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

Patent metadata

Field	Value
Publication number	US-10005072-B2
Application number	US-201313948687-A
Country	US
Kind code	B2
Filing date	Jul 23, 2013
Priority date	Jul 23, 2012
Publication date	Jun 26, 2018
Grant date	Jun 26, 2018

Abstract

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.

First claim

What is claimed is:

1. A high matrix surface area fluid catalytic cracking catalyst having increased activity and improved selectivity for cracking a hydrocarbon feedstock to lower molecular weight products, the catalyst comprising a particulate composition comprising a zeolite having catalytic cracking activity under catalytic cracking conditions, an added silica component, a magnesium salt, clay, an alumina containing binder and optionally at least one matrix material, wherein the composition has a matrix surface area of greater than 60 m 2 /g, wherein (1) the added silica component is either a component of matrix, if present, or is a separate component of the particulate that is not present in any clay, binder or zeolite component of the catalyst particulate, and (2) the magnesium salt is distributed throughout the particulate.

2. The catalyst of claim 1 wherein the zeolite is a faujasite zeolite.

3. The catalyst of claim 2 wherein the faujasite zeolite is a Y-type zeolite.

4. The catalyst of claim 1 wherein the added silica component is a silica component selected from the group consisting of precipitated silica, silica gel, colloidal silica, silica alumina containing greater than 60 wt % silica, and combinations thereof.

5. The catalyst of claim 4 wherein the added silica component is precipitated silica.

6. The catalyst of claim 4 wherein the added silica component is colloidal silica.

7. The catalyst of claim 4 where in the added silica component is present in an amount sufficient to provide at least about 5 wt % silica in the total catalyst composition.

8. The catalyst of claim 1 wherein the added silica component is present in an amount sufficient to provide at least about 5 wt % silica in the total catalyst composition.

9. The catalyst of claim 8 wherein the amount of the added silica component present in the catalyst is an amount sufficient to provide from about 5 wt % to about 30 wt % silica in the total catalyst composition.

10. The catalyst of claim 9 wherein the amount of the added silica component present in the catalyst is an amount sufficient to provide from about 8 wt % to about 25 wt % silica in the total catalyst composition.

11. The catalyst of claim 1 wherein the matrix surface area is greater than 80 m 2 /g.

12. The catalyst of claim 1 wherein the amount of zeolite present in the catalyst ranges from about 10 wt % to about 50 wt % of the total catalyst composition.

13. The catalyst of claim 12 wherein the amount of zeolite present in the catalyst ranges from about 12 wt % to about 40 wt % of the total catalyst composition.

14. The catalyst of claim 1 wherein the binder is selected from the group consisting of alumina sol, peptized alumina, silica-alumina having less than 60 wt % silica and combinations thereof.

15. The catalyst of claim 14 wherein the binder is alumina sol.

16. The catalyst of claim 15 wherein the binder comprises aluminum chlorohydrol.

17. The catalyst of claim 14 wherein the binder is an acid or base peptized alumina.

18. The catalyst of claim 14 wherein the amount of binder present in the catalyst ranges from about 10 wt % to about 60 wt % of the catalyst composition.

19. The catalyst of claim 1 wherein the amount of binder present in the catalyst ranges from about 10 wt % to about 60 wt % of the catalyst composition.

20. The catalyst of claim 1 wherein the particulate composition has an added silica to magnesium oxide molar ratio of about 2 or greater than 2.

21. The catalyst of claim 20 wherein the added silica to magnesium oxide molar ratio in the particulate composition ranges from about 2 to about 40.

22. The catalyst of claim 21 wherein the added silica to magnesium oxide molar ratio in the particulate composition ranges from about 4 to about 30.

23. The catalyst of claim 1 wherein clay is present in the composition in an amount ranging from about 5 wt % to about 65 wt % of the total catalyst composition.

24. The catalyst of claim 1 wherein a matrix material selected from the group consisting of non-peptized alumina, zirconia, titania, and combinations thereof, is present in the catalyst.

25. The catalyst of claim 24 wherein the matrix material is present in the composition in an amount ranging from about 1 wt % to about 70 wt % of the total catalyst composition.

26. The catalyst of claim 1 wherein the amount of magnesium salt present in the catalyst ranges from about 0.2 wt % to about 5.0 wt %, expressed as the oxide, of the total catalyst composition.

27. The catalyst of claim 1 wherein the zeolite has a Na 2 O content sufficient to provide less than about 1.0 wt % Na 2 O, on a zeolite basis, in the total catalyst composition.

28. The catalyst of claim 27 wherein the zeolite has a Na 2 O content sufficient to provide less than 0.7 wt % Na 2 O, on a zeolite basis, in the total catalyst composition.

29. The catalyst of claim 1 , where the particulate composition is free of rare earth metals.

30. A method of forming a catalytic cracking catalyst having a high matrix surface area, said method comprising:
a. forming an aqueous slurry comprising at least one zeolite particle having catalytic cracking activity under catalytic cracking conditions, an added silica component, an alumina containing binder, clay, and optionally at least one matrix material wherein the added silica component is either a component of matrix material, if present, or is a separate component that is not present in the clay, binder or zeolite;
b. optionally, milling the slurry;
c. spray drying the slurry to form catalyst particles;
d. optionally, calcining the catalyst particles at a temperature and for a time sufficient to remove volatiles;
e. optionally, washing the catalyst particles;
f. contacting the catalyst particles with an aqueous solution comprising at least one soluble magnesium salt in an amount sufficient to provide a particulate catalyst composition comprising at least 0.2 wt % magnesium salt and having a matrix surface area of greater than 60 m 2 /g;
g. removing the particles; and
h. drying the catalyst particles to obtain a final catalyst composition having a DI of less than 30.

31. The method of claim 30 wherein the aqueous slurry comprises zeolite particles in an amount sufficient to provide from about 10 wt % to about 50 wt % zeolite in the final catalyst composition.

32. The method of claim 30 wherein the zeolite particle is a faujasite zeolite.

33. The method of claim 30 wherein the aqueous slurry comprises the added silica component in an amount sufficient to provide at least about 5 wt % of silica in the final catalyst composition.

34. The method of claim 30 wherein the added silica component is selected from the group consisting of precipitated silica, silica gel, colloidal silica, silica sol and combinations thereof.

35. The method of claim 34 wherein the added silica component is a precipitated silica.

36. The method of claim 30 wherein the binder is selected from the group consisting of alumina sol, peptized alumina, silica-alumina having less than 60 wt % silica and combinations thereof.

37. The method of claim 36 wherein the binder comprises an alumina sol.

38. The method of cla

Assignees

• Grace W R & Co
• Grace W R & Co

Inventors

• Kumar Ranjit
• Cheng Wu-Cheng
• Sutovich Kevin J
• Ziebarth Michael S
• Shu Yuying

Classifications

• C10G11/05

  Crystalline alumino-silicates, e.g. molecular sieves · CPC title

• B01J29/084 Primary

  Y-type faujasite · CPC title

• B01J29/088

  Y-type faujasite · CPC title

• B01J2229/20

  to introduce other elements in the catalyst composition comprising the molecular sieve, but not specially in or on the molecular sieve itself · CPC title

• C10G11/18

  according to the "fluidised-bed" technique · CPC title