Exxon Research and Engineering Company

Exxonmobil Research and Engineering Company

Exxonmobil Chemical Patents Inc.

Exxon Chemical Patents, Inc.

Exxonmobile Chemical Patents Inc.

William A Wachter

Gordon Frederick Stuntz

Paul K Ladwig

John E Asplin

Shun Chong Fung

Tan-Jen Chen

Brian Erik Henry

B Erik Henry

George A Swan, Iii

Jeffrey T Elks

John Ernest Asplin

Stuart Leon Soled

Ian A Cody

Charles H Mauldin

Marcel Johannes Janssen

Biddanda U Achia

Hyung Suk Woo

Leroy Russell Clavenna

Glen P Hamner, Deceased

Michael Walter Bedell

Stephen Neil Vaughn

David Lawrence Stern

Stephen John McCarthy

Jeffrey S Beck

William E Winter, Jr

Paul E Eberly

Brenda Anne Raich

Claude C Culross

Christine Esther Kliewer

Ronald G Searle

Terry G Roberie

William L Schuette

Nicholas S Rollman

Theodore H West

David O Marler

Ruizhong Hu

Gregg Johnston Howsmon

Heather A Boucher

Theodore E Datz

Colin L Beswick

Jianxin Jason Wu

Mark P Lapinski

James David Bell

Mary T Van Nostrand

Jay F Carpency

Nikos J Maris

Brian Eric Henry

Vinh T Nguyen

Edward Thomas Habib, Jr

Carol P Fitzpatrick

This invention relates to the composition, method of making and use of a fluidized catalytic cracking ('FCC') catalyst that is comprised of a new Y zeolite which exhibits an exceptionally low small mesoporous peak around the 40 &#x212b; (angstrom) range as determined by nitrogen adsorption measurements. FCC catalysts made from this new zeolite exhibit improved rates of heavy oil cracking heavy oil bottoms conversions and gasoline conversions. The fluidized catalytic cracking catalysts herein are particularly useful in fluidized catalytic cracking ('FCC') processes for conversion of heavy hydrocarbon feedstocks such as gas oils and vacuum tower bottoms.

Low small mesoporous peak cracking catalyst and method of using

Catalysts for experimentation are produced having a controlled matrix pore structure. The manufacturing process utilizes tape casting in the drying procedure in which a catalyst slurry is cast on a substrate and dried at a temperature of between about 50&#xb0; C. to 200&#xb0; C. for a period of time of about 0.1 to 1.0 hour. The dried catalyst particles can be removed from the substrate by several techniques, including scraping, burning, and deforming the substrate material. The resulting catalytic particles can be produced in an amount of about ca. 3 g to 300 g from slurries with volumes between 5 cc to 500 cc, which are suitable for small scale FCC reactors and for high throughput experimentation.

Drying device for producing small quantities of controlled particle size catalysts which are appropriate for use in fluidized bed operations such as fluid catalytic cracking

This invention relates to a FCC process using a mesoporous catalytic cracking catalyst. The mesoporous fluidized catalytic cracking catalyst is selective for minimizing the production of coke and light gas. The catalyst comprises at least one amorphous, porous matrix, each matrix having pores ranging in diameter from about 1 &#x212b; to about 10 &#x212b; and pores ranging in diameter from about 40 &#x212b; to about 500 &#x212b;, wherein in the pore range from 50 &#x212b; to 250 &#x212b;, there is a single maximum in differential pore volume distribution over the 50 &#x212b; to 250 &#x212b; range.

FCC process using mesoporous catalyst

This invention relates to a mesoporous catalytic cracking catalyst, a process for the production of such catalysts, and a process utilizing such catalysts in cracking operations. The mesoporous fluidized catalytic cracking catalyst is selective for minimizing the production of coke and light gas. The catalyst comprises an amorphous, porous matrix having pores ranging in diameter from about 1 &#x212b; to about 10 &#x212b; and ranging in diameter from about 40 &#x212b; to about 500 &#x212b;, but substantially free of pores ranging in diameter from about 10 &#x212b; to about 40 &#x212b;.

