Stabilized dual zeolite single particle catalyst composition and a process thereof
AssigneeIndian Oil Corporation Limited
InventorsMohan Prabhu Kuvettu, Sanjay Kumar Ray, Gopal Ravichandran, Venkatchalam Krishnan, Satyen Kumar Das, Satish Makhija, Sobhan Ghosh
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Abstract
The present invention relates to a stabilized dual zeolite catalyst for cracking heavier hydrocarbons into lighter useful products said catalyst comprising two types of zeolites viz., low silica molecular sieve and stabilized high silica zeolite, silica-alumina based binder and kaolin clay and a process for the preparation of the stabilized dual zeolite catalyst.
Claims35
A stabilized dual zeolite low coke forming single particle catalyst, bonded with silica alumina binder, suitable for cracking heavy residual hydrocarbon feeds and having enhanced hydrothermal stability, said catalyst comprising:
- (a) stabilized high silica zeolite in the range of 1 wt % to 50 wt %;
- (b) low silica molecular sieve in the range of 1 wt % to 40 wt %;
- (c) silica in the range of 1 wt % to 15 wt %;
- (d) alumina in the range of 5 wt % to 30 wt %;
- and
- (e) clay in the range of 10 wt % to 50 wt %;
A catalyst according to claim1 wherein the low silica molecular sieve is exchanged with rare earth cations selected from the group consisting of lanthanum, cerium, praseodymium, neodymium, samarium and gadolinium.
A catalyst according to claim1 wherein the particle size of the catalyst is in the range of 30-100 microns.
A process for preparing hydrocarbon conversion, stabilized dual zeolite catalyst, comprising essentially of stabilized high silica zeolite and a low silica molecular sieve, said process comprising the steps of:
- (a) loading high silica zeolite into a reactor and maintaining the zeolite at a temperature ranging between 100-125° C. for about 30 minutes;
- (b) heating the high silica zeolite to a temperature in the range of 450-500° C. for about 90 minutes in nitrogen atmosphere;
- (c) holding the zeolite at about 450-600° C. for about 90 minutes in an atmosphere steam containing phosphate;
- (d) cooling the zeolite to obtain stabilized high silica zeolite;
- (e) treating an alumina with a dilute organic acid and gelling it for about 10 minutes to obtain alumina binder;
- (f) adding demineralised water to the gel alumina to make the alumina binder free flowing;
- (g) adding acidified ammonium polysilicate to the gel alumina;
- (h) adding milled clay slurry to the product of step(h);
- (i) adding milled slurry of low silica molecular sieve;
- (j) adding demineralised water to obtain silica-alumina-clay-low silica molecular sieve slurry;
- (k) adding the stabilized high silica zeolite as obtained in step (d) to the silica-alumina-clay-low silica molecular sieve slurry of step (j);
- and
- (l) spray-drying the slurry and calcining the same to obtain the stabilized dual zeolite catalyst.
Dependencies are inferred from the claim text.