore, even if affected by an external force from the fluid, the catalyst substance 20 is less likely to be detached from the carrier 10. Namely, it is considered that: when the catalyst structure 1 is in a fluid, the fluid flows into the channels 11 from the pores 11a of the carrier 10, and therefore the velocity of the fluid flowing through the channels 11 is lower than the velocity of the fluid flowing through the outer surfaces of the carrier 10 due to flow path resistance (frictional force). Due to the influence of such flow path resistance, the pressure that the catalyst substance 20 held in the channel 11 receives from the fluid is smaller than the pressure that the catalyst substance receives from the fluid outside the carrier 10. Therefore, the catalyst substance 20 present in the carrier 11 can be effectively inhibited from being detached, and the catalytic activity of the catalyst substance 20 can be stably maintained for a long period of time. It should be noted that: the channel 11 of the carrier 10 has a plurality of bends and branches, and the more complicated three-dimensional structure is inside the carrier 10, the greater the flow path resistance as described above.

Furthermore, the channel 11 preferably has: any one of one-dimensional pores, two-dimensional pores, and three-dimensional pores defined by the framework structure of the zeolite-type compound; and an enlarged diameter portion 12 different from any of the one-dimensional hole, the two-dimensional hole, and the three-dimensional hole, in which case, the catalyst substance 20 is preferably present at least in the enlarged diameter portion 12, and more preferably included at least in the enlarged diameter portion 12. The one-dimensional hole as used herein means a tunnel-type or cage-type hole in which one-dimensional channels are formed, or a plurality of tunnel-type or cage-type holes (a plurality of one-dimensional channels) in which a plurality of one-dimensional channels are formed. In addition, the two-dimensional hole refers to a two-dimensional hole formed by two-dimensionally connecting a plurality of one-dimensional holes, and the three-dimensional hole refers to a three-dimensional hole formed by three-dimensionally connecting a plurality of one-dimensional holes.

This can further restrict the movement of the catalyst substance 20 in the carrier 10, and can further effectively prevent the catalyst substance 20 from being detached and the catalyst substances 20 and 20 from being aggregated. Inclusion means a state in which the catalyst substance 20 is contained in the carrier 10. In this case, the catalyst substance 20 and the carrier 10 do not necessarily need to be in direct contact with each other, and the catalyst substance 20 may be indirectly held by the carrier 10 with another substance (for example, a surfactant) interposed between the catalyst substance 20 and the carrier 10.

Fig. 1(b) shows a case where the catalyst substance 20 is enclosed in the enlarged diameter portion 12, but the present invention is not limited to this configuration, and the catalyst substance 20 may be held in the passage 11 in a state where a part thereof protrudes outside the enlarged diameter portion 12. The catalyst substance 20 may be partially embedded in a part of the channel 11 other than the enlarged diameter portion 12 (for example, an inner wall portion of the channel 11), or may be held by fastening or the like.

Further, the enlarged diameter portion 12 preferably causes a plurality of holes 11a, 11a constituting any one of the one-dimensional hole, the two-dimensional hole, and the three-dimensional hole to communicate with each other. Thus, since a separate channel different from the one-dimensional hole, the two-dimensional hole, or the three-dimensional hole is provided inside the skeleton body 10, the metal oxide fine particles 20 can further function.

Further, it is preferable that the channel 11 is three-dimensionally formed so as to include a branching portion or a merging portion in the carrier 10, and the diameter-enlarged portion 12 is provided in the branching portion or the merging portion of the channel 11.

The average inner diameter D of the channels 11 formed in the carrier 10 is calculated from the average of the minor diameter and the major diameter of the holes 11a constituting any one of the one-dimensional holes, the two-dimensional holes, and the three-dimensional holes_FFor example, it is 0.1nm to 1.5nm, preferably 0.5nm to 0.8 nm. Further, the inner diameter D of the enlarged diameter portion 12_EFor example, 0.5nm to 50nm, preferably 1.1nm to 40nm, and more preferably 1.1nm to 3.3 nm. Inner diameter D of enlarged diameter portion 12_EFor example, the pore diameter of the precursor (a) described later and the average particle diameter DC of the enclosed catalyst substance 20. The inner diameter DE of the enlarged diameter portion 12 is a size capable of enclosing the catalyst substance 20.

