Structurally enhanced cracking catalysts

Patent metadata

Field	Value
Publication number	US-9675967-B2
Application number	US-201514827873-A
Country	US
Kind code	B2
Filing date	Aug 17, 2015
Priority date	Jun 20, 2007
Publication date	Jun 13, 2017
Grant date	Jun 13, 2017

Abstract

A cracking catalyst contains a substantially inert core and an active shell, the active shell containing a zeolite catalyst and a matrix. Methods of making and using the cracking catalyst are also described.

First claim

What is claimed is:

1. A process of forming a fluidizable cracking catalyst, the process comprising:
forming a slurry by combining at least water, about 1 to about 70 parts by weight kaolin, about 1 to about 70 parts by weight of substantially inert core microspheres comprising alpha-alumina, and a zeolite catalyst precursor comprising germanium oxide, tin oxide, phosphorus oxide, boron oxide, iron oxide, gallium oxide, indium oxide, gallosilicates, borosilicates, ferrosilicates, or a mixture of two or more thereof; and
spray drying the slurry to form spray dried particles containing the substantially inert core microspheres with an active catalytic shell at least partially surrounding the substantially inert core microspheres; and
crystallizing a zeolite in the active catalytic shell to form the fluidizable cracking catalyst.

2. The process of claim 1 , wherein the fluidizable cracking catalyst comprises from about 30 wt % to about 70 wt % of the active catalytic shell.

3. The process of claim 1 further comprising calcining the spray dried particles.

4. The process of claim 1 , wherein the inert core microsphere have an average diameter of from about 35 μm to about 75 μm.

5. The process of claim 1 , wherein the inert core microsphere have an average diameter of about 45 μm.

6. The process of claim 1 , wherein the slurry further comprises an inorganic binder.

7. The process of claim 6 , wherein the inorganic binder comprises an aluminum stabilized SiO 2 hydrosol, a dispersible pseudo-boehmite binder reinforced with silica, or an aluminum chlorohydrol binder.

8. A cracking process comprising:
contacting a hydrocarbon feedstream and a fluidizable cracking catalyst;
wherein the fluidizable cracking catalyst comprises:
a substantially inert core comprising at least one of mullite or alpha-alumina; and
an active catalytic shell around the substantially inert core, the active catalytic shell comprising a zeolite catalyst incorporated in a matrix, wherein said zeolite catalyst is formed by in-situ crystallization of the zeolite within the matrix, wherein the active catalytic shell comprises 30 to 70 wt. % of said fluidizable cracking catalyst and the zeolite is formed from a zeolite catalyst precursor comprising germanium oxide, tin oxide, phosphorus oxide, boron oxide, iron oxide, gallium oxide, indium oxide, gallosilicates, borosilicates, ferrosilicates, or a mixture of two or more thereof.

9. A cracking process comprising:
contacting a hydrocarbon feedstream and a fluidizable cracking catalyst;
wherein the fluidizable cracking catalyst comprises:
a substantially inert core; and
an active catalytic shell around the core, the active catalytic shell comprising: an alumina having a metals passivation function and a zeolite catalyst incorporated in a matrix, wherein the zeolite catalyst is formed by in-situ crystallization of the zeolite within the matrix, wherein the active catalytic shell comprises 30 to 70 wt. % of said fluidizable cracking catalyst and the zeolite is formed from a zeolite catalyst precursor comprising germanium oxide, tin oxide, phosphorus oxide, boron oxide, iron oxide, gallium oxide, indium oxide, gallosilicates, borosilicates, ferrosilicates, or a mixture of two or more thereof.

Assignees

• Basf Corp

Inventors

• Stockwell David Matheson
• Macaoay John M

Classifications

• B01J29/084 Primary

  Y-type faujasite · CPC title

• B01J2229/64

  in or on refractory materials · CPC title

• B01J21/04

  Alumina · CPC title

• B01J35/0006

  Operations & Transport · mapped topic

• B01J21/16

  Clays or other mineral silicates · CPC title