A fluid catalytic cracking catalyst made from microspheres that initially contain kaolin, a dispersible boehmite alumina and a sodium silicate or silica sol binder. The kaolin portion contains hydrous kaolin and optionally spinel, or mullite, or both spinel and mullite made via kaolin which has been calcined through its characteristic exotherm. Calcination of the hydrous clay to metakaolin and formation of in-situ zeolite by treatment with sodium silicate yields a catalyst containing Y-faujasite and transforms the dispersible boehmite into a transitional alumina. The catalyst can be used to crack resid or resid-containing feeds as the alumina phase formed from the dispersible boehmite passivates nickel and vanadium contaminants.
Mingting Xu - Edison NJ, US John Macaoay - Linden NJ, US
Assignee:
Engelhard Corporation - Iselin NJ
International Classification:
C01B039/38
US Classification:
423709, 423712, 423716, 423DIG 22, 20812001
Abstract:
A novel method of forming ZSM-5 comprises reacting calcined kaolin microspheres with silicate and a seed solution used for forming zeolite Y under conditions of pH, temperature, and time to yield ZSM-5 crystals formed in-situ on said calcined kaolin microspheres. The reaction medium does not contain any organic templates or ZSM-5 seeding crystals.
Enhanced Fcc Catalysts For Gas Oil And Resid Applications
A fluid catalytic cracking catalyst is provided with a high porosity by in-situ crystallizing an aluminosilicate zeolite from a reactive microsphere comprising metakaolin and hydrous kaolin. Any calcination of the reactive microsphere before reaction with a zeolite-forming solution is done at low temperatures so as to ensure the hydrous kaolin is not converted to metakaolin.
Mingting Xu - Edison NJ, US John Macaoay - Linden NJ, US
Assignee:
Engelhard Corporation - Florham Park NJ
International Classification:
C01B 39/28
US Classification:
423709, 423712, 423716
Abstract:
A novel method of forming ZSM-5 comprises reacting calcined kaolin microspheres with silicate and a seed solution used for forming zeolite Y under conditions of pH, temperature, and time to yield ZSM-5 crystals formed in-situ on said calcined kaolin microspheres. The reaction medium does not contain any organic templates or ZSM-5 seeding crystals.
In the regeneration of a cracking catalyst in a regeneration zone operated in a partial combustion mode, NHand HCN in the regenerator flue gas are reduced by incorporating into the regenerator precious metals such as ruthenium, rhodium, iridium, or mixtures thereof.
Fcc Catalysts For Feeds Containing Nickel And Vanadium
Rostam Madon - Flemington NJ, US David Harris - Mountainside NJ, US Mingting Xu - Edison NJ, US David Stockwell - Middlesex NJ, US Bruce Lerner - Princeton Junction NJ, US Glenn Dodwell - Bartlesville OK, US
A fluid catalytic cracking catalyst made from microspheres that initially contain kaolin, a dispersible boehmite alumina and a sodium silicate or silica sol binder. The kaolin portion contains hydrous kaolin and optionally kaolin which has been calcined through its characteristic exotherm. Calcination of the hydrous clay to metakaolin and formation of in-situ zeolite by treatment with sodium silicate yields a catalyst containing Y-faujasite and transforms the dispersible boehmite into a transitional alumina which contains a gamma alumina phase. The transitional alumina may contain a delta alumina phase as well. The catalyst can be used to crack resid or resid-containing feeds as the alumina phase formed from the dispersible boehmite passivates nickel and vanadium contaminants.
Fcc Catalysts For Feeds Containing Nickel And Vanadium
A fluid catalytic cracking catalyst made from microspheres that initially contain kaolin, a dispersible boehmite alumina and a sodium silicate or silica sol binder. The kaolin portion contains hydrous kaolin and a particular kaolin which has been calcined through its characteristic exotherm and which produces a catalyst having a novel morphology comprising a macroporous matrix and crystallized zeolite freely coating the walls of the pores of the matrix. Calcination of the hydrous kaolin to metakaolin and formation of in-situ zeolite by treatment with sodium silicate yields a catalyst containing Y-faujasite and transforms the dispersible boehmite into a transitional alumina. The catalyst can be used to crack resid or resid-containing feeds as the alumina phase formed from the dispersible boehmite passivates nickel and vanadium contaminants.
The amount of NOx formed during regeneration of a cracking catalyst in the presence of a metallic carbon monoxide combustion catalyst is decreased by utilizing as the carbon monoxide combustion catalyst rhodium and/or iridium on an oxide support such as alumina.