FCC catalyst

The propylene production of a fluid catalytic cracking unit employing a large pore zeolite cracking catalyst, produces more propylene by adding a naphtha cracking riser and a medium pore zeolite catalytic component to the unit, and recycling at least a portion of the naphtha crackate to the naphtha riser. The large pore size zeolite preferably comprises a USY zeolite and the medium pore size is preferably ZSM-5. Propylene production per unit of naphtha feed to the naphtha riser is maximized, by using the 60&#x2013;300&#xb0; F. naphtha crackate as the feed.

Fluid cat cracking with high olefins production

A process for producing polypropylene from olefins selectively produced from a catalytically cracked or thermally cracked naphtha stream is disclosed herein. The naphtha stream is contacted with a catalyst containing from about 10 to 50 wt. % of a crystalline zeolite having an average pore diameter less than about 0.7 nanometers at reaction conditions which include temperatures from about 500&deg; C. to 650&deg; C. and a hydrocarbon partial pressure from about 10 to 40 psia. The catalyst may be pre-coked with a carbonaceous feed. Alternatively, the carbonaceous feed used to coke the catalyst may be co-fed with the naphtha feed.

Process for selectively producing propylene in a fluid catalytic cracking process

A process for increasing the hydrogenation activity, particularly the carbon monoxide hydrogenation activity, of a catalyst or catalyst precursor comprised of a particulate solids support component and a catalytic metal, or metals component, preferably cobalt; cobalt alone or cobalt and an additional metal, or metals added to promote or modify the reaction produced by the cobalt. Treatment of the catalyst, or catalyst precursor is conducted at low temperature ranging from ambient to about 275&deg; C. sufficient to form on the surface of a catalyst precursor, e.g., a cobalt catalyst precursor, a cobalt metal hydroxide, low valence cobalt metal oxide, or mixture of cobalt metal hydroxide and low valence cobalt metal oxide. Sometimes also metallic metal, e.g., cobalt, is also formed, and dispersed on the surface of the support. On reduction, as may be produced by contact and treatment of the catalyst or catalyst precursor with hydrogen, the oxidized metal, or metals component of the catalyst or catalyst precursor is reduced to elemental or metallic metal, and the activity of the catalyst thereby increased. A catalyst, activated or produced in this manner, is a useful composition of matter, the catalyst being particularly useful for efficiently conducting carbon monoxide hydrogenation reactions, especially F-T synthesis reactions, to provide a variety of useful products.

Process for increasing carbon monoxide hydrogenation activity of catalysts via low temperature oxidation with water, steam or mixture thereof

A catalyst precursor comprising a composite of a solids support, or powder component, and a compound or salt of a metal, or metals component, inclusive of cobalt, is upon reduction rendered catalytically active for conducting hydrogenation reactions, especially carbon monoxide hydrogenation reactions by contact at low temperature with liquid water, or steam, or a mixture of liquid water and steam, sufficient to oxidize and convert the metal, or metals component of the catalyst precursor to a metal hydroxide, low oxygen-containing metal oxide, or mixture of metal hydroxide and low oxygen-containing metal oxide. On reduction, as may be produced by contact and treatment of the oxidized catalyst precursor with hydrogen, the now well dispersed oxide or hydroxylated catalytic metal, or metals component of the catalyst, is reduced to metallic metal, e.g., Co, and the catalyst thereby activated.

Cobalt catalyst compositions useful for conducting carbon monoxide hydrogenation reactions

A process for producing polypropylene from olefins selectively produced from a catalytically cracked or thermally cracked naphtha stream is disclosed herein. The naphtha stream is contacted with a catalyst containing from about 10 to 50 wt. % of a crystalline zeolite having an average pore diameter less than about 0.7 nanometers at reaction conditions which include temperatures from about 500&deg; C. to 650&deg; C. and a hydrocarbon partial pressure from about 10 to 40 psia.

Process for producing polypropylene from C3 olefins selectively produced in a fluid catalytic cracking process

A process for producing propylene from a catalytically cracked or thermally cracked naphtha stream is disclosed herein. The naphtha stream is contacted with a catalyst containing from about 10 to 50 wt. % of a crystalline zeolite having an average pore diameter less than about 0.7 nanometers at reaction conditions which include temperatures from about 500&deg; C. to 650&deg; C. and a hydrocarbon partial pressure from about 10 to 40 psia. A separate stream containing aromatics may be co-fed with the naphtha stream.

