As zeólitas sintéticas contendo terras raras (TR) são os componentes principais de catalisadores FCC (Fluid Catalytic Cracking) empregados no craqueamento do petróleo e a porcentagem de TR nestes catalisadores pode chegar a 5%. As TR são adicionadas às zeólitas tipo Y para melhorar sua estabilidade térmica e hidrotérmica durante o processo de refino do petróleo. A produção brasileira destes catalisadores está em torno de 25 mil toneladas por ano, necessitando, para tanto, de 900 toneladas de óxido de lantânio no mesmo período. Atualmente, a China é responsável por 90% da produção e comercialização mundial das TR. Desde 2010, a China controla os preços das mesmas (ao final de 2011 chegou a elevar o preço do lantânio em mais de 20 vezes), bem como reduziu substancialmente sua cota de exportação. É nesse contexto que surge a necessidade da reciclagem de materiais que possuem TR em sua constituição, como é o caso dos catalisadores FCC provenientes do craqueamento do petróleo. Outra fonte que merece destaque, tendo sido igualmente explorada neste trabalho, é os pós-fosfóricos responsáveis por gerar a luz branca em lâmpadas fluorescentes. Atualmente a Rhodia, do grupo Solvay, já iniciou a recuperação das TR em pós-fosfóricos. As principais TR utilizadas em lâmpadas fluorescentes são La, Ce, Eu, Tb e Y, encontrados nos compostos Y2O3:Eu3+, BaMgAl10O17:Eu2+ e LaPO4:Ce3+,Tb3+. Os elementos Eu, Tb e Y têm alto valor agregado, representando de 5 a 20% em massa dos pós-fosfóricos. Sendo assim, o objetivo deste trabalho foi desenvolver uma metodologia economicamente viável e, sobretudo, com baixa utilização e produção de substâncias perigosas para a separação e recuperação de íons de TR contidos na zeólita tipo Y, componente dos catalisadores FCC desativados, previamente empregados no craqueamento de petróleo, bem como em lâmpadas fluorescentes. Inicialmente, realizou-se a caracterização preliminar dos componentes dos catalisadores FCC desativados. Posteriormente, buscou-se o desenvolvimento de metodologias de separação química para obtenção dos elementos de TR e caracterização dos mesmos por diversas técnicas, tais como espectroscopia de fotoluminescência, fluorescência de Raios-X, titulometria de complexação, microscopia eletrônica de varredura e espectroscopia de infravermelho / Synthetic zeolites containing rare earths (RE) are the major components of FCC (Fluid Catalytic Cracking) catalysts used in petroleum cracking, where the percentage of such elements is about 5%. RE ions improve the thermal and hydrothermal stability of zeolites-Y during the petroleum refining process. The Brazilian production of these catalysts is around 25 thousand tons per year, requiring 900 tons of lanthanum oxide in the same period. Currently, China is responsible for 90% of the world production and market of RE. Since 2010, China controls the prices of RE elements and substantially reduced the exportation quota. For instance, by the end of 2011 the price of lanthanum was risen by more than 20 times. In this context, the search for recycling materials that have rare earths in their constitution becomes crucial, as is the case of the FCC catalysts from the cracking of petroleum. Another source that deserves significant attention is the phosphoric powders that generate white light in fluorescent lamps, which were also investigated in this work. Rhodia from the Solvay group has already begun the recovery of rare earths in phosphoric powders. The main RE used in fluorescent lamps are La, Ce, Eu, Tb and Y, which occur as Y2O3: Eu3+, BaMgAl10O17:Eu2+ and LaPO4:Ce3+, Tb3+. Eu, Tb and Y are high-value elements, representing by 5 20% of the total mass of phosphoric powders. Therefore, the aim of this work was to develop economically feasible and environmental friendly methodologies for the separation and recovery of RE ions from zeolite-Yin deactivated FCC catalysts and from fluorescent lamp phosphors. To this end, we firstly performed a preliminary characterization of the components of deactivated FCC catalysts. The following steps comprised the development of chemical separation methodologies to obtain rare earth elements and their characterization by several techniques such as photoluminescence spectroscopy, X-ray fluorescence, complexation titration, scanning electron microscopy and infrared spectroscopy

