# US 12,758,952 B2 · Essentially clay free FCC catalyst with increased contaminant resistivity, its preparation and use

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- Number: US 12,758,952 B2
- Document ID: US12758952B2
- Status: Granted
- Kind: B2
- Application number: 18/250,371
- Filed: 2021-10-29
- Published: 2023-12-28
- Granted: 2026-10-13
- Earliest claimed: 2020-10-30
- Assignees: Ketjen Limited Liability Company
- Applicants: Ketjen Limited Liability Company
- Inventors: Eswaramoorthi Iyyamperumal; George Yaluris; Darrell Ray Rainer
- Web page: https://patentgrep.com/patent/US12758952B2

## CPC

- B01J 29/06: Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
- B01J 21/04: Alumina
- B01J 21/08: Silica
- B01J 37/04: Mixing {(B01J37/0009, B01J37/0018 take precedence)}
- C10G 11/04: Oxides
- B01J 35/38: Abrasion or attrition resistance
- B01J 35/70: characterised by their crystalline properties, e.g. semi-crystalline (catalysts comprising carbon B01J21/18; molecular sieves B01J29/00)
- B01J 2235/15: X-ray diffraction
- C10G 2300/1003: Waste materials
- C10G 2300/1014: of vegetal origin
- C10G 2300/1018: of animal origin
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- C10G: CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION (cracking to hydrogen or synthesis gas C01B; cracking or pyrolysis of hydrocarbon gases to individual hydrocarbons or mixtures thereof of definite or specified constitution C07C; cracking to cokes C10B); RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES

## Abstract

Process for the preparation of a particulate FCC catalyst and a particulate FCC catalyst increased contaminants resistivity being essentially free of clay. Thus, in one embodiment, provided is a particulate FCC catalyst composition comprising one or more zeolites, at least one alumina component, at least one silica component, and being essentially free of clay. In a further embodiment, it is provided a particulate FCC catalyst composition comprising at least two different types of alumina and at least one silica component and being essentially free of clay. The alumina components can be selected from the group of peptizable quasicrystalline boehmite, non-peptizable microcrystalline boehmite phase, non-peptizable alpha phase or non-peptizable alumina containing gamma phase or non-peptizable alumina containing chi phase or gibbsite alumina. The silica component can be selected from the group of low sodium stabilized colloidal silica and acid or low sodium or ammonia stabilized colloidal silica or ploy silicic acid.

## Claims

### Claim 1

A particulate FCC catalyst composition comprising about 1 to about 50 wt % one or more zeolites, about 1 to about 45 wt % quasicrystalline boehmite, about 1 to about 45 wt % microcrystalline boehmite, greater than about 0-40 wt % non-peptizable alumina comprising gamma or alpha or chi phase alumina or gibbsite, about 1 wt % to about 20 wt % sodium stabilized silica, and about 0-20 wt % low sodium or acid or ammonia stabilized colloidal silica or poly silicic acid and essentially free of clay.

### Claim 2 (depends on 1)

The particulate FCC catalyst composition of claim 1 wherein the quasicrystalline boehmite alumina has the characteristics sharp XRD peaks at 2θ values at about 14, 28 and 38 degrees corresponding to the (020), (021), and (041) plane reflections.

### Claim 3 (depends on 1)

The particulate FCC catalyst composition of claim 1 wherein the microcrystalline boehmite alumina has the characteristics XRD peaks of 2θ values at about 14, 28 and 38 degrees corresponding to the (020), (021), and (041) plane reflections.

### Claim 4 (depends on 1)

The particulate FCC catalyst composition of claim 1 wherein the non-peptizable alumina comprising alpha-alumina has the characteristics XRD peaks of 2θ values at about 25.5, 35, 43.5, 57.5 and 69 degrees corresponding to (012), (104), (115), (116) and (030) plane reflections.

### Claim 5 (depends on 1)

The particulate FCC catalyst composition of claim 1 wherein the non-peptizable alumina comprising gamma-alumina has the characteristics XRD peaks of 2θ values at about 37.6, 45.8 and 67 degrees corresponding to the (311), (400) and (440) plane reflections.

### Claim 6 (depends on 1)

The particulate FCC catalyst composition of claim 1 wherein the non-peptizable alumina comprising chi phase has the characteristics XRD peaks of 2θ values at about 37, 43, and 67 degrees.

### Claim 7 (depends on 1)

The particulate FCC catalyst composition of claim 1 wherein the non-peptizable alumina comprising gibbsite-alumina has the characteristics XRD peaks of 2θ values at about 18, 20.3 and 38 degrees.

### Claim 8

A particulate FCC catalyst composition comprising one or more zeolites. quasicrystalline boehmite, microcrystalline boehmite, non-peptizable alumina comprising gamma or alpha or chi phase alumina or gibbsite, sodium stabilized silica, and low sodium or acid or ammonia stabilized colloidal silica or poly silicic acid, and essentially free of clay.