Phosphorus-Modified FCC Catalysts
AssigneeBASF SE
InventorsGary M. Smith, Robert McGuire, JR., Bilge Yilmaz
Life of this patent
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Abstract
Described are fluid catalytic cracking (FCC) compositions, methods of manufacture and use. FCC catalyst compositions comprise catalytic microspheres containing a zeolite, a non-zeolitic component, and a rare earth component. The microspheres are modified with phosphorus. The FCC catalyst composition can be used to crack hydrocarbon feeds, particularly resid feeds containing high V and Ni, resulting in lower hydrogen and coke yields.
Claims19
A fluid catalytic cracking (FCC) catalyst composition for processing resid feeds comprising:
- catalytic microspheres containing a non-zeolitic component, 5 to 25% by weight of a transition alumina, 20% to 65% by weight of a zeolite component intergrown with the non-zeolitic component, a rare earth component and 1% to 5% by weight of a phosphorus component on an oxide basis,
- wherein the catalytic microspheres are obtained by forming rare earth-containing microspheres containing the non-zeolitic component, the transition alumina, the zeolite component intergrown within the non-zeolitic component, and yttria or a rare earth component, and further adding the phosphorus component to the rare earth-containing microspheres to provide the catalytic microspheres, and wherein the FCC catalyst composition is effective in preventing at least one of nickel and vanadium from increasing coke and hydrogen yields during cracking of a hydrocarbon.
A method of manufacturing an FCC catalyst comprising:
- pre-forming a precursor microsphere comprising a non-zeolitic material and alumina;
- in situ crystallizing a zeolite on the pre-formed microsphere to provide a zeolite-containing microsphere;
- adding a rare earth component to the zeolite-containing microsphere to provide a rare-earth-containing microsphere;
- and
- adding a phosphorus component to the rare earth-containing precursor microsphere to provide a catalytic microsphere.
The method of claim 28, wherein the method comprises adding a portion of the phosphorus component, then ion exchanging the rare earth component and then adding an additional phosphorus component.
Dependencies are inferred from the claim text.