W.r. Grace & Co. -conn.

Bp Corporation North America Inc.

Bp Oil International Limited

George Yaluris

Avelino Corma Canos

John Allen Rudesill

Michael Scott Ziebarth

Avelino Corma

Xinjin Zhao

Lenny Lee Albin

Alfred Ferdinand Jordan

Cristina Martinez

Eric J Doskocil

Roger Jean Lussier

Meenakshi Sundaram Krishnamoorthy

M Sundaram Krishnamoorthy

Timothy Dougan

Katherine W Dougan, Legal Representative

Wilson Suárez

Eric Doskocil

Compositions for reduction of NOgenerated during a catalytic cracking process, preferably, a fluid catalytic cracking process, are disclosed. The compositions comprise a fluid catalytic cracking catalyst composition, preferably containing a Y-type zeolite, and a particulate NOreduction composition containing ferrierite zeolite particles. Preferably, the NOreduction composition contains ferrierite zeolite particles bound with an inorganic binder. In the alternative, the ferrierite zeolite particles are incorporated into the cracking catalyst as an integral component of the catalyst. NOreduction compositions in accordance with the invention are very effective for the reduction of NOemissions released from the regenerator of a fluid catalytic cracking unit operating under FCC process conditions without a substantial change in conversion or yield of cracked products. Processes for the use of the compositions are also disclosed.

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A preferred embodiment of a system for loading catalyst and/or additives into a fluidized catalytic cracking unit includes a bin for storing at least one of the catalyst and/or additives, and a loading unit in fluid communication with the storage bin and the fluidized catalytic cracking unit on a selective basis. The loading unit is capable of being evacuated so that a resulting vacuum within the loading unit draws the catalyst and/or additive from the bin. The loading unit is also capable of being pressurized so that the catalyst and/or additive is transferred from the loading unit to the fluidized catalytic cracking unit.

System and process for injecting catalyst and/or additives into a fluidized catalytic cracking unit

A modified zeolite catalyst derived from a zeolite of a structural type which consists of a one-dimensional micropore structure of channels made from rings containing between 8 and 12 silicon/aluminum atoms is disclosed. It consists substantially of a plurality of crystallites having additional mesoporosity whose volume is in the range 0.09 to 0.25 cc/g as mentioned by nitrogen adsorption at 77&#xb0; K and calculated by the BJH method. The mesoporosity may be introduced into the crystallites by e.g. treatment with aqueous sodium hydroxide at a pH at 25&#xb0; C. in excess of 8 for an extended period at elevated temperature. The catalyst shows improved resistance to catalyst deactivation and greater selectivity to higher hydrocarbons when used to e.g. oligomerize light alkenes e.g. propene or the butenes.

Modified zeolite catalyst

Disclosed is a process for producing a hydrocarbon fraction rich in components boiling in the range typical for diesel fuel comprising contacting a feedstock comprising one or more Cto Calkenes with a zeolite catalyst having partially neutralised acidity and a one-dimensional or two dimensional micropore structure consisting of channels made from rings containing between 10 and 12 silicon/aluminium atoms at a temperature in the range 373 to 773 K and pressure in the range 0.1 to 200 bar characterised in that the partially neutralized zeolite catalyst contains both protons and basic cations. The basic cations are preferably selected from the group comprising Group IA and IIA cations (preferably sodium, potassium, caesium or mixtures thereof). Relative to their equivalent fully protonic forms the partially neutralized zeolite catalysts described show improved catalyst life and selectivity to hydrocarbons.

Alkene oligomerization process

Disclosed is a process for producing a hydrocarbon fraction rich in components boiling in the range typical for diesel fuel comprising contacting a feedstock comprising one or more Cto Calkenes with a modified zeolite catalyst having a one-dimensional micropore structure consisting of channels made from rings containing between 8 and 12 silicon/aluminum atoms at a temperature in the range 100 to 500&#xb0; C. and pressure in the range 0.1 to 200 bar characterized in that the modified zeolite catalyst is one which has been prepared by treating a corresponding zeolite precursor with an alkaline solution. The alkaline solution used to treat the zeolite precursor can be for example aqueous sodium hydroxide solution. Relative to equivalent untreated zeolites the modified zeolite catalysts described show improved catalyst life and selectivity to hydrocarbons boiling in the range 250 to 350&#xb0; C.

A NOreduction composition and process of using the composition to reduce the content of NOemissions and gas phase reduced nitrogen species released from the regeneration zone during fluid catalytic cracking of a hydrocarbon feedstock into lower molecular weight components is disclosed. The process comprises contacting a hydrocarbon feedstock during a fluid catalytic cracking (FCC) process wherein a regeneration zone of an fluid catalytic cracking unit (FCCU) is operated in a partial or incomplete combustion mode under FCC conditions, with a circulating inventory of an FCC cracking catalyst and a particulate NOreduction composition. The NOreduction composition has a mean particle size of greater than 45 &#x3bc;m and comprises (1) a zeolite component having (i) a pore size of form 2-7 A Angstroms and (ii) a SiOto AlOmolar ratio of less than 500, and (2) at least one noble metal selected from the group consisting of platinum, palladium, rhodium, iridium, osmium, ruthenium, rhenium and mixtures thereof.

