W. R. Grace Co.-conn.

Exxonmobil Research and Engineering Company

Ranjit Kumar

Michael Scott Ziebarth

Wu-Cheng Cheng

Charles G Carter

Xinjin Zhao

Terry G Roberie

Kevin John Sutovich

Yuying Shu

Ronald E Ritter

Howard J Schaeffer, Iii

James C Vartuli

Arthur W Chester

Charles T Kresge

Hye Kyung Cho Timken

Richard Franklin Wormsbecher

Donald Albert Bansleben

Alan W Peters

Ruizhong Hu

Meenakshi Sundaram Krishnamoorthy

Frederick Earl Daugherty

Anthony Shiu Lun Fung

Wu Cheng Cheng

Philip S Deitz

Kevin J Sutovich

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

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

A particulate catalytic cracking catalyst which comprises a zeolite having catalytic cracking ability under catalytic cracking conditions, added silica, precipitated alumina and, optionally clay. 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 improve bottoms conversion at a constant coke formation.

Catalytic cracking catalyst compositions having improved bottoms conversion

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.

Gasoline sulfur reduction in fluid catalytic cracking

A process for catalytic cracking of a hydrocarbon feedstock comprises contacting the feedstock with a catalyst composition comprising a primary cracking component, such as zeolite Y, and a mesoporous aluminophosphate material which includes a solid aluminophosphate composition modified with at least one element selected from zirconium, cerium, lanthanum, manganese, cobalt, zinc, and vanadium. The mesoporous aluminophosphate material has a specific surface area of at least 100 m /g, an average pore size less than or equal to 100 &angst;, and a pore size distribution such that at least 50% of the pores have a pore diameter less than 100 &angst;.

Catalytic cracking process using a modified mesoporous aluminophosphate material

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 non-molecular sieve support containing a high content of vanadium. Preferably, the support is alumina. The sulfur reduction catalyst is used in the form of a separate particle additive in combination with the active catalytic cracking catalyst (normally a faujasite such as zeolite Y) to process hydrocarbon feedstocks in the fluid catalytic cracking (FCC) unit to produce low-sulfur gasoline and other liquid products.

Catalytically active phosphorus-containing zeolites/molecular sieves, particularly ultrastable zeolite Y, are prepared by reacting an exchanged zeolite/molecular sieve with a phosphorus compound such as H.sub.3 PO.sub.4, steaming, and reacting the steamed product with additional phosphorus compound.

Phosphorus zeolites/molecular sieves

Catalytic cracking catalysts/additives which comprise rare-earth, preferably lanthanum, oxide and/or oxychloride dispersed in an acid reacted metakaolin matrix. The catalysts/additives may be combined with zeolite-containing cracking catalysts to enhance catalytic activity/selectivity in the presence of metals (Ni and V).

Catalytic cracking catalysts and additives

Polyether bis-phosphonic acid compounds are disclosed which have the formula (HO).sub.2 OP--R--(OR').sub.n --OR--PO(OH).sub.2 where R is selected from the group consisting of methylene and ethylene, R' is selected from the group consisting of ethylene and ethylene substituted with one or more methyl groups, and n is an integer from 1 to 4, water soluble salts thereof, and esters thereof with alkyl groups having from 1 to 6 carbon atoms. Also disclosed is a novel preparation of these compounds by reacting hydroxyalkylphosphonic acid dialkyl ester compounds with 2-benzyloxyalkyl organic sulfonates; reacting the intermediate formed therefrom with hydrogen or a hydrogen source; reacting the intermediate formed therefrom with a hydrogen ion acceptor and certain sulfonyl chlorides; and reacting the intermediate formed therefrom with hydroxyalkylphosphonic acid dialkyl ester compounds to form a polyether bis-phosphonic acid compound which may be hydrolyzed to form the polyether bis-phosphonic acid.

Polyether bis-phosphonic acid compounds

Catalytic cracking catalysts are combined with a rare-earth, preferably lanthanum-containing catalyst/additive to enhance the cracking activity and selectivity in the presence of nickel and vanadia (Ni and V). The preferred additives comprise lanthanum, neodynium oxide and/or oxychloride dispersed in a clay/alumina matrix, wherein the alumina is derived from an aluminum hydroxychloride sol.

Polyether bis-phosphonic acid compounds are disclosed which have the formula (HO).sub.2 OP--R--(OR').sub.n --OR--PO(OH).sub.2 where R is selected from the group consisting of methylene and ethylene, R' is selected from the group consisting of ethylene and ethylene substituted with one or more methyl groups, and n is an integer from 1 to 4, water soluble salts thereof, and esters thereof with alkyl groups having from 1 to 6 carbon atoms. Also disclosed is a novel preparation of certain of these compounds by reacting certain hydroxyalkylphosphonic acid dialkyl ester compounds with certain 2-benzyloxyalkyl organic sulfonates; reacting the intermediate formed therefrom with hydrogen or a hydrogen source; reacting the intermediate formed therefrom with a hydrogen ion acceptor and certain sulfonyl chlorides; and reacting the intermediate formed therefrom with certain hydroxyalkyl-phosphonic acid dialkyl ester compounds to form a polyether bis-phosphonic acid compound which may be hydrolyzed to form the polyether bis-phosphonic acid. Useful intermediates are disclosed which have the formulas ##STR1## HOR'--OR--PO(OR').sub.2, HOR'--OR--PO(OH).sub.2, and X--O.sub.2 S--OR'--OR--PO(OR').sub.2, wherein the above-indicated benzene rings of said formulas are optionally substituted with selected groups, wherein R and R' are as defined above, wherein R' is an alkyl group having from 1 to 6 carbon atoms, and wherein X is selected from ##STR2## and alkyl groups having from about 1 to 6 carbon atoms.

Catalytic cracking catalysts are combined with a rare-earth, preferably lanthanum-containing catalyst/additive to enhance the cracking activity and selectivity in the presence of nickel and vanadia (Ni & V). The preferred additives comprise lanthanum, neodynium oxide and/or oxychloride dispersed in a clay/alumina matrix, wherein the alumina is derived from an aluminum hydroxychloride sol.

Catalytic cracking catalysts which comprise molecular sieves/zeolites dispersed in an inorganic oxide matrix that includes pollucite.

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Columbia, MD, United States of America

Ranjit Kumar