Abstract: Process for the preparation of a particulate FCC catalyst and a particulate FCC catalyst increased contaminants resistivity being essentially free of clay. Thus, in one embodiment, provided is a particulate FCC catalyst composition comprising one or more zeolites, at least one alumina component, at least one silica component, and being essentially free of clay. In a further embodiment, it is provided a particulate FCC catalyst composition comprising at least two different types of alumina and at least one silica component and being essentially free of clay. The alumina components can be selected from the group of peptizable quasicrystalline boehmite, non-peptizable microcrystalline boehmite phase, non-peptizable alpha phase or non-peptizable alumina containing gamma phase or non-peptizable alumina containing chi phase or gibbsite alumina.

Abstract: Compositions for reduction of NOx generated during a catalytic cracking process, preferably, a fluid catalytic cracking process, are disclosed. The compositions comprise a fluid catalytic cracking catalyst composition, preferably containing a Y-type zeolite, and a particulate NOx reduction composition containing ferrierite zeolite particles. Preferably, the NOx reduction composition contains ferrierite zeolite particles bound with an inorganic binder. In the alternative, the ferrierite zeolite particles are incorporated into the cracking catalyst as an integral component of the catalyst. NOx reduction compositions in accordance with the invention are very effective for the reduction of NOx emissions released from the regenerator of a fluid catalytic cracking unit operating under FCC process conditions without a substantial change in conversion or yield of cracked products. Processes for the use of the compositions are also disclosed.

Abstract: A preferred embodiment of a system for loading catalyst and/or additives into a fluidized catalytic cracking unit includes a bin for storing at least one of the catalyst and/or additives, and a loading unit in fluid communication with the storage bin and the fluidized catalytic cracking unit on a selective basis. The loading unit is capable of being evacuated so that a resulting vacuum within the loading unit draws the catalyst and/or additive from the bin. The loading unit is also capable of being pressurized so that the catalyst and/or additive is transferred from the loading unit to the fluidized catalytic cracking unit.

Abstract: A modified zeolite catalyst derived from a zeolite of a structural type which consists of a one-dimensional micropore structure of channels made from rings containing between 8 and 12 silicon/aluminum atoms is disclosed. It consists substantially of a plurality of crystallites having additional mesoporosity whose volume is in the range 0.09 to 0.25 cc/g as mentioned by nitrogen adsorption at 77° K and calculated by the BJH method. The mesoporosity may be introduced into the crystallites by e.g. treatment with aqueous sodium hydroxide at a pH at 25° C. in excess of 8 for an extended period at elevated temperature. The catalyst shows improved resistance to catalyst deactivation and greater selectivity to higher hydrocarbons when used to e.g. oligomerize light alkenes e.g. propene or the butenes.

Abstract: A preferred embodiment of a system for loading catalyst and/or additives into a fluidized catalytic cracking unit includes a bin for storing at least one of the catalyst and/or additives, and a loading unit in fluid communication with the storage bin and the fluidized catalytic cracking unit on a selective basis. The loading unit is capable of being evacuated so that a resulting vacuum within the loading unit draws the catalyst and/or additive from the bin. The loading unit is also capable of being pressurized so that the catalyst and/or additive is transferred from the loading unit to the fluidized catalytic cracking unit.

Abstract: Disclosed is a process for producing a hydrocarbon fraction rich in components boiling in the range typical for diesel fuel comprising contacting a feedstock comprising one or more C2 to C10 alkenes with a modified zeolite catalyst having a one-dimensional micropore structure consisting of channels made from rings containing between 8 and 12 silicon/aluminum atoms at a temperature in the range 100 to 500° C. and pressure in the range 0.1 to 200 bar characterized in that the modified zeolite catalyst is one which has been prepared by treating a corresponding zeolite precursor with an alkaline solution. The alkaline solution used to treat the zeolite precursor can be for example aqueous sodium hydroxide solution. Relative to equivalent untreated zeolites the modified zeolite catalysts described show improved catalyst life and selectivity to hydrocarbons boiling in the range 250 to 350° C.

Abstract: Disclosed is a process for producing a hydrocarbon fraction rich in components boiling in the range typical for diesel fuel comprising contacting a feedstock comprising one or more C2 to C10 alkenes with a zeolite catalyst having partially neutralised acidity and a one-dimensional or two dimensional micropore structure consisting of channels made from rings containing between 10 and 12 silicon/aluminium atoms at a temperature in the range 373 to 773 K and pressure in the range 0.1 to 200 bar characterised in that the partially neutralized zeolite catalyst contains both protons and basic cations. The basic cations are preferably selected from the group comprising Group IA and IIA cations (preferably sodium, potassium, caesium or mixtures thereof). Relative to their equivalent fully protonic forms the partially neutralized zeolite catalysts described show improved catalyst life and selectivity to hydrocarbons.

