Catalyst – solid sorbent – or support therefor: product or process – Zeolite or clay – including gallium analogs – Including organic component
Patent
1981-03-30
1984-02-21
Dees, Carl F.
Catalyst, solid sorbent, or support therefor: product or process
Zeolite or clay, including gallium analogs
Including organic component
208120, 502 64, 502 65, 502 68, B01J 2908, B01J 2918
Patent
active
044328907
DESCRIPTION:
BRIEF SUMMARY
TECHNICAL FIELD
This invention relates to an improved catalyst, one or more methods for its preparation, and a process for its use in the conversion of carbo-metallic oils to liquid transportation and/or heating fuels. More particularly, the invention is related to a catalyst composition comprising a catalytically active crystalline aluminosilicate zeolite uniformly dispersed within a matrix containing a metal additive as a free metal, its oxides or its salts to immobilize vanadium oxides deposited on the catalyst during the conversion reaction. The metal additive for vanadia immobilization may be added during catalyst manufacture, after manufacture by impregnation of virgin catalyst, or at any point in the catalyst cycle for conversion of the oil feed.
BACKGROUND OF THE INVENTION
The introduction of catalytic cracking to the petroleum industry in the 1930's constituted a major advance over previous techniques with the object of increasing the yield of gasoline and its quality. Early fixed bed, moving bed, and fluid bed catalytic cracking FCC processes employed vacuum gas oils (VGO) from crude sources that were considered sweet and light. The terminology of sweet refers to low sulfur content and light refers to the amount of material boiling below approximately 1000.degree.-1025.degree. F.
The catalysts employed in early homogeneous fluid dense beds were of an amorphous siliceous material, prepared synthetically or from naturally occurring materials activated by acid leaching. Tremendous strides were made in the 1950's in FCC technology in the areas of metallurgy, processing equipment, regeneration and new more-active and more stable amorphous catalysts. However, increasing demand with respect to quantity of gasoline and increased octane number requirements to satisfy the new high horsepower-high compression engines being promoted by the auto industry, put extreme pressure on the petroleum industry to increase FCC capacity and severity of operation.
A major breakthrough in FCC catalysts come in the early 1960's with the introduction of molecular sieves or zeolites. These materials were incorporated into the matrix of amorphous and/or amorphous/kaolin materials constituting the FCC catalysts of that time. These new zeolitic catalysts, containing a crystalline aluminosilicate zeolite in an amorphous or amorphous/kaloin matrix of silica, alumina, silica-alumina, kaolin, clay or the like were at least 1,000-10,000 times more active for cracking hydrocarbons than the earlier amorphous or amorphous/kaolin containing silica-alumina catalysts. This introduction of zeolitic cracking catalysts revolutionized the fluid catalytic cracking process. New innovations were developed to handle these high activities, such as riser cracking, shortened contact times, new regeneration processes, new improved zeolitic catalyst developments, and the like.
The new catalyst developments revolved around the development of various zeolites such as synthetic types X and Y and naturally occuring faujasites; increased thermalsteam (hydrothermal) stability of zeolites through the inclusion of rare earth ions or ammonium ions via ionexchange techniques; and the development of more attrition resistant matrices for supporting the zeolites. These zeolitic catalyst developments gave the petroleum industry the capability of greatly increasing throughput of feedstock with increased conversion and selectivity while employing the same units without expansion and without requiring new unit construction.
After the introduction of zeolitic containing catalysts the petroleum industry began to suffer from a lack of crude availability as to quantity and quality accompanied by increasing demand for gasoline with increasing octane values. The world crude supply picture changed dramatically in the late 1960's and early 1970's. From a surplus of light, sweet crudes the supply situation changed to a tighter supply with an ever increasing amount of heavier crudes with higher sulfur contents. These heavier and higher sulfur crudes presented processing pro
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Beck H. Wayne
Carruthers James D.
Cornelius Edward B.
Hettinger, Jr. William P.
Kovach Stephen M.
Ashland Oil Inc.
Dees Carl F.
McCrae Charles A.
Willson, Jr. Richard C.
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