The support 10 is composed of a zeolite-type compound. Examples of the zeolite-type compound include: silicate compounds such as zeolite (aluminosilicate), cation-exchange zeolite, and silicalite (silicalite); zeolite-like compounds such as aluminoborate, aluminoarsenate, germanate and the like; and phosphate-based zeolite-like substances such as molybdenum phosphate. Among them, the zeolite-type compound is preferably a silicate compound.

The framework structure of the zeolite-type compound is selected from FAU-type (Y-type or X-type), MTW-type, MFI-type (ZSM-5), FER-type (ferrierite), LTA-type (a-type), MWW-type (MCM-22), MOR-type (mordenite), LTL-type (L-type), BEA-type (β -type), and the like, and when the catalyst material 20 is a metal fine particle, the FAU-type is preferable, and the Y-type is more preferable, from the viewpoint of catalytic activity as a catalyst for FCC. In addition, in the case where the catalyst material 20 is a solid acid, it is preferably an MFI type, and more preferably ZSM-5.

The zeolite-type compound has a plurality of pores formed therein and having pore diameters corresponding to the respective framework structures, and for example, FAU-type zeolite has a maximum pore diameter of 0.80nm

Average pore diameter of 0.74nm

The catalyst substance 20 will be described in detail below.

The catalyst substance 20 is a metal particulate or a solid acid. In the case where the catalyst substance 20 is a solid acid, fine particles are preferable. The fine metal particles or the fine solid acid particles (hereinafter referred to as "fine solid acid particles") may be primary particles or secondary particles formed by aggregating the primary particles, but the fine metal particles or the fine solid acid particles have an average particle diameter D_CPreferably greater than the average internal diameter D of the channel 11_FAnd is not more than the inner diameter D of the diameter-expanding portion 12_E(D_F<D_C≤D_E). The catalyst material 20 is preferably enclosed in the diameter-enlarged portion 12 in the channel 11 to restrict the movement of the catalyst material 20 in the carrier 10. Therefore, even when the catalyst substance 20 receives an external force from the fluid, the catalyst substance 20 can be suppressed from being supported on the carrierThe catalyst substances 20, … … contained in the diameter-enlarged portions 12, … … of the channels 11 of the carrier 10 can be effectively prevented from coming into contact with each other even when the catalyst substances move within the carrier 10.

In the case of either the primary particles or the secondary particles, the average particle diameter D of the fine metal particles_CPreferably 0.08 to 30nm, more preferably 0.08 to less than 25nm, still more preferably 0.4 to 11.0nm, and particularly preferably 0.8 to 2.7 nm. Further, the average particle diameter D of the metal fine particles_CRelative to the mean internal diameter D of the channel 11_FRatio (D)_C/D_F) Preferably 0.05 to 300, more preferably 0.1 to 30, further preferably 1.1 to 30, and particularly preferably 1.4 to 3.6.

In the case of either the primary particles or the secondary particles, the average particle diameter D of the fine solid acid particles_CPreferably 0.1 to 50nm, more preferably 0.1 to less than 30nm, still more preferably 0.45 to 14.0nm, and particularly preferably 1.0 to 3.3 nm. Further, the average particle diameter D of the solid acid 20_CRelative to the mean internal diameter D of the channel 11_FRatio (D)_C/D_F) Preferably 0.06 to 500, more preferably 0.1 to 36, further preferably 1.1 to 36, and particularly preferably 1.7 to 4.5.

The content of the metal element (M) in the fine metal particles or the solid acid is preferably 0.5 to 2.5 mass% with respect to the catalyst structure 1, and more preferably 0.5 to 1.5 mass% with respect to the catalyst structure 1. For example, in the case where the metal element (M) is Co, the content (mass%) of the Co element is represented by (mass of the Co element)/(mass of all elements of the catalyst structure 1) × 100.