Process for selectively producing C3 olefins in a fluid catalytic cracking process

A process for producing polymers from olefins selectively produced by a two stage process for selectively producing C,to C,olefins from a gas oil or resid is disclosed herein. The gas oil or resid is reacted in a first stage comprising a fluid catalytic cracking unit wherein it is converted in the presence of conventional large pore zeolitic catalyst to reaction products, including a naphtha boiling range stream. The naphtha boiling range stream is introduced into a second stage comprising a process unit containing a reaction zone, a stripping zone, a catalyst regeneration zone, and a fractionation zone. The naphtha feed is contacted in the reaction zone with a catalyst containing from about 10 to 50 wt. % of a crystalline zeolite having an average pore diameter less than about 0.7 nanometers at reaction conditions which include temperatures ranging from about 500 to 650&deg; C. and a hydrocarbon partial pressure from about 10 to 40 psia. Vapor products are collected overhead and the catalyst particles are passed through the stripping zone on the way to the catalyst regeneration zone. Volatiles are stripped with steam in the stripping zone and the catalyst particles are sent to the catalyst regeneration zone where coke is burned from the catalyst, which is then recycled to the reaction zone.

Process for producing polypropylene from C3 olefins selectively produced by a two stage fluid catalytic cracking process

A process for producing polymers from C,-C,olefins selectively produced from a catalytically-cracked or thermally-cracked naphtha stream is disclosed herein. A mixture of the naphtha stream and a stream of steam is feed into a reaction zone where it is contacted with a catalyst containing from about 10 to 50 wt. % of a crystalline zeolite having an average pore diameter less than about 0.7 nanometers at reaction conditions that include temperatures from about 500&deg; C. to 650&deg; C. and a hydrocarbon partial pressure from about 10 to 40 psia.

Process for producing polypropylene from C3 olefins selectively produced in a fluid catalytic cracking process from a naphtha/steam feed

Catalysts that are useful for hydrocarbon conversions and oxygenate conversions, and a method for making such catalysts. The method for making the catalysts comprises forming a mixture comprising molecular sieves comprising pores having a diameter smaller than about 10 Angstroms, an inorganic sol, and an external phosphorus source, and drying the mixture.

Methods for making catalysts

A process for selectively producing C.sub.2 -C.sub.4 olefins from a catalytically cracked or thermally cracked naphtha stream is disclosed. A mixture of the naphtha stream and a stream of steam is feed into a reaction zone where it is contacted with a catalyst containing from about 10 to 50 wt. % of a crystalline zeolite having an average pore diameter less than about 0.7 nanometers at reaction conditions which include temperatures from about 500 to 650.degree. C. and a hydrocarbon partial pressure from about 10 to 40 psia.

Process for selectively producing light olefins in a fluid catalytic

C.sub.2 to C.sub.4 olefins are selectively produced from a gas oil or resid in a two stage process. The gas oil or resid is reacted in a first stage comprised of a fluid catalytic cracking unit wherein it is converted in the presence of conventional large pore zeolitic catalyst to reaction products, including a naphtha boiling range stream. The naphtha boiling range stream is introduced into a second stage comprised of a process unit containing a reaction zone, a stripping zone, a catalyst regeneration zone, and a fractionation zone. The naphtha feedstream is contacted in the reaction zone with a catalyst containing from about 10 to 50 wt. % of a crystalline zeolite having an average pore diameter less than about 0.7 nanometers at reaction conditions which include temperatures ranging from about 500 to 650.degree. C. and a hydrocarbon partial pressure from about 10 to 40 psia. Vapor products are collected overhead and the catalyst particles are passed through the stripping zone on the way to the catalyst regeneration zone. Volatiles are stripped with steam in the stripping zone and the catalyst particles are sent to the catalyst regeneration zone where coke is burned from the catalyst, which is then recycled to the reaction zone.

Two stage fluid catalytic cracking process for selectively producing     b.

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Baton Rouge, LA, United States of America

William A Wachter