FCC catalyst having alumina derived from crystalline boehmite

Patent metadata

Field	Value
Publication number	US-10633596-B2
Application number	US-201615264428-A
Country	US
Kind code	B2
Filing date	Sep 13, 2016
Priority date	Jun 17, 2016
Publication date	Apr 28, 2020
Grant date	Apr 28, 2020

Abstract

A zeolite fluid catalytic cracking catalyst is provided that passivates nickel and vanadium during catalytic cracking. The zeolite fluid catalytic cracking catalyst includes Y-faujasite crystallized in-situ from a metakaolin-containing calcined microsphere. The zeolite fluid catalytic cracking catalyst further includes an alumina-containing matrix obtained by calcination of a dispersible crystalline boehmite and a kaolin contained in the metakaolin-containing calcined microsphere, where the dispersible crystalline boehmite has a crystallite size of less than 500 Å. Also provided are a method of reducing contaminant coke and hydrogen yields and a method of catalytic cracking of heavy hydrocarbon feed stocks.

First claim

What is claimed is:

1. A zeolite fluid catalytic cracking catalyst that passivates nickel and vanadium during catalytic cracking, the zeolite fluid catalytic cracking catalyst comprising:
Y-faujasite crystallized in-situ from:
a metakaolin-containing calcined microsphere; and
an alumina-containing matrix contained in the metakaolin-containing calcined microspheres, the alumina-containing matrix obtained by calcination of a dispersible crystalline boehmite and a hydrous kaolin, wherein the dispersible crystalline boehmite comprises crystalline agglomerates having an average particle size of 50 nm to 300 nm, the crystalline agglomerates being formed from discrete and nonspherical boehmite crystallites each characterized by a crystallite size of 50 Å to 500 Å, the crystallite size of a given crystallite being defined by a greatest dimension of the given crystallite.

2. The zeolite fluid catalytic cracking catalyst of claim 1 , wherein the crystallite size of the dispersible crystalline boehmite is greater than 150 Å.

3. The zeolite fluid catalytic cracking catalyst of claim 1 , wherein the crystallite size of the dispersible crystalline boehmite is less than 400 Å.

4. The zeolite fluid catalytic cracking catalyst of claim 1 , wherein the crystallite size of the dispersible crystalline boehmite is less than 300 Å.

5. The zeolite fluid catalytic cracking catalyst of claim 1 , wherein an average BrunauerEmmettTeller (BET) surface area of the zeolite fluid catalytic cracking catalyst is less than 500 m 2 /g.

6. The zeolite fluid catalytic cracking catalyst of claim 1 , wherein an average BET surface area of the zeolite fluid catalytic cracking catalyst is less than 475 m 2 /g.

7. The zeolite fluid catalytic cracking catalyst of claim 1 , wherein an average BET surface area of the zeolite fluid catalytic cracking catalyst is from about 300 to about 450 m 2 /g.

8. The zeolite fluid catalytic cracking catalyst of claim 1 , wherein the zeolite fluid catalytic cracking catalyst is macroporous.

9. The zeolite fluid catalytic cracking catalyst of claim 1 , wherein the zeolite fluid catalytic cracking catalyst comprises macropore walls lined with zeolite.

10. The zeolite fluid catalytic cracking catalyst of claim 1 , wherein the alumina-containing matrix is mesoporous and contains pores with diameters between 2 and 50 nm.

11. The zeolite fluid catalytic cracking catalyst of claim 1 , wherein the alumina-containing matrix is microporous and contains pores with diameters less than 2 nm.

12. The zeolite fluid catalytic cracking catalyst of claim 1 , wherein the crystallites have a defined x-ray diffraction (XRD) pattern.

13. The zeolite fluid catalytic cracking catalyst of claim 1 , wherein calcination of the dispersible crystalline boehmite and the hydrous kaolin occurs at a temperature of less than 1000° F. so as to avoid endothermic transformation of the hydrous kaolin to metakaloin.

14. The zeolite fluid catalytic cracking catalyst of claim 1 , wherein after calcination, the dispersible crystalline boehmite has a surface area ranging from 99 to 468 m 2 /g and a particle size of 1.5 microns to 264 microns.

15. The zeolite fluid catalytic cracking catalyst of claim 1 , wherein an overall hydrogen yield ranges from 0.8 to 1.2 wt %.

Assignees

• Basf Corp

Inventors

• Mcguire Robert
• Smith Gary M
• Yilmaz Bilge
• Serneels Sven

Classifications

• C10G2300/205

  Metal content · CPC title

• C10G11/05 Primary

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

• C10G11/18

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

• B01J29/084

  Y-type faujasite · CPC title

• B01J2229/42

  Addition of matrix or binder particles · CPC title