The fine metal particles may be composed of an unoxidized metal, and may be composed of a single metal or a mixture of two or more metals. In the present specification, "metal" constituting (as a material of) the metal fine particles means a single metal containing one metal element (M) and a metal alloy containing two or more metal elements (M), and is a generic term for metals containing one or more metal elements.

The metal fine particles as the catalyst material 20 are fine particles of at least one metal selected from the group consisting of nickel (Ni), cobalt (Co), iron (Fe), copper (Cu), gold (Au), silver (Ag), platinum (Pt), palladium (Pd), rhodium (Rd), iridium (Ir), ruthenium (Ru), osmium (Os), and molybdenum (Mo). The metal fine particles as the catalyst substance 20 are fine particles of a metal containing one or more of these metals as a main component.

Among these metals, from the viewpoint of catalytic activity as an FCC catalyst, at least one selected from the group consisting of nickel (Ni), cobalt (Co), iron (Fe), copper (Cu), platinum (Pt), and molybdenum (Mo) is more preferable, and at least one selected from the group consisting of nickel (Ni), cobalt (Co), iron (Fe), and platinum (Pt) is more preferable. It is further preferred that these fine particles of the preferred metal or more preferred metal are used in combination with Y-type zeolite, respectively.

On the other hand, as the solid acid of the catalyst substance 20, specific examples include: metal oxides and hydrates thereof, sulfides, metal salts, composite oxides, and heteropolyacids. Examples of the metal oxide include: iron oxide (FeOx), zinc oxide (ZnO), aluminum oxide (Al)₂O₃) Zirconium oxide (ZrO)₂) Titanium oxide (TiO)₂) Selenium trioxide (SeO)₃) Selenium dioxide (SeO)₂) Tellurium trioxide (TeO)₃) Tellurium dioxide (TeO)₂) Tin dioxide (SnO)₂) Manganese oxide (Mn)₂O₇) Technetium oxide (Tc)₂O₇) And rhenium oxide (Re)₂O₇). Examples of the sulfide include cadmium sulfide (CdS) and zinc sulfide (ZnS). In addition, as the metal salt, magnesium sulfate (MgSO) can be mentioned₄) Iron sulfate (FeSO)₄) And aluminum chloride (AlCl)₃). Further, the composite oxide may be SiO₂-TiO₂、SiO₂MgO and TiO₂-ZrO₂. Furthermore, examples of the heteropoly acid include phosphotungstic acid, silicotungstic acid, phosphomolybdic acid, and silicomolybdic acid. These solid acids may be used alone or in combination of two or more. As the solid acid, among these metal oxides, it is preferable to select from the group consisting of aluminum oxide (Al)₂O₃) Zirconium oxide (ZrO)₂) And zinc oxide (ZnO). The solid acid is distinguished from the zeolite-type compound constituting the carrier 10. The solid acid does not contain, for example, zeolite.

The ratio (atomic ratio Si/M) of silicon (Si) constituting the carrier 10 to the metal element (M) constituting the fine metal particles or the solid acid is preferably 10 to 1000. When the above ratio is 1000 or less, the activity is high and the function as a catalyst substance can be sufficiently obtained. On the other hand, when the ratio is 10 or more, the ratio of the metal fine particles does not become too large, and a decrease in the strength of the carrier 10 can be suppressed. The metal fine particles referred to herein are fine particles held or carried in the carrier 10, and do not include metal fine particles attached to the outer surface of the carrier 10.

