Abstract: A process for catalytic cracking of an iron-contaminated fluid catalytic cracking (FCC) feedstock. The process may include combining a FCC catalyst, a slurry containing a magnesium compound, and an iron-contaminated FCC feedstock during a FCC process under fluid catalytic cracking conditions, thereby generating an equilibrium FCC catalyst with reduced iron poisoning. The slurry containing the magnesium compound may not contain a calcium compound.

Abstract: An improved process and catalyst composition for cracking hydrocarbons in a fluidized cracking process are disclosed. The process employs circulating inventory of a regenerated cracking having a minimal carbon content. The regenerated catalyst comprises a catalyst/additive composition which contains a pentasil zeolite, iron oxide, and a phosphorous compound. In accordance with the present disclosure, the catalyst/additive contains controlled amounts of iron oxide which is maintained in an oxidized state by maintaining low amounts of carbon on the regenerated catalyst inventory. In this manner it was discovered that the catalyst composition greatly enhances the production and selectivity of light hydrocarbons, such as propylene.

Abstract: A process for preparing a peptized alumina having increased solids and acid contents and a decreased water content. The process comprising mixing a boehmite or pseudoboehmite alumina and acid with a high intensity, high energy mixer at a ratio of 0.16 to 0.65 moles acid/moles alumina for a time period sufficient to form a substantially free-flowing solid particulate having a solids content of 45 to 65 wt %. When used in catalyst manufacture, peptized alumina produced by the process provides an increased rate in catalyst production and decreased costs due to high solids concentration and the presence of less water to be evaporated.

Abstract: A process for preparing a peptized alumina having increased solids and acid contents and a decreased water content. The process comprising mixing a boehmite or pseudoboehmite alumina and acid with a high intensity, high energy mixer at a ratio of 0.16 to 0.65 moles acid/moles alumina for a time period sufficient to form a substantially free-flowing solid particulate having a solids content of 45 to 65 wt %. When used in catalyst manufacture, peptized alumina produced by the process provides an increased rate in catalyst production and decreased costs due to high solids concentration and the presence of less water to be evaporated.

Abstract: Particulate catalytic cracking catalysts which comprise a zeolite having catalytic cracking ability under catalytic cracking conditions, added silica, a magnesium salt, an alumina containing binder, clay and optionally, a matrix material. The catalytic cracking catalyst has a high matrix surface area and is useful in a catalytic cracking process, in particularly, a fluid catalytic cracking process, to provide increased catalytic activity and improved coke and hydrogen selectivity without the need to incorporate rare earth metals.

Abstract: A rare earth free particulate catalytic cracking catalyst which comprises a zeolite having catalytic cracking ability under catalytic cracking conditions, an acidified silica sol binder, magnesium salt, clay and a matrix material. The catalytic cracking catalyst has a high matrix surface area and is useful in a catalytic cracking process, in particularly, a fluid catalytic cracking process, to provide increased catalytic activity and improved hydrogen and coke selectivity without the need to incorporate rare earth metals.

Abstract: This invention relates to a process of preparing a catalyst from zeolite and peptized alumina. The invention comprises adding a yttrium compound to the zeolite, either prior to, during, or after its combination with the peptized alumina. The yttrium compound can be added to the zeolite via exchange of yttrium onto the zeolite prior to addition of peptized alumina, or the yttrium can be added as a soluble salt during the combination of the zeolite and peptized alumina. In either embodiment, the zeolite catalyst is then formed from the zeolite, yttrium and peptized alumina, optionally containing other inorganic oxide. This invention is suitable for preparing fluid cracking catalysts.

Abstract: This invention relates to a process of preparing an improved catalyst comprising a clay derived zeolite. In particular, the invention comprises combining an yttrium compound with a zeolite produced by treating clay with a silica source and under alkaline conditions. The clay derived zeolite can be further combined with conventional matrix and/or binder precursors to form particulates suitable for use as catalysts in fluid catalytic cracking (FCC). Alternatively, the clay that is treated with the silica source and alkaline conditions can be in particulate form having sizes suitable for use in FCC, and the zeolite is produced in situ within the particulate. Yttrium compound is then combined with the zeolite in the particulate, e.g., via impregnation. It has been shown that the addition of the yttrium compound improves zeolite surface area retention, and zeolite stability in catalysts comprising clay derived zeolites.

Abstract: A catalyst composition comprising at least about 10% by weight pentasil, at least about 12% by weight Y-type zeolite at a pentasil to Y zeolite ratio of at least 0.25, and wherein the pentasil and Y zeolite comprise at least about thirty-five percent of the catalyst have been shown to optimize light olefin yields and LPG from FCC processes. Embodiments having matrix surface areas greater than 25 m2/g, phosphorous and rare earth are preferred. The compositions of this invention are particularly useful in typical fluid catalytic cracking (FCC) processes.

Abstract: A rare earth free, ultra low soda, particulate fluid catalytic cracking catalyst which comprises a reduced soda zeolite having fluid catalytic cracking ability under fluid catalytic cracking conditions, a magnesium salt, an inorganic binder, clay and optionally, a matrix material. The catalytic cracking catalyst is useful in a fluid catalytic cracking process to provide increased catalytic activity, and improved coke and hydrogen selectivity without the need to incorporate rare earth metals.