As zeólitas sintéticas contendo terras raras (TR) são os componentes principais de catalisadores FCC (Fluid Catalytic Cracking) empregados no craqueamento do petróleo e a porcentagem de TR nestes catalisadores pode chegar a 5%. As TR são adicionadas às zeólitas tipo Y para melhorar sua estabilidade térmica e hidrotérmica durante o processo de refino do petróleo. A produção brasileira destes catalisadores está em torno de 25 mil toneladas por ano, necessitando, para tanto, de 900 toneladas de óxido de lantânio no mesmo período. Atualmente, a China é responsável por 90% da produção e comercialização mundial das TR. Desde 2010, a China controla os preços das mesmas (ao final de 2011 chegou a elevar o preço do lantânio em mais de 20 vezes), bem como reduziu substancialmente sua cota de exportação. É nesse contexto que surge a necessidade da reciclagem de materiais que possuem TR em sua constituição, como é o caso dos catalisadores FCC provenientes do craqueamento do petróleo. Outra fonte que merece destaque, tendo sido igualmente explorada neste trabalho, é os pós-fosfóricos responsáveis por gerar a luz branca em lâmpadas fluorescentes. Atualmente a Rhodia, do grupo Solvay, já iniciou a recuperação das TR em pós-fosfóricos. As principais TR utilizadas em lâmpadas fluorescentes são La, Ce, Eu, Tb e Y, encontrados nos compostos Y2O3:Eu3+, BaMgAl10O17:Eu2+ e LaPO4:Ce3+,Tb3+. Os elementos Eu, Tb e Y têm alto valor agregado, representando de 5 a 20% em massa dos pós-fosfóricos. Sendo assim, o objetivo deste trabalho foi desenvolver uma metodologia economicamente viável e, sobretudo, com baixa utilização e produção de substâncias perigosas para a separação e recuperação de íons de TR contidos na zeólita tipo Y, componente dos catalisadores FCC desativados, previamente empregados no craqueamento de petróleo, bem como em lâmpadas fluorescentes. Inicialmente, realizou-se a caracterização preliminar dos componentes dos catalisadores FCC desativados. Posteriormente, buscou-se o desenvolvimento de metodologias de separação química para obtenção dos elementos de TR e caracterização dos mesmos por diversas técnicas, tais como espectroscopia de fotoluminescência, fluorescência de Raios-X, titulometria de complexação, microscopia eletrônica de varredura e espectroscopia de infravermelho / Synthetic zeolites containing rare earths (RE) are the major components of FCC (Fluid Catalytic Cracking) catalysts used in petroleum cracking, where the percentage of such elements is about 5%. RE ions improve the thermal and hydrothermal stability of zeolites-Y during the petroleum refining process. The Brazilian production of these catalysts is around 25 thousand tons per year, requiring 900 tons of lanthanum oxide in the same period. Currently, China is responsible for 90% of the world production and market of RE. Since 2010, China controls the prices of RE elements and substantially reduced the exportation quota. For instance, by the end of 2011 the price of lanthanum was risen by more than 20 times. In this context, the search for recycling materials that have rare earths in their constitution becomes crucial, as is the case of the FCC catalysts from the cracking of petroleum. Another source that deserves significant attention is the phosphoric powders that generate white light in fluorescent lamps, which were also investigated in this work. Rhodia from the Solvay group has already begun the recovery of rare earths in phosphoric powders. The main RE used in fluorescent lamps are La, Ce, Eu, Tb and Y, which occur as Y2O3: Eu3+, BaMgAl10O17:Eu2+ and LaPO4:Ce3+, Tb3+. Eu, Tb and Y are high-value elements, representing by 5 20% of the total mass of phosphoric powders. Therefore, the aim of this work was to develop economically feasible and environmental friendly methodologies for the separation and recovery of RE ions from zeolite-Yin deactivated FCC catalysts and from fluorescent lamp phosphors. To this end, we firstly performed a preliminary characterization of the components of deactivated FCC catalysts. The following steps comprised the development of chemical separation methodologies to obtain rare earth elements and their characterization by several techniques such as photoluminescence spectroscopy, X-ray fluorescence, complexation titration, scanning electron microscopy and infrared spectroscopy