[ function of catalyst Structure ]

As described above, the catalyst structure 1 includes: a support 10 having a porous structure; and at least one catalyst material 20 present within the support. The catalyst structure 1 exhibits a catalytic function corresponding to the function of the catalyst substance 20 when the catalyst substance 20 present in the carrier comes into contact with a fluid. Specifically, the fluid that contacts the outer surface 10a of the catalyst structure 1 flows into the inside of the carrier 10 from the holes 11a formed in the outer surface 10a, is guided into the channels 11, moves through the channels 11, and flows out of the catalyst structure 1 through the other holes 11 a. In the path of the fluid moving through the inside of the channel 11, by contacting with the catalyst substance 20 held in the channel 11, a catalytic reaction corresponding to the catalyst substance 20 occurs. Further, since the support has a porous structure, the catalyst structure 1 has a molecular sieve function.

First, the molecular sieve function of the catalyst structure 1 will be described by taking a case where the fluid is a liquid containing benzene, propylene, and mesitylene as an example, with reference to fig. 2 (a). As shown in fig. 2(a), a compound (e.g., benzene, propylene) composed of molecules having a size equal to or smaller than the pore diameter of the pores 11a, in other words, equal to or smaller than the inner diameter of the channels 11 can be impregnated into the carrier 10. On the other hand, a compound (e.g., mesitylene) composed of molecules having a size larger than the pore diameter of the pores 11a cannot infiltrate into the support 10. In this way, when the fluid contains a plurality of compounds, the reaction of the compounds that cannot be impregnated into the carrier 10 is restricted, and the compounds impregnated into the carrier 10 can be reacted.

Among the compounds generated in the carrier 10 by the reaction, only compounds composed of molecules having a size not larger than the pore diameter of the pores 11a can be obtained as reaction products by flowing out of the carrier 10 through the pores 11 a. On the other hand, if the compound that cannot flow out of the pores 11a to the outside of the carrier 10 is converted into a compound composed of molecules having a size that can flow out of the carrier 10, the compound can flow out of the carrier 10. In this manner, a specific reaction product can be selectively obtained by using the catalyst structure 1.

In the catalyst structure 1, as shown in fig. 2(b), the catalyst substance 20 is enclosed in the enlarged diameter portion 12 of the channel 11. The average particle diameter D of the metal fine particles as the catalyst material 20_CGreater than the average internal diameter D of the channel 11_FAnd is smaller than the inner diameter D of the diameter-enlarged part 12_EIn the case of (D)_F<D_C<D_E) Small passages 13 are formed between the fine metal particles and the diameter-enlarged portion 12. Therefore, as shown by the arrows in fig. 2(b), the fluid that has entered the small passages 13 comes into contact with the metal particles. Since each fine metal particle is wrapped in the enlarged diameter portion 12, the movement of the fine metal particles in the carrier 10 is restricted. This prevents the metal microparticles in the carrier 10 from aggregating with each other. As a result, a large contact area between the metal fine particles and the fluid can be stably maintained.

In the present embodiment, by using the catalyst structure 1 in the FCC process, it is possible to produce gasoline having a high octane number together with propylene or the like, using hydrocarbons having a high boiling point such as alkylbenzene as a raw material. As described above, in the catalyst structure 1, since the aggregation of the catalyst substances 20 is suppressed, the catalytic activity can be maintained for a long period of time as compared with the conventional catalyst, and the life of the catalyst structure 1 can be extended.

[ method for producing catalyst Structure ]

Fig. 3 is a flowchart illustrating a method of manufacturing the catalyst structure 1 of fig. 1. An example of a method for producing a catalyst structure in which the catalyst material present in the carrier is fine metal particles will be described below.

(step S1: preparation Process)

As shown in fig. 3, first, a precursor material (a) for obtaining a support having a porous structure made of a zeolite-type compound is prepared. The precursor material (a) is preferably a regular mesoporous substance, and may be appropriately selected depending on the kind (composition) of the zeolite-type compound constituting the support of the catalyst structure.

