US 4,493,902 A · Fluid catalytic cracking catalyst comprising microspheres containing more than about 40 percent by weight Y-faujasite and methods for making

Abstract

This application discloses novel fluid catalytic cracking catalysts comprising microspheres containing more than about 40%, preferably 50-70%, by weight Y-faujasite zeolite, methods for making such catalysts, and the use of such catalysts to crack petroleum feedstocks, particularly those containing large amounts of contaminant metals. The microspheres of the catalyst of the invention are characterized by a combination of desirable catalytic and physical characteristics, including exceptionally high activity, excellent hydrothermal stability, good to excellent attrition resistance, and desirable selectivity characteristics.

Claims62

Dependent claims

A fluid catalytic cracking catalyst comprising microspheres containing at least about 40% by weight Y-faujasite and having less than about 0.20 cc/g. of pores having diameters in the range of 20-100.ANG., said microspheres having the following characteristics:

(a) a deactivated activity at least about 1.5 times that of standard commercial catalyst;
(b) a severely deactivated activity at least about 1.5 times that of standard commercial catalyst;
(c) a coke yield no greater than about that of standard commercial catalyst at 70% conversion;
and
(d) an EAI no more than about 5.0 times that of standard commercial catalyst.

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The method for making a fluid catalytic cracking catalyst comprising the steps of:

(a) forming an aqueous slurry of finely divided hydrous kaolin clay and finely divided kaolin clay that has been calcined at least substantially through its characteristic exotherm;
(b) spray drying the aqueous slurry to obtain microspheres comprising a mixture of hydrous kaolin clay and kaolin clay that has been calcined at least substantially through its characteristic exotherm;
(c) calcining the microspheres obtained in step (b) at a temperature and for a time sufficient to convert the hydrous kaolin clay in the microspheres substantially to metakaolin and to obtain microspheres of calcined clay comprising a mixture of about 30-60% by weight metakaolin and about 40-70% by weight kaolin clay that has been calcined at least substantially through its characteristic exotherm;
(d) mixing the microspheres obtained in step (c) with one or more sources of sodium silicate and water to obtain an alkaline slurry of microspheres of calcined clay in an aqueous solution containing sodium silicate, said sodium silicate being provided in an amount so that microspheres having a SiO.sub.2 /Al.sub.2 O.sub.3 molar ratio of about 1.7-3.4 are obtained in step (h) below;
(e) adding zeolite initiator to the kaolin clay that has been calcined at least substantially through its characteristic exotherm before step (f) below;
(f) heating the slurry of microspheres of calcined clay to a temperature and for a time sufficient to crystallize at least about 40% by weight Y-faujasite in the microspheres, said Y-faujasite being in the sodium form;
(g) separating the microspheres containing at least about 40% by weight Y-faujasite from at least a major portion of its mother liquor;
(h) replacing sodium cations in the microspheres separated in step (g) with ammonium or rare earth cations or both.

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Dependencies are inferred from the claim text.

Fluid catalytic cracking catalyst comprising microspheres containing more than about 40 percent by weight Y-faujasite and methods for making

Life of this patent

Fluid catalytic cracking catalyst comprising microspheres containing more than about 40 percent by weight Y-faujasite and methods for making

Life of this patent

Abstract

Claims62