Catalyst to increase propylene yields from a fluid catalytic cracking unit

Patent metadata

Field	Value
Publication number	US-9227181-B2
Application number	US-201113231522-A
Country	US
Kind code	B2
Filing date	Sep 13, 2011
Priority date	Sep 13, 2011
Publication date	Jan 5, 2016
Grant date	Jan 5, 2016

Abstract

A catalyst composition resulting in increased propylene yields during fluid catalytic cracking processes comprises (i) Y zeolite, (ii) ZSM-5 zeolite, and (iii) Beta zeolite.

First claim

The invention claimed is:

1. A hydrocarbon conversion catalyst blend comprising:
(a) a Y zeolite in an amount of 5 to 50 wt. % of said catalyst blend;
(b) a ZSM-5 zeolite in an amount of 5 to 40 wt. % of said catalyst blend; and
(c) a Beta zeolite in an amount of 35 to 70 wt. % of said catalyst blend, wherein each of said ZSM-5 zeolite, said Beta zeolite, and said Y zeolite is a separate microsphere.

2. The catalyst blend of claim 1 , wherein the Y zeolite is a large-pore zeolite comprising Y zeolite crystallized as a layer on the surface of a porous alumina-containing matrix, said zeolite-layered matrix arranged in a configuration to provide macropores in which the zeolite layer is provided on the walls of the macropores.

3. The catalyst blend of claim 1 , wherein the Y zeolite contains up to 12% of a rare earth element ion exchanged onto the Y zeolite.

4. The catalyst blend of claim 1 wherein the ZSM-5 additive contains zeolite comprises phosphorus stabilized ZSM-5 zeolite, alumina, and kaolin bound together with phosphorus-containing compound.

5. The catalyst blend of claim 1 wherein the Beta zeolite is a H-Beta with a silica/alumina ratio greater than 10.

6. The catalyst blend of claim 5 wherein the silica/alumina ratio of the Beta zeolite is greater than 100.

7. The catalyst blend of claim 1 wherein the Beta zeolite is modified with a phosphorus-containing compound.

8. The catalyst blend of claim 7 wherein the Beta zeolite has a phosphorus level between 1-7% P 2 O 5 .

9. The catalyst blend of claim 8 wherein the phosphorus level is between 3-5% P 2 O 5 .

10. The catalyst blend of claim 1 wherein the catalyst comprises 25-30 wt. % of said Y zeolite, 15-20 wt. % of said ZSM-5 zeolite, and 50-60 wt. % of said Beta zeolite.

11. A hydrocarbon conversion catalyst blend comprising:
(a) a Y zeolite, wherein the Y zeolite is a large-pore zeolite comprising Y zeolite crystallized as a layer on the surface of a porous alumina-containing matrix, said zeolite-layered matrix arranged in a configuration to provide macropores in which the zeolite layer is provided on the walls of the macropores;
(b) a ZSM-5 zeolite; and
(c) a Beta zeolite,
wherein said blend contains by wt. % more said Beta zeolite than said Y zeolite, and more said Y zeolite than said ZSM-5 zeolite, and each of said ZSM-5 zeolite, said Beta zeolite, and said Y zeolite is a separate microsphere.

12. The catalyst of claim 11 wherein the catalyst blend comprises 5-50 wt. % of said Y zeolite, 5-40 wt. % ZSM-5 zeolite, and 35-70 wt. % of said Beta zeolite.

13. The catalyst of claim 11 wherein the catalyst blend comprises 25-30 wt. % of said Y zeolite, 15-20 wt. % of said ZSM-5 zeolite, and 50-60 wt. % of said Beta zeolite.

14. The catalyst of claim 11 wherein the ZSM-5 zeolite is a phosphorus stabilized ZSM-5 zeolite, alumina, and kaolin bound together with a phosphorus-containing compound.

15. The catalyst of claim 14 , wherein the Y zeolite contains 1% or less of a rare earth element ion exchanged onto the Y zeolite.

16. The catalyst of claim 14 wherein the Beta zeolite is a H-Beta with a silica/alumina ratio greater than 100.

17. The catalyst of claim 14 wherein the Beta zeolite is modified with a phosphorous-containing compound.

18. A process for the improved production of propylene comprising cracking a hydrocarbon feedstock under fluid catalytic cracking conditions with the catalyst of claim 1 .

19. A process for the improved production of propylene comprising cracking a hydrocarbon feedstock under fluid catalytic cracking conditions with the catalyst of claim 15 .

Assignees

• Harris David H
• Basf Corp

Inventors

• Harris David H

Classifications

• C07C2529/70

  of types characterised by their specific structure not provided for in groups C07C2529/08 - C07C2529/65 · CPC title

• C10G11/18

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

• C07C2529/80

  Mixtures of different zeolites · CPC title

• C07C4/06

  Catalytic processes {(C07C4/025 takes precedence)} · CPC title

• C07C2529/08

  of the faujasite type, e.g. type X or Y · CPC title