Here, when the zeolite-type compound constituting the carrier of the catalyst structure is a silicate compound, the regular mesoporous material is preferably a compound containing an Si — O framework in which pores having a pore diameter of 1nm to 50nm are uniformly and regularly developed in one-dimensional, two-dimensional or three-dimensional size. Such a ordered mesoporous material is obtained as various compositions according to synthesis conditions, and specific examples of the compositions include: SBA-1, SBA-15, SBA-16, KIT-6, FSM-16, MCM-41 and the like, wherein MCM-41 is preferred. The pore diameter of SBA-1 is 10nm to 30nm, the pore diameter of SBA-15 is 6nm to 10nm, the pore diameter of SBA-16 is 6nm, the pore diameter of KIT-6 is 9nm, the pore diameter of FSM-16 is 3nm to 5nm, and the pore diameter of MCM-41 is 1nm to 10 nm. Examples of such a regular mesoporous material include: mesoporous silica, mesoporous aluminosilicates, mesoporous metallosilicates, and the like.

The precursor (a) may be any of commercially available products and synthetic products. In the case of synthesizing the precursor material (a), it can be carried out by a known method for synthesizing a regular mesoporous substance. For example, a mixed solution containing a raw material containing a constituent element of the precursor material (a) and a template agent for specifying the structure of the precursor material (a) is prepared, and hydrothermal treatment (hydrothermal synthesis) is performed by adjusting the pH as necessary. Thereafter, the precipitate (product) obtained by the hydrothermal treatment is recovered (for example, filtered), washed and dried as necessary, and further fired, whereby the precursor material (a) as a regular mesoporous substance in a powder form can be obtained. Here, as the solvent of the mixed solution, for example, water, an organic solvent such as alcohol, or a mixed solvent thereof can be used. The raw material is selected depending on the kind of the carrier, and examples thereof include: silicon agents (silica agents) such as Tetraethoxysilane (TEOS), fumed silica, quartz sand, and the like. Further, as the template agent, various surfactants, block copolymers and the like can be used, and it is preferably selected according to the kind of the composition of the ordered mesoporous material, and for example, in the case of preparing MCM-41, a surfactant such as cetyltrimethylammonium bromide is preferred. The hydrothermal treatment may be carried out, for example, in a closed vessel under the treatment conditions of 80 to 800 ℃ for 5 to 240 hours and 0 to 2000 kPa. The firing treatment may be carried out, for example, in air under the treatment conditions of 350 to 850 ℃ for 2 to 30 hours.

(step S2: impregnation step)

Next, the prepared precursor material (a) is immersed in a metal-containing solution to obtain a precursor material (B).

The metal-containing solution may be a solution containing a metal component (for example, metal ion) corresponding to the metal element (M) constituting the fine metal particles or the solid acid of the catalyst structure, and may be prepared by dissolving a metal salt containing the metal element (M) in a solvent, for example. Examples of such metal salts include: chlorides, hydroxides, oxides, sulfates, nitrates, etc., among which nitrates are preferred. Examples of the solvent include water, organic solvents such as alcohols, and mixed solvents thereof.

The method for immersing the metal-containing solution in the precursor material (a) is not particularly limited, and for example, it is preferable to add the metal-containing solution in small amounts in a plurality of times while stirring the powdery precursor material (a) before the firing step described later. In addition, from the viewpoint that the metal-containing solution is more likely to infiltrate into the inside of the pores of the precursor material (a), it is preferable to add a surfactant as an additive in advance before adding the metal-containing solution to the precursor material (a). It is considered that such an additive has an effect of covering the outer surface of the precursor material (a), and it suppresses the metal-containing solution added later from adhering to the outer surface of the precursor material (a), and the metal-containing solution is more likely to infiltrate into the inside of the pores of the precursor material (a).

Examples of such additives include polyoxyethylene alkyl ethers such as polyoxyethylene oleyl ether and nonionic surfactants such as polyoxyethylene alkylphenyl ether. Consider that: these surfactants have large molecular sizes and cannot enter the pores of the precursor material (a), and therefore do not adhere to the inside of the pores and do not inhibit the metal-containing solution from entering the inside of the pores. As a method for adding the nonionic surfactant, for example, 50 to 500 mass% of the nonionic surfactant is preferably added to the precursor material (a) before the firing step described later. If the amount of the nonionic surfactant added to the precursor material (a) is less than 50 mass%, the above-described inhibiting effect is difficult to be exhibited, and if the amount of the nonionic surfactant added to the precursor material (a) is more than 500 mass%, the viscosity is excessively increased, which is not preferable. Therefore, the amount of the nonionic surfactant added to the precursor material (a) is set to a value within the above range.

