# US 2018/0021762 A1 · Heat generating catalyst for hydrocarbons cracking

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- Number: US 2018/0021762 A1
- Document ID: US20180021762A1
- Status: Published application
- Kind: A1
- Application number: 15/720,185
- Filed: 2017-09-29
- Published: 2018-01-25
- Earliest claimed: 2016-05-12
- Assignees: Saudi Arabian Oil Company
- Applicants: Saudi Arabian Oil Company
- Inventors: Ola S. Ali; Hussain Al Yami; Mark P. Kaminsky; Sohel Shaikh; Wei Xu
- Web page: https://patentgrep.com/patent/US20180021762A1

## CPC

- B01J 29/18: of the mordenite type
- B01J 29/185: {containing rare earth elements, titanium, zirconium, hafnium, zinc, cadmium, mercury, gallium, indium, thallium, tin or lead}
- B01J 29/20: containing iron group metals, noble metals or copper
- B01J 29/24: Iron group metals or copper
- B01J 29/26: containing arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
- B01J 29/40: of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively
- B01J 29/405: {containing rare earth elements, titanium, zirconium, hafnium, zinc, cadmium, mercury, gallium, indium, thallium, tin or lead}
- B01J 29/42: containing iron group metals, noble metals or copper
- B01J 29/46: Iron group metals or copper
- B01J 29/48: containing arsenic, antimony, bismuth, vanadium, niobium tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
- B01J 35/19: {Catalysts containing parts with different compositions}
- B01J 35/40: characterised by dimensions, e.g. grain size (in a colloidal state B01J35/23; crystallite size B01J35/77)
- B01J 35/45: Nanoparticles
- B01J 37/0201: {Impregnation}
- B01J 37/0209: {involving a reaction between the support and a fluid}
- B01J 37/035: {Precipitation on carriers}
- B01J 37/14: with gases containing free oxygen
- B01J 37/28: Phosphorising
- C10G 11/04: Oxides
- C10G 11/05: Crystalline alumino-silicates, e.g. molecular sieves
- C10G 11/10: with stationary catalyst bed
- C10G 11/16: according to the "moving bed" method
- C10G 11/18: according to the "fluidised-bed" technique
- B01J 29/90: Regeneration or reactivation
- B01J 38/12: Treating with free oxygen-containing gas
- B01J 2229/186: not in framework positions
- B01J 2235/30: Scanning electron microscopy; Transmission electron microscopy
- C10G 2300/104: Light gasoline having a boiling range of about 20 - 100 °C
- C10G 2300/1044: Heavy gasoline or naphtha having a boiling range of about 100 - 180 °C
- C10G 2300/1048: Middle distillates
- C10G 2300/70: Catalyst aspects
- C10G 2400/20: C2-C4 olefins
- C10G 2400/22: Higher olefins
- 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

A method of using a heat generating catalyst in a hydrocarbon cracking process. The method includes providing a catalyst bed reactor which includes a catalyst bed of the heat generating catalyst disposed in the catalyst bed reactor. The heat generating catalyst includes at least one mordenite framework-inverted (MFI) zeolite catalyst having a Si/Al molar ratio of 15 or greater, and at least one metal oxide dispersed within a microstructure of the MFI zeolite catalyst. The method additionally includes introducing a hydrocarbon feed to the catalyst bed reactor and cracking the hydrocarbon feed to produce a cracking product. Additionally, an associated method of making the heat generating catalyst for hydrocarbon cracking is provided.

## Claims

### Claim 1

A method of using a heat generating catalyst in a hydrocarbon cracking process, the method comprising:
providing a catalyst bed reactor,
where the catalyst bed reactor includes a catalyst bed of the heat generating catalyst disposed in the catalyst bed reactor,
the heat generating catalyst comprising:
at least one mordenite framework-inverted (MFI) zeolite catalyst having a Si/Al molar ratio of 15 or greater, and
at least one metal oxide dispersed within a microstructure of the MFI zeolite catalyst;
introducing a hydrocarbon feed to the catalyst bed reactor; and
cracking the hydrocarbon feed to produce a cracking product.

### Claim 2 (depends on 1)

The method of claim 1 where the catalyst bed reactor comprises a fluidized bed reactor or a fixed-bed reactor.

### Claim 3 (depends on 2)

The method of claim 2 where the catalyst bed reactor is a fixed-bed reactor and the catalyst bed of the heat generating catalyst comprises a layer of the heat generating catalyst disposed before a layer of MFI zeolite catalyst, a layer of heat generating catalyst disposed after a layer of MFI zeolite catalyst, or at least one layer of heat generating catalyst disposed between at least two layers of MFI zeolite catalyst.

### Claim 4 (depends on 1)

The method of claim 1 where the at least one metal oxide is chemically bonded to the microstructure of the MFI zeolite catalyst.

### Claim 5 (depends on 1)

The method of claim 1 where the heat generating catalyst further comprises a promoter.

### Claim 6 (depends on 5)

The method of claim 5 where the promoter is at least one of an alkali metal, an alkaline earth metal, a rare earth metal, a transition metal, phosphorous, and their combinations.

### Claim 7 (depends on 1)

The method of claim 1 where the MFI zeolite catalyst is a ZSM-5 catalyst.

### Claim 8 (depends on 7)

The method of claim 7 where the ZSM-5 catalyst is an H-ZSM-5 catalyst.

### Claim 9 (depends on 1)

The method of claim 1 where the at least one metal oxide is at least one of an oxide of iron, copper, zinc, chromium, molybdenum, vanadium, cerium, manganese, bismuth, silver, cobalt, vanadium, zirconium, tungsten, magnesium, and their combinations.

### Claim 10 (depends on 1)

The method of claim 1 where the at least one metal oxide comprises copper oxide.

### Claim 11 (depends on 1)

The method of claim 1 where the MFI zeolite catalyst is crushed ZSM-5 catalyst having an average particle size of 5 to 850 nanometers.