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Based on density functional theory (DFT) calculation and microkinetic analysis, metal single-atom-doped ZSM-5 zeolite catalysts for naphtha cracking are screened. The calculation results show that the strong electronic interaction between metal single atom and zeolite skeleton (especially Ag and Cu) could enhance structural stability. The volcanic diagram of turnover frequency shows that Ag and Cu doped ZSM-5 zeolite catalyst is at the top of the volcano, which is close to the best choice. [Display omitted] • Metal single-atom-doped ZSM-5 zeolite catalyst exhibits good structural stability. • The adsorption of naphtha hydrocarbon molecules and the activation of C–H bond are greatly promoted. • The binding energy of carbon and hydrogen can be used as a descriptor for the catalytic cracking of naphtha on M−ZSM−5. • Ag and Cu single-atom-doped ZSM-5 are predicted to exhibit excellent catalytic activity. • Mo and Pd single-atom-doped ZSM-5 display great potential in the enhancement of propylene selectivity. Metal doped ZSM-5 catalyst has attracted much attention due to its unique catalytic activity for C–H bond activation. In this work, based on density functional theory (DFT) calculations and microkinetic analysis, we prospectively explored the catalytic activity of 12 kinds of transition metals (M = Fe, Co, Ni, Cu, Mo, Ru, Rh, Pd, Ag, W, Pt, Au) single-atom-doped ZSM-5 zeolite catalysts in the catalytic cracking of naphtha. The results show that there is a strong electronic interaction between metal atom and ZSM-5 skeleton. This induced stable structure could improve the adsorption ability of hydrocarbon, thus promoting the activation of C–H bond and the cracking of carbenium ion. Moreover, C and H binding energy were identified as descriptors in describing catalytic activity via good scaling relations. The turnover frequency volcano diagram shows that the Ag and Cu doped ZSM-5 zeolite catalyst is close to the best choice. In addition, Pd and Mo are potential metal choices with good selectivity through selectivity analysis. This work has important guiding significance for understanding the fluid catalytic cracking (FCC) mechanism and designing high-efficiency cracking catalysts. [ABSTRACT FROM AUTHOR]

Our study developed the one-step catalytic cracking conceptual design using a two-stage riser reactor (OSCO). Molecular-level process models and multi-objective optimization strategies are also carried out. Results show that the OSCO process exhibits superior techno-economic, society, people's livelihood, and environmental performance. [Display omitted] • A novel process is proposed to crack naphtha, kerosene, diesel and heavy oil in the two-stage riser reactor efficiently. • A novel integration model of mixed fraction structure and molecular level is proposed. • The multi-objective optimization strategies using systematic solution algorithm are performed. • The novel process shows superior techno-economic, society, people's livelihood, and environmental performance. With the demand for vehicle fuels (i.e., gasoline and diesel) is expected to decline soon, crude oil to chemical technology exhibits great potential to drive the next industry transition. This megatrend has led to studies on maximizing the production of low-carbon petrochemicals at the cost of fuels, which requires aggressive ways of converting oil into chemicals in a clean and efficient pattern. Herein, we proposed a novel process, termed OSCO, to crack naphtha, kerosene, diesel and heavy oil in a two-stage riser reactor efficiently, which can perform several refining procedures in the two-stage riser reactor vessel. A novel integration model of mixed fraction structure and molecular level is proposed. The multi-objective optimization strategies are also carried out to solve the optimization problem. As a result, the OSCO process can stably convert untreated heavy Daqing crude oil into light olefins with total yields of ethylene and propylene over 33 wt%, which also exhibits superior techno-economic, society, people's livelihood, and environmental performance. These insights may have a positive pushing role in engineering design, process intensification, and the optimization of direct catalytic cracking of crude oil. [ABSTRACT FROM AUTHOR]