Abstract: Catalytic cracking catalyst compositions and processes for cracking hydrocarbons to maximize light olefins production are disclosed. Catalyst compositions comprise at least one zeolite having catalytic cracking activity under catalytic cracking conditions, preferably Y-type zeolite, which zeolite has low amounts of yttrium in specified ratios to rare earth metals exchanged on the zeolite. Catalyst and processes of the invention provide increased yields of light olefins and gasoline olefins during a FCC process as compared to conventional lanthanum containing Y-type zeolite FCC catalysts.

Abstract: A particulate catalytic cracking catalyst which comprises a zeolite having catalytic cracking ability under catalytic cracking conditions, added silica, precipitated alumina and, optionally clay. The catalytic cracking catalyst has a high matrix surface area and is useful in a catalytic cracking process, in particularly, a fluid catalytic cracking process, to improve bottoms conversion at a constant coke formation.

Abstract: Particulate catalytic cracking catalysts which comprise a zeolite having catalytic cracking ability under catalytic cracking conditions, added silica, a magnesium salt, an alumina containing binder, clay and optionally, a matrix material. The catalytic cracking catalyst has a high matrix surface area and is useful in a catalytic cracking process, in particularly, a fluid catalytic cracking process, to provide increased catalytic activity and improved coke and hydrogen selectivity without the need to incorporate rare earth metals.

Abstract: A rare earth free particulate catalytic cracking catalyst which comprises a zeolite having catalytic cracking ability under catalytic cracking conditions, an acidified silica sol binder, magnesium salt, clay and a matrix material. The catalytic cracking catalyst has a high matrix surface area and is useful in a catalytic cracking process, in particularly, a fluid catalytic cracking process, to provide increased catalytic activity and improved hydrogen and coke selectivity without the need to incorporate rare earth metals.

Abstract: This invention relates to a process of preparing a catalyst from zeolite having a relatively high content of sodium of 18.6 ?g Na2O per zeolite surface area, or greater. The invention comprises adding yttrium compound to the zeolite, either prior to, during, or after its combination with precursors for catalyst matrix. This invention is suitable for preparing zeolite containing fluid cracking catalysts.

Abstract: Catalytic cracking catalyst compositions and processes for cracking hydrocarbons to maximize light olefins production are disclosed. Catalyst compositions comprise at least one zeolite having catalytic cracking activity under catalytic cracking conditions, preferably Y-type zeolite, which zeolite has low amounts of yttrium in specified ratios to rare earth metals exchanged on the zeolite. Catalyst and processes of the invention provide increased yields of light olefins and gasoline olefins during a FCC process as compared to conventional lanthanum containing Y-type zeolite FCC catalysts.

Abstract: This invention relates to a process of preparing a catalyst from zeolite and peptized alumina. The invention comprises adding a yttrium compound to the zeolite, either prior to, during, or after its combination with the peptized alumina. The yttrium compound can be added to the zeolite via exchange of yttrium onto the zeolite prior to addition of peptized alumina, or the yttrium can be added as a soluble salt during the combination of the zeolite and peptized alumina. In either embodiment, the zeolite catalyst is then formed from the zeolite, yttrium and peptized alumina, optionally containing other inorganic oxide. This invention is suitable for preparing fluid cracking catalysts.

Abstract: This invention relates to a process of preparing an improved catalyst comprising a clay derived zeolite. In particular, the invention comprises combining an yttrium compound with a zeolite produced by treating clay with a silica source and under alkaline conditions. The clay derived zeolite can be further combined with conventional matrix and/or binder precursors to form particulates suitable for use as catalysts in fluid catalytic cracking (FCC). Alternatively, the clay that is treated with the silica source and alkaline conditions can be in particulate form having sizes suitable for use in FCC, and the zeolite is produced in situ within the particulate. Yttrium compound is then combined with the zeolite in the particulate, e.g., via impregnation. It has been shown that the addition of the yttrium compound improves zeolite surface area retention, and zeolite stability in catalysts comprising clay derived zeolites.

Abstract: This invention comprises USY zeolite prepared by treating a USY zeolite under hydrothermal conditions after forming the USY zeolite from heat treating ammonium exchanged zeolite Y, e g, by calcination. When this invention is used in a FCC catalyst, a significant improvement of activity and selectivity in the fluid catalytic cracking (FCC) performance is observed, compared to FCC catalysts containing conventional USY zeolite. The process used to make the invention is efficient and comprises treating the USY zeolite in an exchange bath under the aforementioned hydrothermal conditions. The surface of the resulting USY zeolite has a molar ratio of alumina to silica that is higher than that seen in the bulk USY zeolite and has a unique structure as viewed by SEM and TEM.

Abstract: A process in which a catalytic cracking unit is operated to crack a hydrocarbon feedstock in a manner to enhance light olefin yields. The accompanying benzene-containing naphtha product stream is further processed through a benzene selective membrane to provide a low content benzene stream. Refiners frequently operate their cracking units to optimize light olefin yields, e.g. propylene, in response to needs in the petrochemical industry, and it has been discovered that units operated in this manner frequently produce naphtha containing increased amounts of benzene. The method of this invention therefore allows one to operate the unit when it is desired to optimize light olefin yields, yet at the same time produce a naphtha yield having a low benzene content. The invention is particularly useful when the cracking unit utilizes pentasil zeolites at increased concentrations to enhance light olefins yield.