Catalyst for light olefins and LPG in fludized catalytic units

Patent metadata

Field	Value
Publication number	US-9365779-B2
Application number	US-66714905-A
Country	US
Kind code	B2
Filing date	Nov 3, 2005
Priority date	Nov 5, 2004
Publication date	Jun 14, 2016
Grant date	Jun 14, 2016

Abstract

A catalyst composition comprising at least about 10% by weight pentasil, at least about 12% by weight Y-type zeolite at a pentasil to Y zeolite ratio of at least 0.25, and wherein the pentasil and Y zeolite comprise at least about thirty-five percent of the catalyst have been shown to optimize light olefin yields and LPG from FCC processes. Embodiments having matrix surface areas greater than 25 m 2 /g, phosphorous and rare earth are preferred. The compositions of this invention are particularly useful in typical fluid catalytic cracking (FCC) processes.

First claim

We claim:

1. A catalyst composition comprising
a. about twelve to about sixty percent by weight Y-type zeolite;
b. at least about ten percent by weight pentasil and wherein pentasil and Y-type zeolite is present in a weight ratio (pentasil:Y-type zeolite) of at least 0.25 and no more than 2.3; and
c. the Y-type zeolite and pentasil comprises at least about thirty-five percent by weight of the catalyst composition; and wherein the pentasil and the Y-type zeolite are contained in separate particles, and the separate particles of Y-type zeolite comprise two to eight percent by weight rare earth (measured as rare earth oxide) based on the Y type zeolite.

2. A catalyst composition according to claim 1 wherein the composition further comprises phosphorus.

3. A catalyst composition according to claim 2 wherein the composition comprises up to about 12% by weight phosphorus, as measured by the content of P 2 O 5 .

4. A catalyst composition according to claim 1 wherein the composition further comprises matrix having a surface area of at least 25 m 2 /g.

5. A catalyst composition according to claim 2 wherein the pentasil-containing particles comprise phosphorus.

6. A catalyst composition according to claim 5 wherein the pentasil-containing particles comprises phosphorus in amounts in the range of about six to about twenty-four % by weight, as measured by the content of P 2 O 5 .

7. A catalyst composition according to claim 2 wherein the Y-type zeolite-containing particles comprise phosphorus.

8. A catalyst composition according to claim 7 wherein the Y-type zeolite-containing particles comprise 0.01 to about 3 weight percent phosphorus as measured by P 2 O 5 .

9. A catalyst composition according to claim 1 wherein the composition has a surface area of at least 150 m 2 /g.

10. A catalyst composition according to claim 1 wherein the composition has a surface area of at least 150 m 2 /g after being treated at 816° C. for 4 hours with 100% steam.

11. A catalyst composition according to claim 1 comprising about ten percent to about fifty percent by weight pentasil.

12. A catalyst composition according to claim 1 having a Davison Attrition Index of about 20 or less.

13. A catalyst composition according to claim 1 having a Davison Attrition Index of about 10 or less.

14. A catalyst composition according to claim 1 having a Davison Attrition Index of about 5 or less.

15. A catalyst composition according to claim 1 wherein (a) the pentasil-containing particles comprise phosphorous, and (b) the catalyst further comprises matrix having a surface area of at least 25 m 2 /g.

16. A catalyst composition according to claim 15 comprising about one to about twelve percent by weight phosphorous.

17. A catalyst composition according to claim 15 comprising matrix having a surface area in the range of about 45 to about 130 m 2 /g.

18. A catalyst composition according to claim 15 having a total surface area of at least about 150 m 2 /g.

19. A catalyst composition according to claim 16 having a surface area of at least about 150 m 2 /g.

20. A catalyst composition according to claim 15 comprising about ten to about fifty weight percent pentasil.

21. A catalyst composition according to claim 20 wherein the pentasil is ZSM-5 or ZSM-11.

22. A catalyst composition according to claim 16 wherein the Y-type zeolite is exchanged with cerium cations, lanthanum cations, neodymium cation, praseodymium cations, or mixtures thereof.