Abstract: A modified zeolite catalyst derived from a zeolite of a structural type which consists of a one-dimensional micropore structure of channels made from rings containing between 8 and 12 silicon/aluminium atoms is disclosed. It consists substantially of a plurality of crystallites having additional mesoporosity whose volume is in the range 0.09 to 0.25 ml3g?1 as measured by nitrogen absorption at 77° K and calculated by the BJH method. The mesoporosity may be introduced into the crystallites by e.g. treatment with aqueous sodium hydroxide at a pH at 25° C. in excess of 8 for an extended period at elevated temperature. The catalyst shows improved resistance to catalyst deactivation and greater selectivity to higher hydrocarbons when used to e.g. oligomerize light alkenes e.g. propene or the butenes.

Abstract: Disclosed is a process for producing a hydrocarbon fraction rich in components boiling in the range typical for diesel fuel comprising contacting a feedstock comprising one or more C2 to C10 alkenes with a modified zeolite catalyst having a one-dimensional micropore structure consisting of channels made from rings containing between 8 and 12 silicon/aluminium atoms at a temperature in the range 100 to 500° C. and pressure in the range 0.1 to 200 bar characterised in that the modified zeolite catalyst is one which has been prepared by treating a corresponding zeolite precursor with an alkaline solution. The alkaline solution used to treat the zeolite precursor can be for example aqueous sodium hydroxide solution. Relative to equivalent untreated zeolites the modified zeolite catalysts described show improved catalyst life and selectivity to hydrocarbons boiling in the range 250 to 350° C.

Abstract: A process for regenerating coked particles, which process comprises contacting a hydrocarbon feedstock with solid particles in a reaction zone to produce coked particles, which coked particles are transferred to a regeneration zone in which they are contacted with steam to produce hydrogen and at least one or more oxides of carbon, wherein the solid particles comprise one or more of the following components: (i) an aluminosilicate zeolite comprising one or more of Mn, Ti and Zn; (ii) a Ce-containing aluminosilicate zeolite with a Ce loading of at least 0.05 wt % and/or a molar ratio of total other rare earth elements:Ce in the range of from 0:1 to 5:1; (iii) a magnesium and aluminium-containing anionic clay; (iv) a material with the Perovskite structure.

Abstract: A preferred embodiment of a system for loading catalyst and/or additives into a fluidized catalytic cracking unit includes a bin for storing at least one of the catalyst and/or additives, and a loading unit in fluid communication with the storage bin and the fluidized catalytic cracking unit on a selective basis. The loading unit is capable of being evacuated so that a resulting vacuum within the loading unit draws the catalyst and/or additive from the bin. The loading unit is also capable of being pressurized so that the catalyst and/or additive is transferred from the loading unit to the fluidized catalytic cracking unit.

Abstract: A preferred embodiment of a system for loading catalyst and/or additives into a fluidized catalytic cracking unit includes a bin for storing at least one of the catalyst and/or additives, and a loading unit in fluid communication with the storage bin and the fluidized catalytic cracking unit on a selective basis. The loading unit is capable of being evacuated so that a resulting vacuum within the loading unit draws the catalyst and/or additive from the bin. The loading unit is also capable of being pressurized so that the catalyst and/or additive is transferred from the loading unit to the fluidized catalytic cracking unit.

Abstract: Disclosed is a process for producing a hydrocarbon fraction rich in components boiling in the range typical for diesel fuel comprising contacting a feedstock comprising one or more C2 to C10 alkenes with a zeolite catalyst having partially neutralised acidity and a one-dimensional or two dimensional micropore structure consisting of channels made from rings containing between 10 and 12 silicon/aluminium atoms at a temperature in the range 373 to 773 K and pressure in the range 0.1 to 200 bar characterised in that the partially neutralized zeolite catalyst contains both protons and basic cations. The basic cations are preferably selected from the group comprising Group IA and IIA cations (preferably sodium, potassium, caesium or mixtures thereof).

Abstract: A preferred embodiment of a system for loading catalyst and/or additives into a fluidized catalytic cracking unit includes a bin for storing at least one of the catalyst and/or additives, and a loading unit in fluid communication with the storage bin and the fluidized catalytic cracking unit on a selective basis. The loading unit is capable of being evacuated so that a resulting vacuum within the loading unit draws the catalyst and/or additive from the bin. The loading unit is also capable of being pressurized so that the catalyst and/or additive is transferred from the loading unit to the fluidized catalytic cracking unit.

