W. R. Grace Co.-Conn.

W. R. Grace Co.

Roger Jean Lussier

David E Vaughan

John S Magee

John Storey Magee, Jr

George J Surland

Michael Scott Ziebarth

Stanislaw Plecha

Edwin W Albers

Charles Cross Wear

M Sundaram Krishnamoorthy

William A Welsh

John Allen Rudesill

George Yaluris

Gordon Dean Weatherbee

Meenakshi Sundaram Krishnamoorthy

Michael David Wallace

James M Masselli

Leon Kutik

Charles C Wear

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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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

Porous composite particles are provided which comprise an aluminum oxide component, e.g., crystalline boehmite, and a swellable clay component, e.g., synthetic hectorite, intimately dispersed within the aluminum oxide component at an amount effective to increase the hydrothermal stability, pore volume, and/or the mesopore pore mode of the composite particles relative to the absence of the swellable clay. Also provided is a method for making the composite particles, agglomerate particles derived therefrom, and a process for hydroprocessing petroleum feedstock using the agglomerates to support a hydroprocessing catalyst.

Hydrothermally stable high pore volume aluminum oxide/swellable clay composites and methods of their preparation and use

Porous composite particles are provided which comprise an aluminum oxide component, e.g., crystalline boehmite having a crystallite size of from about 20 to about 200 Angstroms and additive component residue, e.g., silicate, phosphate, of a crystal size growth inhibitor, intimately dispersed within the aluminum oxide component. The aluminum oxide component of the composite particles are derived from a mixture of alumina trihydrate (e.g., gibbsite) and an alumina seed component, i.e., active alumina, which are both converted to crystalline boehmite in the presence of the additive component. Also provided is a method for making the composite particles, agglomerate particles derived therefrom, and a process for hydroprocessing petroleum feedstock using the agglomerates.

Alumina trihydrate derived high pore volume, high surface area aluminum oxide composites and methods of their preparation and use

Alkali metal and alkaline earth metal containing silica alumina spinel-mullite-gamma alumina sorbents which may be used to remove sulfur oxides (SO.sub.x components) from gas streams.

Inorganic oxide sorbents for sulfur oxides

Zeolites free from heavy metal cations are ion-exchanged with alkaline earth metal cations. The exchanged zeolites provide corrosion resistance to paints for metals, especially ferrous metals, without environmental hazard caused by use of heavy-metal anti-corrosion materials such as lead, chromium, zinc, etc.

Cation exchange Y zeolites as corrosion inhibitors

Acid reacted metakaolin useful for the preparation of catalyst and catalyst support compositions. The compositions may include solid inorganic oxides, such as zeolites, clay and/or inorganic gels. The compositions are spray dried and calcined to obtain highly active, dense, attrition resistant fluid cracking catalysts, or used in the preparation of formed catalyst supports.

Catalytic cracking process employing an acid-reacted metakaolin catalyst

Catalytic compositions which comprise alumina bound spinel and/or spinel-mullite mixtures having an alkali metal content of below about 0.50 weight percent, preferably below about 0.10. The compositions are obtained by calcining and caustic leaching preformed particulate composites of clay and alumina sol, preferably chlorhydrol. The catalysts are particularly useful for the catalytic cracking of heavy hydrocarbon feedstocks to obtain gasoline and light cycle oil. When used for cracking feedstocks high in vanadium content these compositions may contain added alkaline earth oxide in order to passivate the vanadium.

Catalytic cracking process employing an aluminum silicon

Catalytic compositions which comprise alumina bound spinel and/or spinel-mullite mixtures having an alkali metal content of below about 0.50 weight percent, preferably below about 0.10. The compositions are obtained by calcining a caustic leaching preformed particulate composites of clay and alumina sol, preferably chlorhydrol. The catalysts are particularly useful for the catalytic cracking of heavy hydrocarbon feedstocks to obtain gasoline and light cycle oil. When used for cracking feedstocks high in vanadium content these compositions may contain added alkaline earth oxide in order to passivate the vanadium.

Catalysts and catalyst supports

Acid reacted metakaolin useful for the preparation of catalyst and catalyst support compositions. The compositions may include solid inorganic oxides, such as zeolities, clay and/or inorganic gels. The compositions are spray dried and calcined to obtain highly active, dense, attrition resistant fluid cracking catalysts, or used in the preparation of formed catalyst supports.

Acid-reacted metakaolin catalyst and catalyst support compositions

Catalysts which comprise or contain caustic leached spinel/mullite are found to possess a particularly high activity and stability for the catalytic conversion of hydrocarbons.

Catalytic cracking process exploying a zeolite as catalysts and catalyst

Pillared interlayered clays are reacted with a base such as ammonium hydroxide to increase the ion exchange capacity thereof. The pillared interlayered clays are prepared by reacting a smectite clay, such as bentonite, with a metal complex polymer, such as chlorhydrol, and calcining the resulting product.

Pillared interlayered clay products

Stable pillared interlayered clays are prepared by reacting smectite clays with high molecular weight cationic metal complexes of metals such as aluminum and zirconium. The high molecular weight complexes are prepared by hydrolysis of copolymerization of a metal complex such as aluminum chlorohydrol. The pillared, interlayered clays possess a high degree of thermal and hydrothermal stability and may be used in the preparation of catalysts and sorbents.

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Ellicott City, MD, United States of America

Roger Jean Lussier