W. R. Grace Co.-Conn.

John Allen Rudesill

George Yaluris

Wu-Cheng Cheng

Alan W Peters

Gordon Dean Weatherbee

Edward F Rakiewicz

Xinjin Zhao

Nicholas D Spencer

Norman R Laine

Mary Jane A Barbato-Grauso

Mary Jane Barbato-Grauso

Richard Franklin Wormsbecher

Michael Scott Ziebarth

Roger Jean Lussier

Wie-Hin Pan

Meenakshi Sundaram Krishnamoorthy

M Sundaram Krishnamoorthy

Pilip Stephen Deitz

Wilson Suárez

Katherine W Dougan, Legal Representative

Timothy Dougan

Wie H Pan

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.

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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.

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 gas phase reduced nitrogen species and NOgenerated during a partial or incomplete combustion 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, and (iv) a noble metal component, preferably rhodium or iridium, and mixtures thereof, are disclosed. Preferably, the compositions are used as separate additives particles circulated along with the circulating FCC catalyst inventory. Reduced emissions of gas phase reduced nitrogen species and NOin an effluent off gas of a partial or incomplete combustion FCC regenerator provide for an overall NOreduction as the effluent gas stream is passed from the FCC regenerator to a CO boiler, whereby as CO is oxidized to COa lesser amount of the reduced nitrogen species is oxidized to NO.

NOx reduction compositions for use in FCC processes

Compositions for reduction of gas phase reduced nitrogen species and NO generated during a partial or incomplete combustion 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, and (iv) a noble metal component, preferably rhodium or iridium, and mixtures thereof, are disclosed. Preferably, the compositions are used as separate additives particles circulated along with the circulating FCC catalyst inventory. Reduced emissions of gas phase reduced nitrogen species and NO in an effluent off gas of a partial or incomplete combustion FCC regenerator provide for an overall NO reduction as the effluent gas stream is passed from the FCC regenerator to a CO boiler, whereby as CO is oxidized to CO a lesser amount of the reduced nitrogen species is oxidized to NO .

The present invention is directed to certain catalyst compositions and processes that are capable of reducing sulfur compounds normally found as part of the gasoline fraction streams of fluid catalytic cracking processes. The present invention requires an equilibrium cracking catalyst composition comprises at least one Y-type zeolite having kinetic conversion activity of at least about 3 in combination with a Lewis acid containing alumina composite present in at least 50 weight percent of the composition. The resultant equilibrium catalyst composition has a kinetic conversion activity of at least about 2.

Gasoline sulfur reduction catalyst for fluid catalytic cracking process

Compositions comprising a component containing (i) an acidic oxide support, (ii) an alkali metal and/or alkaline earth metal or mixtures thereof, (iii) a transition metal oxide having oxygen storage capability, and (iv) a transition metal selected from Groups Ib and/or IIb of the Periodic Table provide NO control performance in FCC processes. The acidic oxide support preferably contains silica alumina. Ceria is the preferred oxygen storage oxide. Cu and Ag are preferred Group I/IIb transition metals. The compositions are especially useful in the cracking of hydrocarbon feedstocks having above average nitrogen content.

Compositions comprising a component containing (i) an acidic oxide support, (ii) an alkali metal and/or alkaline earth metal or mixtures thereof, (iii) a transition metal oxide having oxygen storage capability, and (iv) a transition metal selected from Groups Ib and/or IIb of the Periodic Table provide NO,control performance in FCC processes. The acidic oxide support preferably contains silica alumina. Ceria is the preferred oxygen storage oxide. Cu and Ag are preferred Group I/IIb transition metals. The compositions are especially useful in the cracking of hydrocarbon feedstocks having above average nitrogen content.

A silica-containing bayerite alumina is prepared by reacting aluminum sulfate, sodium aluminate and sodium silicate at a pH of about 10.5 to 11.5, preferably in the presence of finely divided magnesium hydroxide 'seeds'. The silica-containing bayerite is heated to obtain a hydrothermally stable silica 'stabilized' eta alumina which may be used in the preparation of catalytic compositions.

Silica bayerite/eta alumina

Compositions comprising a component containing (i) an acidic oxide support, (ii) an alkali metal and/or alkaline earth metal or mixtures thereof, (iii) a transition metal oxide having oxygen storage capability, and (iv) a transition metal selected from Groups Ib and/or IIb of the Periodic Table provide NO.sub.x control performance in FCC processes. The acidic oxide support preferably contains silica alumina. Ceria is the preferred oxygen storage oxide. Cu and Ag are preferred Group I/IIIb transition metals. The compositions are especially useful in the cracking of hydrocarbon feedstocks having above average nitrogen content.

NO.sub.x reduction compositions for use in FCC processes

Compositions comprising a component containing (i) an acidic oxide support, (ii) an alkali metal and/or alkaline earth metal or mixtures thereof, (iii) a transition metal oxide having oxygen storage capability, and (iv) a transition metal selected from Groups Ib and/or IIb of the Periodic Table provide NO.sub.x control performance in FCC processes. The acidic oxide support preferably contains silica alumina. Ceria is the preferred oxygen storage oxide. Cu and Ag are preferred Group I/IIb transition metals. The compositions are especially useful in the cracking of hydrocarbon feedstocks having above average nitrogen content.

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Columbia, MD, United States of America

John Allen Rudesill