W. R. Grace Co.-conn.

Mobil Oil Corporation

Exxonmobil Research and Engineering Company

Exxonmobil Oil Corporation

Megtec Systems, Inc.

Exxonmobil Corporation

Michael Scott Ziebarth

Terry G Roberie

Arthur W Chester

Xinjin Zhao

Ranjit Kumar

Hye Kyung Cho Timken

Wu-Cheng Cheng

Jean Willem Beeckman

George Yaluris

Stanislaw Plecha

Michael J Hager

Richard Franklin Wormsbecher

Roger Jean Lussier

Hye Kyung C Timken

Cristian Libanati

Nazeer A Bhore

Yuying Shu

Kevin John Sutovich

Mohit Uberoi

M Sundaram Krishnamoorthy

James C Vartuli

Charles T Kresge

Hye Kyung Timken

John Allen Rudesill

Ruizhong Hu

Meenakshi Sundaram Krishnamoorthy

Frederick Earl Daugherty

Philip Stephen Deitz

Michael D Amiridis

Scott Kevin Purnell

Sundaram Krishnamoorthy

Robert H Harding

Udayshankar Singh

Anthony Shiu Lun Fung

Wu Cheng Cheng

Philip S Deitz

Kevin J Sutovich

Philip S Dietz

A process for preparing a peptized alumina having increased solids and acid contents and a decreased water content. The process comprising mixing a boehmite or pseudoboehmite alumina and acid with a high intensity, high energy mixer at a ratio of 0.16 to 0.65 moles acid/moles alumina for a time period sufficient to form a substantially free-flowing solid particulate having a solids content of 45 to 65 wt %. When used in catalyst manufacture, peptized alumina produced by the process provides an increased rate in catalyst production and decreased costs due to high solids concentration and the presence of less water to be evaporated.

Process to peptize alumina for fluidizable catalysts

Particulate catalytic cracking catalysts which comprise a zeolite having catalytic cracking ability under catalytic cracking conditions, added silica, a magnesium salt, an alumina containing binder, clay and optionally, a matrix material. The catalytic cracking catalyst has a high matrix surface area and is useful in a catalytic cracking process, in particularly, a fluid catalytic cracking process, to provide increased catalytic activity and improved coke and hydrogen selectivity without the need to incorporate rare earth metals.

High matrix surface area catalytic cracking catalyst stabilized with magnesium and silica

A rare earth free particulate catalytic cracking catalyst which comprises a zeolite having catalytic cracking ability under catalytic cracking conditions, an acidified silica sol binder, magnesium salt, clay and a matrix material. The catalytic cracking catalyst has a high matrix surface area and is useful in a catalytic cracking process, in particularly, a fluid catalytic cracking process, to provide increased catalytic activity and improved hydrogen and coke selectivity without the need to incorporate rare earth metals.

Silica sol bound catalytic cracking catalyst stabilized with magnesium

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 catalyst composition comprising at least about 10% by weight pentasil, at least about 12% by weight Y-type zeolite at a pentasil to Y zeolite ratio of at least 0.25, and wherein the pentasil and Y zeolite comprise at least about thirty-five percent of the catalyst have been shown to optimize light olefin yields and LPG from FCC processes. Embodiments having matrix surface areas greater than 25 m/g, phosphorous and rare earth are preferred. The compositions of this invention are particularly useful in typical fluid catalytic cracking (FCC) processes.

Catalyst for light olefins and LPG in fludized catalytic units

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 is a cracking catalyst composition comprising a zeolite in combination with a Lewis Acid containing component, wherein the cracking catalyst composition comprises 0.2% NaO or less. It has been found that sulfur compounds in hydrocarbon feeds to fluid catalytic cracking processes can be reduced by at least 15% compared to the same composition, which does not comprise the aforementioned Lewis Acid containing component.

Gasoline sulfur reduction catalyst for fluid catalytic cracking process

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.

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 NOreducing zeolite having a pore size ranging from about 2 to about 7.2 Angstroms and a SiOto AlOmolar ratio of less than about 500 and being stabilized with a metal or metal ion selected from the group consisting of zinc, iron and mixtures thereof. Preferably, the NOreducing zeolite particles are bound with an inorganic binder to form a particulate composition. In the alternative, the NOreducing zeolite particles are incorporated into the cracking catalyst as an integral component of the catalyst. Compositions in accordance with the invention exhibit improved effectiveness 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.

Compositions and processes for reducing NOx emissions during fluid catalytic cracking

The sulfur content of liquid cracking products, especially the cracked gasoline, of the catalytic cracking process is reduced by the use of a sulfur reduction catalyst composition comprising a porous molecular sieve which contains a metal in an oxidation state above zero within the interior of the pore structure of the sieve as well as a cerium component which enhances the stability and sulfur reduction activity of the catalyst. The molecular sieve is normally a faujasite such as USY. The primary sulfur reduction component is normally a metal of Period 3 of the Periodic Table, preferably vanadium. The sulfur reduction catalyst may be used in the form of a separate particle additive or as a component of an integrated cracking/sulfur reduction catalyst.

Gasoline sulfur reduction in fluid catalytic cracking

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.

The sulfur content of liquid cracking products, especially the cracked gasoline, of the catalytic cracking process is reduced by the use of a sulfur reduction additive comprising a porous molecular sieve which contains a metal in an oxidation state above zero within the interior of the pore structure of the sieve. The molecular sieve is normally a large pore size zeolite such as USY or zeolite beta or an intermediate pore size zeolite such as ZSM-. The metal is normally a metal of Period 3 of the Periodic Table, preferably zinc or vanadium. The sulfur reduction catalyst may be used in the form of a separate particle additive or as a component of an integrated cracking/sulfur reduction catalyst.

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.

The sulfur content of liquid cracking products, especially the cracked gasoline, is reduced in a catalytic cracking process employing a cracking catalyst containing a high content of vanadium. The cracking process involves introducing at least one vanadium compound into a hydrocarbon-sulfur containing feedstock to be charged to a fluid catalytic cracking reactor operating under steady state conditions and containing an equilibrium fluid cracking catalyst inventory within the reactor. The amount of sulfur in the liquid products, in particular gasoline and LCO fractions, is reduced as a result of the increased vanadium content on the equilibrium catalyst. Advantageously, sulfur reduction is achieved even in the presence of other metal contaminants, such as nickel and iron, on the equilibrium catalyst.

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Columbia, MD, United States of America

Michael Scott Ziebarth