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.

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: The catalyst of this invention is capable of enhancing light olefin, e.g., propylene, yields in fluidizable catalytic cracking (FCC) processes. The catalyst comprises (a) pentasil zeolite, (b) at least 5% by weight phosphorus (P2O5) based on particles containing the pentasil, and at least about 1% by weight iron oxide, as measured by Fe2O3, outside of the pentasil zeolite's framework. The catalyst is fluidizable and has an average particle size in the range of about 20 to about 200 microns. The catalyst composition can further comprise additional zeolite suitable for cracking hydrocarbons in a FCC process. The catalyst has been shown to be highly active compared to other catalysts and shows a high selectivity for propylene produced in an FCC process.

Abstract: The sulfur content of liquid cracking products, especially the cracked gasoline, of the catalytic cracking process is reduced by the use of a sulfur reduction catalyst composition comprising a porous molecular sieve which contains a metal in an oxidation state above zero within the interior of the pore structure of the sieve as well as a rare earth component which enhances the cracking activity of the cracking catalyst. The molecular sieve is normally a faujasite such as USY. The primary sulfur reduction component is normally a metal of Period 3 of the Periodic Table, preferably vanadium. The rare earth component preferably includes cerium which enhances the sulfur reduction activity of the catalyst. The sulfur reduction catalyst may be used in the form of a separate particle additive or as a component of an integrated cracking/sulfur reduction catalyst.

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: The sulfur content of liquid cracking products, especially the cracked gasoline, is reduced in a catalytic cracking process employing a cracking catalyst containing a high content of vanadium. The cracking process involves introducing at least one vanadium compound into a hydrocarbon-sulfur containing feedstock to be charged to a fluid catalytic cracking reactor operating under steady state conditions and containing an equilibrium fluid cracking catalyst inventory within the reactor. The amount of sulfur in the liquid products, in particular gasoline and LCO fractions, is reduced as a result of the increased vanadium content on the equilibrium catalyst. Advantageously, sulfur reduction is achieved even in the presence of other metal contaminants, such as nickel and iron, on the equilibrium catalyst.

Abstract: The sulfur content of liquid cracking products, especially the cracked gasoline, of the catalytic cracking process is reduced by the use of a sulfur reduction catalyst composition comprising a porous molecular sieve which contains a metal in an oxidation state above zero within the interior of the pore structure of the sieve as well as a rare earth component which enhances the cracking activity of the cracking catalyst. The molecular sieve is normally a faujasite such as USY. The primary sulfur reduction component is normally a metal of Period 3 of the Periodic Table, preferably vanadium. The rare earth component preferably includes cerium which enhances the sulfur reduction activity of the catalyst. The sulfur reduction catalyst may be used in the form of a separate particle additive or as a component of an integrated cracking/sulfur reduction catalyst.

Abstract: A catalyst useful in cracking of hydrocarbon feedstock comprising particulate material composed of at least 70 weight percent zeolite and the remainder substantially composed of silica sol, alumina sol or mixtures thereof; wherein the particulate material has a kinetic conversion activity of at least about 3; and compositions for fluid catalytic cracking of petroleum feedstock comprising said catalyst and a second particulate material having a kinetic conversion activity of less than 3 wherein said catalyst composition having a kinetic conversion activity of at least about 2.

Abstract: The sulfur content of liquid cracking products, especially the cracked gasoline, of the catalytic cracking process is reduced by the use of a sulfur reduction catalyst composition comprising a porous molecular sieve which contains a metal in an oxidation state above zero within the interior of the pore structure of the sieve as well as a rare earth component which enhances the cracking activity of the cracking catalyst. The molecular sieve is normally a faujasite such as USY. The primary sulfur reduction component is normally a metal of Period 4 of the Periodic Table, preferably vanadium. The rare earth component preferably includes cerium which enhances the sulfur reduction activity of the catalyst. The sulfur reduction catalyst may be used in the form of a separate particle additive or as a component of an integrated cracking/sulfur reduction catalyst.

