Mobil Oil Corporation

Other

Union Carbide Corporation

Mobil Oil Coproration

Mobil Coil Corporation

Joseph A Herbst

Hartley Owen

Paul H Schipper

Albin Huss, Jr

Robert P Absil

Pochen Chu

Girish K Chitnis

Robert G Bundens

Philip Jay Angevine

James C Vartuli

Garry W Kirker

Donald J Klocke

Ernest W Valyocsik

Charles T Kresge

Mae K Rubin

Ajit V Sapre

Sadi Mizrahi

Gerald J Teitman

Catherine L Markham

Mohsen N Harandi

Scott S Han

Arthur W Chester

David S Shihabi

Kirk D Schmitt

John P McWilliams

David H Olson

Robert T Thomson

Brent A Aufdembrink

Jocelyn A Kowalski

Yun-Yang Huang

Daniel I Wang

Willis W Weber

Moshe Trop

Methods for separation of substances are provided. The methods include contacting a mixture of at least two components in flowable conditions with mesoporous, crystalline materials termed M41S which also include MCM-41 materials. The mesoporous crystalline materials may be used in separations as is or functionalized.

Method for separation of substances

A process is provided for converting feedstock hydrocarbon compounds over a catalyst composition which comprises clay and a zeolite component, at least one of which has been treated with a phosphorus-containing compound, for example, ammonium dihydrogen phosphate or phosphoric acid, and which is spray dried at a low pH, preferably lower than about 3. An embodiment of the present invention comprises an improved catalytic cracking process to produce high octane gasoline and increased lower olefins, especially propylene and butylene.

Catalytic conversion with improved catalyst

A process is provided for converting feedstock hydrocarbon compounds over a catalyst composition which comprises a molecular sieve material and a boron phosphate-containing matrix. An embodiment of the present invention comprises a catalytic cracking process to produce higher octane gasoline.

Catalytic cracking with a catalyst comprising a boron phosphate matrix

A layered catalyst contains a core of at least one, and preferably three, molecular sieve components within a shell layer of reduced molecular sieve content. A preferred catalyst consists of a core of a large pore molecular sieve, preferably a dealuminized Y-type zeolite, a shape selective paraffin cracking/isomerization component, preferably HZSM-5, and a shape selective aliphatic aromatization component, preferably gallium ZSM-5, within a shell of an alumina-rich, matrix. The shell can capture metals from the feeds being processed, it can act as a metals sink, and can remove metals form the unit by attrition. The catalyst is preferably prepared by forming the core and then coating or encapsulating the core with a shell having a reduced molecular sieve content. The shell may contain a pillared clay or other very large pore cracking component. The shell may be an attritable coating of an amorphous rare earth oxide, aluminum oxide and aluminum phosphate composite, which traps metals.

Catalytic cracking using a layered cracking catalyst

A process for demetallizing metals contaminated FCC catalyst in an FCC regenerator. A metals getter additive, with higher settling velocity, is added to the regenerator, to remove metals from FCC catalyst by solid-solid interaction. The FCC catalyst forms a light, discrete, dense phase fluidized bed on top of a fluidized bed of additive. FCC catalyst is recycled to the cracking reactor from the top fluidized bed, while additive can be withdrawn from the lower fluidized bed for disposal or for metals recovery and recycle. Additive can be optimized for metals removal and will not dilute the cracking catalyst in the FCC reactor.

Demetallation in FCC regenerator

A process and catalyst for catalytic cracking comprising a non-layered, ultra-large pore crystalline material. The crystalline material preferably has a benzene adsorption capacity greater than about 15 grams benzene/100 grams at 50 torr and 25.degree. C. Preferred materials have a hexagonal electron diffraction pattern that can be indexed with a d.sub.100 value greater than about 18 Angstrom Units and a hexagonal arrangement of uniformly sized pores with a maximum perpendicular cross section of at least about 13 Angstrom units. Preferred cracking catalysts comprise ultra-large pore materials having pore openings formed by at least 20 tetrahedrally coordinated members, most preferably with 36 or 42 tetahedrally coordinated members.

Ultra large pore cracking catalyst and process for catalytic cracking

A catalytic cracking process for converting a hydrocarbon fraction, preferably boiling in the range of a heavy gas oil, is disclosed in which the cracking catalyst is a large crystal fully crystalline zeolite Beta having a broad range of silica-to-alumina mole ratios, i.e. 20-&gt;1000. The zeolite Beta catalyst is synthesized with a nitrogenous organic chelating agent, such as a tertiary alkanolamine, preferably triethanolamine, in the synthesis mixture along with at least one source of organic directing agent such as tetraethylammonium hydroxide, tetraethylammonium bromide and tetraethylammonium fluoride. The zeolite Beta can be used as a stand alone catalyst or an additive catalyst for hydrocarbon cracking reactions along with another molecular seive type catalyst such as a faujasite catalyst or ZSM-5. The large crystal zeolite Beta can also be treated with a source of phosphorus to enhance the properties of the zeolite.