The amount of the metal-containing solution added to the precursor material (a) is preferably adjusted as appropriate in consideration of the amount of the metal element (M) contained in the metal-containing solution impregnated in the precursor material (a) (that is, the amount of the metal element (M) present in the precursor material (B)). For example, the amount of the metal-containing solution added to the precursor material (a) is preferably adjusted so that the ratio (atomic ratio Si/M) of silicon (Si) constituting the precursor material (a) to a metal element (M) contained in the metal-containing solution added to the precursor material (a) is 10 to 1000, more preferably 50 to 200, before the firing step described later. For example, when a surfactant is added as an additive to the precursor material (a) before the metal-containing solution is added to the precursor material (a), the content of the metal element (M) in the metal oxide fine particles can be set to 0.5 to 2.5 mass% relative to the catalyst structure 1 by setting the amount of the metal-containing solution added to the precursor material (a) to 50 to 200 in terms of the atomic ratio Si/M.

In the state of the precursor material (B), if the metal concentration of the metal-containing solution, the presence or absence of the additive, and other conditions such as temperature and pressure are the same, the amount of the metal element (M) present in the pores thereof is substantially proportional to the amount of the metal-containing solution added to the precursor material (a). Further, the amount of the metal element (M) present in the precursor material (B) is in proportional relation to the amount of the metal element constituting the metal fine particles present in the carrier of the catalyst structure. Therefore, by controlling the amount of the metal-containing solution added to the precursor material (a) within the above range, the metal-containing solution can be sufficiently impregnated into the pores of the precursor material (a), and the amount of the metal fine particles present in the support of the catalyst structure can be adjusted.

After the precursor material (a) is immersed in the metal-containing solution, a cleaning treatment may be performed as needed. As the cleaning solution, water, an organic solvent such as alcohol, or a mixed solution thereof can be used. Further, it is preferable that the metal-containing solution is immersed in the precursor material (a) and, after a cleaning treatment is performed as necessary, a drying treatment is further performed. Examples of the drying treatment include natural drying at about evening-out and high-temperature drying at 150 ℃. When the firing treatment described later is performed in a state where a large amount of moisture contained in the metal-containing solution or moisture in the cleaning solution remains in the precursor (a), the skeleton structure of the regular mesoporous material as the precursor (a) may be broken, and therefore, it is preferable to sufficiently dry the precursor (a).

(step S3: firing Process)

Next, a precursor material (B) obtained by impregnating a precursor material (a) for obtaining a support having a porous structure made of a zeolite-type compound with a metal-containing solution is fired to obtain a precursor material (C).

The firing treatment is preferably carried out in air at a temperature of 350 to 850 ℃ for 2 to 30 hours, for example. By such firing treatment, the metal component crystals impregnated into the pores of the regular mesoporous material grow, and metal fine particles are formed in the pores.

(step S4: hydrothermal treatment Process)

Next, a mixed solution in which the precursor material (C) and the structure directing agent are mixed is prepared, and the precursor material (C) obtained by firing the precursor material (B) is subjected to hydrothermal treatment to obtain the catalyst structure.

The structure-directing agent is a template agent for defining the framework structure of the support of the catalyst structure, and for example, a surfactant can be used. The structure-directing agent is preferably selected according to the skeletal structure of the support of the catalyst structure, and is preferably a surfactant such as tetramethylammonium bromide (TMABr), tetraethylammonium bromide (TEABr), tetrapropylammonium bromide (TPABr), or the like.