Submitted by Irene Nascimento (irene.kessia@ufpe.br) on 2016-04-15T15:07:33Z No. of bitstreams: 2 license_rdf: 1232 bytes, checksum: 66e71c371cc565284e70f40736c94386 (MD5) Dissertação CONTROLE DA INJEÇÃO DE CATALISADOR EM UMA UNIDADE PILOTO TIPO FCC A FRIO.pdf: 3413557 bytes, checksum: 5abbf7dd3a8cab8c21085e585d6282f6 (MD5) / Made available in DSpace on 2016-04-15T15:07:33Z (GMT). No. of bitstreams: 2 license_rdf: 1232 bytes, checksum: 66e71c371cc565284e70f40736c94386 (MD5) Dissertação CONTROLE DA INJEÇÃO DE CATALISADOR EM UMA UNIDADE PILOTO TIPO FCC A FRIO.pdf: 3413557 bytes, checksum: 5abbf7dd3a8cab8c21085e585d6282f6 (MD5) Previous issue date: 2015-08-31 / CNPQ / O Craqueamento Catalítico Fluidizado (FCC) é largamente utilizado no processo de refino do petróleo para transformar hidrocarbonetos de baixo valor comercial em produtos de elevado valor agregado, como gasolina, diesel e GLP. A crescente demanda de combustíveis fósseis, que são recursos não renováveis, requer melhor compreensão do processo e da operação, desafios que tem atraído o interesse da indústria e da academia pelo FCC. Esse processo é bastante competitivo e está em continuo desenvolvimento tecnológico, cujas pesquisas estão divididas em duas grandes linhas: modelos fluidodinâmicos frios e modelos cinéticos. A combinação das informações obtidas nas linhas de pesquisas deve retornar ao processo industrial e garantir a competitividade. Com essa perspectiva, foi construída uma Unidade Piloto a Frio (UPF), no Departamento de Energia Nuclear da UFPE, para a investigação de parâmetros fluidodinâmicos no riser da unidade com auxílio das medidas de transmissão gama. A transmissão gama é requerida como método não intrusivo para medir a distribuição da concentração do catalisador no reator do FCC o riser. Com a operação da UPF realizam-se medidas em tempo real de pressão, vazão, intensidade da radiação, com a condição de que a automação garante que as variáveis do sistema estão sob controle. Este controle é necessário para realização das medidas porque as hipóteses dos modelos matemáticos para simular o escoamento bifásico ar–catalisador de FCC, assumem que o sistema é um leito fluidizado circulando em regime estacionário. Numa unidade piloto como no processo industrial, o controle da injeção de catalisador é um processo de extrema importância, pois a eficiência da reação de craqueamento dos hidrocarbonetos depende da concentração e da distribuição do catalisador no riser. No presente trabalho foi desenvolvido um novo tipo de injetor de sólidos, com desempenho avaliado em função da pressão, intensidade gama e da estabilidade do sistema sob controle automatizado. Os resultados apresentados demonstram que as variáveis do processo, medidas em tempo real, apresentaram a precisão requerida para a operação do sistema em regime estacionário. / The Fluid Catalyst Cracking FCC is a worldwide used process in petroleum refinery aiming to break fossils long carbohydrates chains into more commercial interesting products as gasoline, diesel, GLP. Increasing demand for renewable energy due to time limiting of the fossils sources and also for environmental reasons requires a continuous development and innovation of the FCC process. Such a demand brings technologic and academic efforts in order to keep FCC as a competitive commercial process. Therefore, the research follows two big lines: fluid dynamics and kinetic which for physical models are developed to simulate industrial plants for studying and return the obtained innovation. Looking for such a research perspective a cold model UPF was installed at Nuclear Energy Department of UFPE for fluid dynamic parameters investigation by means of gamma ray transmission measurements. The nuclear nonintrusive technique is required in the riser for the solid concentration distribution measurements. Online measurements of pressure, flow and gamma intensity are carried out during UPF automated operation that is keeping by control a stead state regime. Such operational conditions are assumed in the hypotheses of mathematical models that air-FCC catalyst flow can be simulated as a circulating fluidized bed in a stead state regime. As for a pilot unit in industrial plants the solid injection in riser is very important as the catalyst concentration distribution maps the cracking reactions, therefore, determining process efficiency. In this work a new solid injector was developed, its capability in keeping stable operational conditions was demonstrated by pressure and gamma intensity measurements under automation control.