Abstract: A NOx reduction composition and process of using the composition to reduce the content of NOx emissions and gas phase reduced nitrogen species released from the regeneration zone during fluid catalytic cracking of a hydrocarbon feedstock into lower molecular weight components is disclosed. The process comprises contacting a hydrocarbon feedstock during a fluid catalytic cracking (FCC) process wherein a regeneration zone of an fluid catalytic cracking unit (FCCU) is operated in a partial or incomplete combustion mode under FCC conditions, with a circulating inventory of an FCC cracking catalyst and a particulate NOx reduction composition. The NOx reduction composition has a mean particle size of greater than 45 ?m and comprises (1) a zeolite component having (i) a pore size of form 2-7 A Angstroms and (ii) a SiO2 to Al2O3 molar ratio of less than 500, and (2) at least one noble metal selected from the group consisting of platinum, palladium, rhodium, iridium, osmium, ruthenium, rhenium and mixtures thereof.

Abstract: Reduced emissions of gas phase reduced nitrogen species in the off gas of an FCC regenerator operated in a partial or incomplete mode of combustion is achieved by contacting the off gas with an oxidative catalyst/additive composition having the ability to reduce gas phase nitrogen species to molecular nitrogen and to oxidize CO under catalytic cracking conditions. The oxidative catalyst/additive composition is used in an amount less than the amount necessary to prevent afterburn. Fluidizable particles of the oxidative catalyst/additives are circulated throughout the partial or incomplete burn FCC unit along with the FCC catalyst inventory. The flue gas having a reduced content of gas phase reduced nitrogen species and NOx is passed to a downstream CO boiler, preferably a low NOx CO boiler. In the CO boiler, as CO is oxidized to CO2, a reduced amount of gas phase reduced nitrogen species is oxidized to NOx, thereby providing an increase in the overall reduction of NOx emitted into the environment.

Abstract: Reduced emissions of gas phase reduced nitrogen species in the off gas of an FCC regenerator operated in a partial or incomplete mode of combustion is achieved by contacting the off gas with an oxidative catalyst/additive composition having the ability to reduce gas phase nitrogen species to molecular nitrogen and to oxidize CO under catalytic cracking conditions. The oxidative catalyst/additive composition is used in an amount less than the amount necessary to prevent afterburn. Fluidizable particles of the oxidative catalyst/additives are circulated throughout the partial or incomplete burn FCC unit along with the FCC catalyst inventory. The flue gas having a reduced content of gas phase reduced nitrogen species and NOx is passed to a downstream CO boiler, preferably a low NOx CO boiler. In the CO boiler, as CO is oxidized to CO2, a reduced amount of gas phase reduced nitrogen species is oxidized to NOx, thereby providing an increase in the overall reduction of NOx emitted into the environment.

Abstract: A method is disclosed for controlling or monitoring the injection of one or more solids in a system, process, unit or apparatus by mathematically modeling the independent injection of the solids to maintain a determined or pre-determined ratio, percentage, fraction or relative amounts of total solids injected. The model uses historical process data, current process data and/or data from an external source to adjust set points in the master controller to maintain a predetermined amount of solids to be injected within a given period of time. In accordance with the process of the invention, new set-points are generated in the master controller using variables other than a unit or system response variable as input into the model.

Abstract: Compositions for reduction of NOx generated during a catalytic cracking process, preferably, a fluid catalytic cracking process, are disclosed. The compositions comprise a fluid catalytic cracking catalyst composition, preferably containing a Y-type zeolite, and a particulate NOx reduction composition containing ferrierite zeolite particles. Preferably, the NOx reduction composition contains ferrierite zeolite particles bound with an inorganic binder. In the alternative, the ferrierite zeolite particles are incorporated into the cracking catalyst as an integral component of the catalyst. NOx reduction compositions in accordance with the invention are very effective for the reduction of NOx emissions released from the regenerator of a fluid catalytic cracking unit operating under FCC process conditions without a substantial change in conversion or yield of cracked products. Processes for the use of the compositions are also disclosed.

Abstract: A process for the reduction of NOx emissions from a regeneration zone during a fluid catalytic cracking (FCC) process are disclosed. The process comprises contacting a hydrocarbon feedstock with a circulating inventory of an FCC cracking catalyst and a NOx reduction composition during an FCC process. The NOx reduction composition comprises at least one reduced nitrogen species component having the ability to reduce the content of reduced nitrogen species to molecular nitrogen under reducing or partial burn FCC conditions and at least one NOx reduction component having the ability to convert NOx to molecular nitrogen under oxidizing or full burn FCC conditions.