The mixing of the precursor material (C) and the structure-directing agent may be performed in the present hydrothermal treatment step, or may be performed before the hydrothermal treatment step. The method for preparing the mixed solution is not particularly limited, and the precursor material (C), the structure-directing agent, and the solvent may be mixed at the same time, or the precursor material (C) and the structure-directing agent may be dispersed in the solvent in the respective solutions and then the respective dispersed solutions may be mixed. Examples of the solvent include water, organic solvents such as alcohols, and mixed solvents thereof. It is preferable that the pH of the mixed solution is adjusted in advance with an acid or an alkali before the hydrothermal treatment.

The hydrothermal treatment can be carried out by a known method, and is preferably carried out in a closed vessel under treatment conditions of, for example, 80 to 800 ℃ for 5 to 240 hours and 0 to 2000 kPa. Further, it is preferable to perform hydrothermal treatment in an alkaline environment.

Although the reaction mechanism is not necessarily clear here, when the precursor material (C) is subjected to hydrothermal treatment as a raw material, the skeleton structure of the regular mesoporous material as the precursor material (C) is gradually destroyed, but the position of the metal fine particles inside the pores of the precursor material (C) is substantially maintained, and a new skeleton structure (porous structure) serving as a support of the catalyst structure is formed by the action of the structure-directing agent. The catalyst structure obtained in this way comprises a support having a porous structure and metal fine particles present in the support, the support further has channels that communicate the plurality of pores with each other through the porous structure of the support, and at least a part of the metal fine particles are held in the channels of the support.

In the present embodiment, in the hydrothermal treatment step, a mixed solution in which the precursor material (C) and the structure-directing agent are mixed is prepared, and the hydrothermal treatment is performed on the precursor material (C), but the present invention is not limited thereto, and the hydrothermal treatment may be performed on the precursor material (C) without mixing the precursor material (C) and the structure-directing agent.

It is preferable that the precipitate (catalyst structure) obtained after the hydrothermal treatment is recovered (e.g., filtered), and then washed, dried, and fired as necessary. As the cleaning solution, water, an organic solvent such as alcohol, or a mixed solution thereof can be used. Examples of the drying treatment include natural drying at about evening-out and high-temperature drying at 150 ℃. When the calcination treatment is performed in a state where a large amount of water remains in the precipitate, the skeleton structure of the carrier serving as the catalyst structure may be broken, and therefore, it is preferable to sufficiently dry the catalyst structure. The firing treatment may be performed, for example, in air under the treatment conditions of 350 to 850 ℃ for 2 to 30 hours. By such a firing treatment, the structure directing agent attached to the catalyst structure is burned off. Further, depending on the purpose of use, the catalyst structure may be used as it is without subjecting the recovered precipitate to firing treatment. For example, when the environment in which the catalyst structure is used is a high-temperature environment such as an oxidizing environment, the structure-directing agent is burned off by exposure to the use environment for a certain period of time, and the catalyst structure can be obtained as it is as in the case of performing the firing treatment.

The above-described production method is an example of the case where the metal element (M) contained in the metal-containing solution impregnated into the precursor material (a) is a metal species (for example, noble metal) that is difficult to oxidize.

When the metal element (M) contained in the metal-containing solution impregnated in the precursor (a) is a metal species (for example, Fe, Co, Cu, or the like) that is easily oxidized, it is preferable to perform a reduction treatment on the precursor (C) after the hydrothermal treatment step. When the metal element (M) contained in the metal-containing solution is a metal species that is easily oxidized, the metal component is oxidized by the heat treatment in the step (steps S3 to 4) after the impregnation treatment (step S2). Therefore, the metal oxide fine particles are present in the carrier formed in the hydrothermal treatment step (step S4). Therefore, in order to obtain a catalyst structure in which fine metal particles are present in the carrier, it is preferable that the collected precipitate is subjected to a firing treatment after the hydrothermal treatment, and further subjected to a reduction treatment in a reducing gas atmosphere such as hydrogen gas. By performing the reduction treatment, the metal oxide fine particles present in the carrier are reduced to form metal fine particles corresponding to the metal element (M) constituting the metal oxide fine particles. As a result, a catalyst structure in which fine metal particles are present in the carrier is obtained. For example, when the environment in which the catalyst structure is used is a reducing environment, the metal oxide fine particles are reduced by exposure to the reducing environment for a certain period of time, and the catalyst structure similar to the case where the reducing treatment is performed is obtained, and therefore, the catalyst structure can be used as it is with the oxide fine particles present in the carrier.