Catalytic pyrolysis technology is one of the thermochemical platforms used to produce high quality bio-oil and chemicals from biomass feedstocks. In the catalytic pyrolysis process, the biomass is rapidly heated under inert atmosphere in the presence of an acid catalyst or zeolite to promote deoxygenation and cracking of the primary vapors into hydrocarbons and small oxygenates. This dissertation examines the utilization of conventional fluid catalytic cracking (FCC) catalyst in the fractional catalytic pyrolysis of hybrid poplar wood. The influence of Y-zeolite content, steam treatment, addition of ZSM-5 additive, process conditions (temperature, weight hourly space velocity (WHSV) and vapor residence time) and recycling of the non-condensable gases (NCG) on the product distribution and the quality of the bio-oil were investigated. The first part of the study demonstrates the influence of catalytic property of FCC catalyst on the product distribution and quality of the bio-oil. It was found that FCC catalyst with higher Y-zeolite content produces higher coke yield and lower organic liquid fraction (OLF). Conversely, FCC catalyst with lower Y-zeolite content results in lower coke yield and higher OLF. The results showed that higher Y-zeolite content extensively cracks dehydrated products from cellulose decomposition and demethoxylates phenolic compounds from lignin degradation. The Y-zeolite promoted both deoxygenation and coke forming reactions due to its high catalytic activity and large pore size. Higher Y-zeolite content increased the quality of the bio-oil with respect to higher heating value (HHV), pH, density, and viscosity. The steam treatment at 732 oC and 788 oC decreased the total BET surface area of the FCC catalyst. The findings suggest that steam treatment reduces the coking tendency of the FCC catalyst and enhances the yield of the OLF. Analysis of the bio-oils showed that the steamed FCC catalyst produces bio-oil with lower viscosity and density. Gas chromatography and 13C-NMR spectrometry suggest that steam treatment affect the catalyst selectivity in the formation of CO, CO2, H2, CH4, C2-C5 hydrocarbons and aromatic hydrocarbons. The addition of ZSM-5 additive to the FCC catalyst was found to alter the characteristic/functionality of the catalytic medium. The product slate showed decrease in coke yield and increase in OLF with increase in ZSM-5 additive. The FCC/ZSM-5 additive hybrid catalysts produced bio-oils with relatively lower viscosity and higher pH value. The formation of CO2, CH4, and H2 decreased whilst C5 and aromatic hydrocarbons increased with increase in ZSM-5 additive level. The second part of the work assesses the effect of operating conditions on the catalytic pyrolysis process. The response surface methodology study showed reaction temperature to be the most influential statistically significant independent variable on char/coke yield, concentration of non-condensable gases, carbon content, oxygen content, pH and viscosity of the bio-oils. The WHSV was the most important statistically significant independent variable that affects the yield of organic liquid and water. Adequate and statistically significant models were generated for the prediction of the responses with the exception of viscosity. Recycling of the NCG in the process was found to potentially increase the liquid yield and decrease char/coke yield. The experiments with the model fluidizing gases showed that CO/N2, CO2/N2, CO/CO2/N2 and H2/N2 increase the liquid yield and CO2/N2 decrease char/coke yield. The results showed that recycling of NCG increases the higher heating value and the pH of the bio-oil as well as decreases the viscosity and density. The concept of recycling the NCG in the catalytic cracking of biomass vapors with FCC catalyst improved the overall process. The evaluation of the reactivity of conventional FCC catalyst towards bio-based molecules provide essential direction for FCC catalyst formulation and design for the production of high quality bio-oils from catalytic pyrolysis of biomass. / Ph. D.