23. A catalyst composition according to claim 1 wherein the catalyst composition has a kinetic conversion activity of at least about 2.3.

24. A catalyst composition according to claim 1 wherein the catalyst composition has a kinetic conversion activity of at least about 3.

25. A catalyst composition according to claim 1 wherein the catalyst composition has a kinetic conversion activity in the range of about 3.5 to about 5.5.

26. A catalyst composition according to claim 1 wherein the catalyst composition has a kinetic conversion activity in the range of about 4 to about 5.

27. A catalytic cracking process comprising:
a. introducing a hydrocarbon feedstock into a reaction zone of a catalytic cracking unit comprised of a reaction zone, stripping zone, and a regeneration zone, which feedstock is characterized as having an initial boiling point from about 120° C. with end points up to about 850° C.;
b. catalytically cracking said feedstock in said reaction zone at a temperature from about 400° C. to about 700° C., by causing the feedstock to be in contact with a cracking catalyst comprising:
i. about twelve to about sixty percent by weight Y-type zeolite;
ii. two to eight percent by weight rare earth (measured as rare earth oxide) based on the Y-type zeolite;
iii. at least about ten percent by weight pentasil and wherein pentasil and Y-type zeolite is present in a weight ratio pentasil:Y-type zeolite of at least 0.25 and no more than 2.3;
iv. the Y-type zeolite and pentasil comprises at least about thirty-five percent by weight of the catalyst composition; and wherein the pentasil and the Y-type zeolite are contained in separate particles, and the separate particles of Y-type zeolite comprise two to eight percent by weight rare earth (measured as rare earth oxide) based on the Y type zeolite; and

c. stripping recovered used catalyst particles with a stripping fluid in a stripping zone to remove therefrom some hydrocarbonaceous material; and
d. recovering stripped hydrocarbonaceous material from the stripping zone and circulating stripped used catalyst particles to the regenerator or regeneration zone; and
e. regenerating said coked catalyst in a regeneration zone by burning-off a substantial amount of the coke on said catalyst, and with any added fuel component to maintain the regenerated catalyst at a temperature which will maintain the catalytic cracking reactor at a temperature from about 400° C. to about 700° C.; and
f. recycling said regenerated hot catalyst to the reaction zone.

28. A process according to claim 27 wherein the catalyst in step (b) further comprises phosphorous.

29. A process according to claim 27 wherein the catalyst in step (b) further comprises matrix having a surface area of at least 25 m 2 /g.

30. A process according to claim 27 wherein the process is a fluidized catalytic cracking process.

31. A process according to claim 30 wherein the pentasil-containing particles comprise phosphorus.

32. A process according to claim 31 wherein the Y-type zeolite-containing particles comprise phosphorus.

33. A process according to claim 31 wherein the catalyst in step (b) comprises phosphorous in amounts in the range of about one to about twelve % by weight, as measured by the content of P 2 O 5 .

34. A process according to claim 31 wherein the pentasil-containing particles comprises phosphorus in amounts in the range of about six to about twenty-four % by weight, as measured by the content of P 2 O 5 .

35. A process according to claim 27 wherein the catalyst in step (b) has a surface area of at least 150 m 2 /g.

36. A process according to claim 27 wherein the catalyst in step (b) has a surface area of at least 150 m 2 /g after being treated at 1500° F. for 4 hours

Assignees

• Cheng Wu Cheng
• Krishnamoorthy Meenakshi Sundaram
• Kumar Ranjit
• Zhao Xinjin
• Ziebarth Michael Scott
• Grace W R & Co

Inventors

• Cheng Wu Cheng
• Krishnamoorthy Meenakshi Sundaram
• Kumar Ranjit
• Zhao Xinjin
• Ziebarth Michael Scott

Classifications

• C10G11/05

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

• C10G11/18

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

• C10G2300/301

  Boiling range · CPC title

• C10G2400/28

  Propane and butane · CPC title

• C10G2300/202

  Heteroatoms content, i.e. S, N, O, P · CPC title