[ modified example of catalyst Structure 1]

Fig. 4 is a schematic diagram showing a modification of the catalyst structure 1 of fig. 1.

Although the catalyst structure 1 in fig. 1 is shown to include the carrier 10 and the catalyst substance 20 present in the carrier 10, the present invention is not limited to this configuration, and the catalyst structure 2 may further include another catalyst substance 30 held on the outer surface 10a of the carrier 10, as shown in fig. 4, for example.

The catalyst material 30 is a material that performs one or more catalytic functions. The catalytic function of the other catalyst substance 30 may be the same as or different from the catalytic function of the catalyst substance 20. In the case where both of the catalyst substances 20 and 30 have the same catalytic function, the material of the other catalyst substance 30 may be the same as or different from the material of the catalyst substance 20. According to the present configuration, the content of the catalyst substance held by the catalyst structure 2 can be increased, and the catalytic activity of the catalyst substance can be further promoted.

In this case, it is preferable that the content of the catalyst substance 20 present in the carrier 10 is greater than the content of the other catalyst substance 30 held on the outer surface 10a of the carrier 10. Thus, the catalytic function of the catalyst substance 20 held in the carrier 10 becomes dominant, and the catalytic function of the catalyst substance is stably exhibited.

The catalyst structure according to the embodiment of the present invention has been described above, but the present invention is not limited to the above embodiment, and various modifications and changes can be made based on the technical idea of the present invention.

For example, in the above embodiment, the appearance of the catalyst structure is a powder, but the catalyst structure is not limited thereto, and may be in the form of cylindrical, leaf-shaped, dumbbell-shaped, or annular particles. The molding method for obtaining the catalyst structure having the above shape is not particularly limited, but a general method such as extrusion molding, tablet molding, or granulation in oil can be used. Further, for example, a method of obtaining a catalyst structure may be adopted in which a catalyst structure is produced by molding a catalyst powder by a uniaxial pressurizer, and then the catalyst structure is made to pass through a screen while pulverizing the catalyst molded body, thereby obtaining a catalyst structure composed of at least one type of secondary particles having a target secondary particle diameter. A catalyst structure or a molded catalyst body can be referred to as a catalyst structure or a molded catalyst body in a state where the catalyst structure is granulated by the above-described method. When the catalyst structure is granulated, for example, a catalyst structure having an average particle diameter (or an average of equivalent circle diameters) of, for example, 0.01 to 15 μm can be molded. When the catalyst structure is enlarged to several centimeters or more, it may be molded by mixing a binder such as alumina. The catalyst structure or the catalyst molded body having the above shape and size can prevent the catalyst layer from being clogged with impurities, fractions, and the like when cracking high-boiling hydrocarbons such as vacuum gas oil, atmospheric residual oil, and the like to produce high-octane gasoline, for example.

The catalyst structure of the present invention may be a powder or a molded body, and the form thereof is not particularly limited, but for example, when the amount of the organic metal compound such as vanadium or nickel contained in the FCC feed oil is large, the metal component is deposited on the catalyst, and the reaction may be stopped by pressure loss, and the molded body is preferable.

Further, for example, an apparatus for fluid catalytic cracking provided with the catalyst structure can be provided. Examples of such an apparatus include an FCC apparatus, a propylene rectifying apparatus provided with an FCC apparatus, and a desulfurization apparatus for cracked gasoline. The same effects as described above can be obtained by using the catalyst structure of the present invention in a catalytic reaction using such a device.