Catalytic cracking process utilizing a zeolite beta catalyst synthesized

The present invention is directed to a phosphorus containing catalyst which is formed by spray drying at a pH preferably less than 3. The present invention also comprises methods for preparing catalysts comprising phosphoric acid treated clay, as well as methods for cracking hydrocarbons utilizing the novel catalysts disclosed herein. The catalysts of the present invention advantageously exhibit low attritability.

Cracking catalysts comprising phosphorus and method of preparing and

The catalytic cracking of a hydrocarbon oil to provide a product of increased octane number and increased light olefin content is carried out employing a cracking catalyst composition containing both a large port crystalline zeolite component and a ZSM-57 zeolite component.

Use of ZSM-57 in catalytic cracking for gasoline octane improvement and

A layered catalyst suited to the catalytic cracking of heavy feeds comprises a core and a shell. The shell comprises at least 5 wt % of at least 1 molecular sieve having openings of at least 8 angstroms. The core comprises at least 10 wt % of at least 1 molecular sieve having openings comprising a 12 or less-membered ring and has a reduced, if any, content of said molecular sieve having openings of at least 8 angstroms, relative to its concentration in the shell. Suitable molecular sieve materials having openings of at least 8 angstroms include MCM-41, VPI-5, MCM-9 and layered metal oxides, e.g., pillared clays. The required molecular sieve of the core can include zeolite Y, Ultrastable Y or intermediate pore size zeolites such as ZSM-5. The shell which may further contain a metals passivator can act as a metals sink, and can remove metals from the unit by attrition. The catalyst is preferably prepared by forming the core and then coating or encapsulating the core with a shell material. The shell may also comprise an attritable coating of an amorphous rare earth oxide, aluminum oxide and aluminum phosphate composite, which traps metals.

Layered cracking catalyst and method of manufacture and use thereof

A catalyst composition comprises a molecular sieve material and a boron phosphate-containing matrix. The catalyst composition is used in a catalytic cracking process to produce higher octane gasoline.

Cracking catalysts

A process for preparing a zeolite containing catalyst which has improved attrition resistance, and causes improved octane with no appreciable change in dry gas and coke make when used during catalytic cracking processes is disclosed. The catalyst is prepared by modifying the zeolite with a phosphate containing solution. The zeolite preferably includes an REY large pore zeolite. Treatment of the zeolite is best accomplished in an aqueous solution, at a pH range from about 2 to about 6, containing a water soluble phosphate compound. The phosphate treatment of the zeolite is carried out by deagglomerating the zeolite in an aqueous mixture in the presence of an aqueous phosphate containing solution, such as an aqueous solution of ammonium monohydrogen phosphate. The aqueous mixture containing phosphate modified zeolite is then combined with matrix precursors to form a slurry. The slurry is preferably spray dried to form the catalyst having a diameter less than 200 microns. The novel catalyst is used in the catalytic cracking of hydrocarbons in an FCC, moving bed or other catalytic cracking apparatus. The catalyst can be used for treating resids in which the hydrocarbon feedstock has a higher average molecular weight, a lower API gravity and/or a higher metals content than gas oil.

Cracking catalysts containing phosphate treated zeolites, and method of

The catalytic cracking of a hydrocarbon oil to provide a product of increased octane number and increased light olefin content is carried out employing a cracking catalyst composition containing both a large pore crystalline zeolite component and a ZSM-57 zeolite component.

Use of SZM-57 in catalytic cracking for gasoline octane improvement and

A layered catalyst contains a core of at least one, and preferably three, molecular sieve components within a shell layer of reduced molecular sieve content. A preferred catalyst consists of a core of a large pore molecular sieve, preferably a dealuminized Y-type zeolite, a shape selective paraffin cracking/isomerization component, preferably HZSM-5, and a shape selective aliphatic aromatization component, preferably gallium ZSM-5, within a shell of an alumina-rich, matrix. The shell can capture metals from the feeds being processed, it can act as a metals sink, and can remove metals from the unit by attrition. The catalyst is preferably prepared by forming the core and then coating or encapsulating the core with a shell having a reduced molecular sieve content. The shell may contain a pillared clay or other very large pore cracking component. The shell may be an attritable coating of an amorphous rare earth oxide, aluminum oxide and aluminum phosphate composite, which traps metals.

A catalytic cracking process operates with enhanced stripper efficiency by subjecting spent catalyst to microwave radiation before catalyst regeneration. Preferably the microwave frequency is one which ignores the catalytic cracking catalyst and preferentially excites the hydrocarbon or coke on the spent catalyst, the stripping steam conventionally used, or both the stripping steam and the hydrocarbonaceous coke. In preferred embodiments, microwave frequencies are used which are selective for various impurities in the coke, such as sulfur and/or nitrogen impurities. Additives, such as ferrous materials, may be added to augment the efficiency of desulfurization during stripping. The process is applicable to fluidized catalytic cracking and moving bed catalytic cracking units.

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Turnersville, NJ, United States of America

Joseph A Herbst