Abstract: The sulfur content of liquid cracking products, especially the cracked gasoline, is reduced in a catalytic cracking process employing a cracking catalyst containing a high content of vanadium. The cracking process involves introducing at least one vanadium compound into a hydrocarbon-sulfur containing feedstock to be charged to a fluid catalytic cracking reactor operating under steady state conditions and containing an equilibrium fluid cracking catalyst inventory within the reactor. The amount of sulfur in the liquid products, in particular gasoline and LCO fractions, is reduced as a result of the increased vanadium content on the equilibrium catalyst. Advantageously, sulfur reduction is achieved even in the presence of other metal contaminants, such as nickel and iron, on the equilibrium catalyst.

Abstract: The present invention is directed to certain catalyst compositions and processes that are capable of reducing sulfur compounds normally found as part of the gasoline fraction streams of fluid catalytic cracking processes. The present invention requires an equilibrium cracking catalyst composition comprises at least one Y-type zeolite having kinetic conversion activity of at least about 3 in combination with a Lewis acid containing alumina composite present in at least 50 weight percent of the composition. The resultant equilibrium catalyst composition has a kinetic conversion activity of at least about 2.

Abstract: A catalyst suitable for use in fluid catalytic cracking of petroleum feedstock in the form of particulate of crystalline zeolite having a coating on it6s surface comprising bayerite phase alumina.

Abstract: The sulfur content of liquid cracking products, especially the cracked gasoline, of the catalytic cracking process is reduced by the use of a sulfur reduction additive comprising a non-molecular sieve support containing a high content of vanadium. Preferably, the support is alumina. The sulfur reduction catalyst is used in the form of a separate particle additive in combination with the active catalytic cracking catalyst (normally a faujasite such as zeolite Y) to process hydrocarbon feedstocks in the fluid catalytic cracking (FCC) unit to produce low-sulfur gasoline and other liquid products.

Abstract: A catalyst useful in cracking of hydrocarbon feedstock comprising particulate material composed of at least 70 weight percent zeolite and the remainder substantially composed of silica sol, alumina sol or mixtures thereof; wherein the particulate material has a kinetic conversion activity of at least about 3; and compositions for fluid catalytic cracking of petroleum feedstock comprising said catalyst and a second particulate material having a kinetic conversion activity of less than 3 wherein said catalyst composition having a kinetic conversion activity of at least about 2.

Abstract: A catalyst suitable for use in fluid catalytic cracking of petroleum feedstock in the form of particulate of crystalline zeolite having a coating on it6s surface comprising bayerite phase alumina.

Abstract: The present invention is directed to certain catalyst compositions and processes that are capable of reducing sulfur compounds normally found as part of the gasoline fraction streams of fluid catalytic cracking processes. The present invention requires an equilibrium cracking catalyst composition comprises at least one Y-type zeolite having kinetic conversion activity of at least about 3 in combination with a Lewis acid containing alumina composite present in at least 50 weight percent of the composition. The resultant equilibrium catalyst composition has a kinetic conversion activity of at least about 2.

Abstract: The sulfur content of liquid cracking products, especially the cracked gasoline, of the catalytic cracking process is reduced by the use of a sulfur reduction additive comprising a non-molecular sieve support containing a high content of vanadium. Preferably, the support is alumina. The sulfur reduction catalyst is used in the form of a separate particle additive in combination with the active catalytic cracking catalyst (normally a faujasite such as zeolite Y) to process hydrocarbon feedstocks in the fluid catalytic cracking (FCC) unit to produce low-sulfur gasoline and other liquid products.

Abstract: A silica-containing bayerite alumina is prepared by reacting aluminum sulfate, sodium aluminate and sodium silicate at a pH of about 10.5 to 11.5, preferably in the presence of finely divided magnesium hydroxide "seeds". The silica-containing bayerite is heated to obtain a hydrothermally stable silica "stabilized" eta alumina which may be used in the preparation of catalytic compositions.

Abstract: Catalytic cracking catalysts which contain bayerite and/or eta alumina are used to process hydrocarbon feedstocks that contain nickel.