Reduced emissions of gas phase reduced nitrogen species in the off gas of an FCC regenerator operated in a partial or incomplete mode of combustion is achieved by contacting the off gas with an oxidative catalyst/additive composition having the ability to reduce gas phase nitrogen species to molecular nitrogen and to oxidize CO under catalytic cracking conditions. The oxidative catalyst/additive composition is used in an amount less than the amount necessary to prevent afterburn. Fluidizable particles of the oxidative catalyst/additives are circulated throughout the partial or incomplete burn FCC unit along with the FCC catalyst inventory. The flue gas having a reduced content of gas phase reduced nitrogen species and NOis passed to a downstream CO boiler, preferably a low NOCO boiler. In the CO boiler, as CO is oxidized to CO, a reduced amount of gas phase reduced nitrogen species is oxidized to NO, thereby providing an increase in the overall reduction of NOemitted into the environment.

Reduction of gas phase reduced nitrogen species in partial burn FCC processes

A process for the reduction of NOemissions from a regeneration zone during a fluid catalytic cracking (FCC) process are disclosed. The process comprises contacting a hydrocarbon feedstock with a circulating inventory of an FCC cracking catalyst and a NOreduction composition during an FCC process. The NOreduction composition comprises at least one reduced nitrogen species component having the ability to reduce the content of reduced nitrogen species to molecular nitrogen under reducing or partial burn FCC conditions and at least one NOreduction component having the ability to convert NOto molecular nitrogen under oxidizing or full burn FCC conditions.

Compositions for reduction of NOemissions generated during catalytic cracking process, preferably, a fluid catalytic cracking process, are disclosed. The compositions comprise (i) an acidic metal oxide containing substantially no zeolite, (ii) an alkali metal, alkaline earth metal, and mixtures thereof, (iii) an oxygen storage component, (iv) palladium and (v) a noble metal component, preferably platinum, rhodium or iridium, and mixtures thereof. Preferably, the compositions are used as separate additives particles circulated along with the circulating FCC catalyst inventory. Reduced content of NOin an effluent off gas of a full or complete combustion FCC regenerator are accomplished while simultaneously promoting the combustion of CO.

Compositions for reduction of NOgenerated during a catalytic cracking process, preferably, a fluid catalytic cracking process, are disclosed. The compositions comprise a fluid catalytic cracking catalyst composition, preferably containing a Y-type zeolite, and a particulate NOcomposition containing particles of a zeolite having a pore size ranging from about 3 to about 7.2 Angstroms and a SiOto AlOmolar ratio of less than about 500. Preferably, the NOreduction composition contains NOreduction zeolite particles bound with an inorganic binder. In the alternative, the NOreduction zeolite particles are incorporated into the cracking catalyst as an integral component of the catalyst. Compositions in accordance with the invention are very effective for the reduction of NOemissions released from the regenerator of a fluid catalytic cracking unit operating under FCC process conditions without a substantial change in conversion or yield of cracked products. Processes for the use of the compositions are also disclosed.

Processes for preparing a composition comprising (i) an acidic metal oxide containing substantially no zeolite, (ii) an alkali metal, alkaline earth metal, and mixtures thereof, and (iii) an oxygen storage component are disclosed. Preferably, the process comprise forming a single slurry of components (i)&#x2013;(iii), spray drying and calcining to obtain metal oxide particles comprising components (i)&#x2013;(iii). Preferably, the slurry comprise a base peptized acidic metal oxide containing slurry wherein the component (ii) is provided in the slurry as a metal of the base. Compositions prepared are impregnated with a noble metal to provide compositions useful to reduce gas phase reduced nitrogen species and NOin an effluent off gas of a fluid catalytic cracking regenerator.

Compositions for reduction of NOgenerated during a catalytic cracking process, preferably, a fluid catalytic cracking process, are disclosed. The compositions comprise a fluid catalytic cracking catalyst composition, preferably containing a Y-type zeolite, and a particulate NOcomposition containing particles of a zeolite having a pore size ranging from about 3 to about 7.2 Angstoms and a SiOto AlOmolar ratio of less than about 500. Preferably, the NOreduction composition contains NOreduction zeolite particles bound with an inorganic binder. In the alternative, the NOreduction zeolite particles are incorporated into the cracking catalyst as an integral component of the catalyst. Compositions in accordance with the invention are very effective for the reduction of NOemissions released from the regenerator of a fluid catalytic cracking unit operating under FCC process conditions without a substantial change in conversion or yield of cracked products, e.g., gasoline and light olefins. Processes for the use of the compositions are also disclosed.

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Columbia, MD, United States of America

George Yaluris