Abstract: The present invention provides a catalyst and a process for its preparation and its use in cracking heavy feedstocks. The catalyst comprises one or more zeolites having a controlled silica to alumina ratio and preferably treated with alkali in the presence of a matrix component selected from the group consisting of clays, synthetic matrix other than pillared clay, and mixtures thereof. The catalyst are particularly useful in treating heavy feedstock such as residues from oil sands processing.

Abstract: A composition comprising FCC catalyst particles and additive particles suitable for the reduction of NOx emissions from a FCC regenerator, said additive particles comprising a Mg and Al-containing anionic clay or solid solution, a rare earth metal oxide, alumina and/or silica-alumina, and Y-type zeolite. The invention further relates to a process for preparing such a composition and its use for reducing NOx emissions.

Abstract: A catalyst composition suitable for reacting hydrocarbons such as in fluidized catalytic cracking (FCC) comprises an attrition-resistant particulate having at least 30% of an intermediate pore zeolite, kaolin, a phosphorous compound, and a high density unreactive component. An example of an unreactive component is alpha-alumina. The catalyst can also contain a reactive alumina of high surface area.

Abstract: A method for obtaining a petroleum distillate product is provided, the method includes subjecting a Fischer-Tropsch wax to a process of hydrocraking carried out at a pressure which is substantially lower that the pressure previously used. A catalyst including a noble metal is used in this method. An apparatus for carrying out the method is also provided.

Abstract: A fluid catalytic cracking process for the preparation of cracked products by contacting in a reactor a hydrocarbon feedstock with a cracking catalyst, wherein the hydrocarbon feedstock comprises a paraffinic feedstock and triglycerides.

Abstract: The present invention refers to a microporous crystalline material of zeolitic nature (ITQ-22) which, in the calcined state, has the empirical formula x(M1/nX02):yYO2:zR:wH20 wherein M is H+ or at least one inorganic cation of charge +n; X is at least one chemical element of oxidation state +3, preferably selected from the group consisting of Al, Ga, B, Fe and Cr; Y is at least one chemical element with oxidation state +4 other than Si and Ge, preferably selected from the group consisting of Ti, Sn and V; x has a value less than 0.2, preferably less than 0.1 and can take the value zero, y has a value less than 0.1, preferably less than 0.05 and can take the value zero, z has a value less than 0.8, preferably between 0.005 and 0.5 and can take the value zero, with a characteristic X-ray diffraction pattern, to the method of preparation and to the use of the material in separation and transformation processes of organic compounds.

Abstract: A process for conversion of a hydrocarbon feedstock comprising a relatively heavy main feedstock with a boiling point above approximately 350° C., and a relatively light secondary feedstock with a boiling point below approximately 320° C., wherein, the main feedstock, representing at least 50 wt. % of the hydrocarbon feedstock, is cracked in a fluidized-bed reactor in the presence of a cracking catalyst, the secondary feedstock is cracked in a fluidized bed with the same cracking catalyst, separately or mixed with the main feedstock, said secondary feedstock comprising oligomers with at least 8 carbon atoms of light olefins with 4 and/or 5 carbon atoms.

Abstract: An FCC process for obtaining light olefins comprises contacting a hydrocarbon feed stream with blended catalyst comprising regenerated catalyst and coked catalyst. The catalyst has a composition including a first component and a second component. The second component comprises a zeolite with no greater than medium pore size wherein the zeolite comprises at least 1 wt-% of the catalyst composition. The contacting occurs in a riser to crack hydrocarbons in the feed stream and obtain a cracked stream containing hydrocarbon products including light olefins and coked catalyst. The cracked stream is passed out of an end of the riser such that the hydrocarbon feed stream is in contact with the blended catalyst in the riser for less than or equal to 2 seconds on average. The hydrocarbon products including light olefins are separated from the coked catalyst. The first portion of the coked catalyst is passed to a regeneration zone in which coke is combusted from the catalyst to produce a regenerated catalyst.

Abstract: This invention relates to the catalytic cracking of a hydrocarbon feed. In particular, this invention relates to an apparatus and process utilizing a catalyst stripper section of a fluid catalytic cracking (FCC) reactor with chordal trays designed to provide improved stripping of hydrocarbons from spent FCC catalyst in an FCC reactor stripping zone.

Abstract: The propylene production of a fluid catalytic cracking unit employing a large pore zeolite cracking catalyst, produces more propylene by adding a naphtha cracking riser and a medium pore zeolite catalytic component to the unit, and recycling at least a portion of the naphtha crackate to the naphtha riser. The large pore size zeolite preferably comprises a USY zeolite and the medium pore size is preferably ZSM-5. Propylene production per unit of naphtha feed to the naphtha riser is maximized, by using the 60–300° F. naphtha crackate as the feed.

Abstract: Hydrocarbon or oxygenate conversion process in which a feedstock is contacted with a non zeolitic molecular sieve which has been treated to remove most, if not all, of the halogen contained in the catalyst. The halogen may be removed by one of several methods. One method includes heating the catalyst in a low moisture environment, followed by contacting the heated catalyst with air and/or steam. Another method includes steam-treating the catalyst at a temperature from 400° C. to 1000° C. The hydrocarbon or oxygenate conversion processes include the conversion of oxygenates to olefins, the conversion of oxygenates and ammonia to alkylamines, the conversion of oxygenates and aromatic compounds to alkylated aromatic compounds, cracking and dewaxing.

Abstract: The present invention relates to a cracking catalyst comprising layered clays and a process for cracking hydrocarbon oils using said catalyst. Said catalyst is prepared by the process comprising the following steps: mixing and slurrying an expandable clay, a modifier component, pseudo-boehmite and water for 0.1-10 h to obtain a slurry, aging the slurry at 50-85° C. for 0.1-10 h, then drying and forming the slurry to obtain a formed material, water washing and aging the solid, and finally drying and calcining the solid, and said modifier being one or more selected from the group consisting of hydroxyl polymers of silicon, aluminum, zirconium or titanium, and substances comprising one or more of said hydroxyl polymers.

Abstract: A microporous crystalline material of a zeolitic nature, that corresponds to the empirical formula

Abstract: The invention provides a method for converting a hydrocarbon feedstock to propylene comprising: contacting an olefinic hydrocarbon feedstock boiling in the naphtha range with a catalyst comprising a zeolitic catalyst selected from the group consisting of medium pore zeolites having a ratio of silica to alumina above 200 and pore diameter less than 0.7 nm under cracking conditions to selectively produce propylene. The preferred catalyst comprises of a zeolite having an 8, 10, or 12 membered ring pore structure. The preferred catalysts are selected from the group consisting of zeolites from the families MFI, MEL, MTW, TON, MTT, FER, MFS, and the zeolites ZSM-21, ZSM-38 and ZSM-48. Preferably the method is carried out to produce propylene with greater than 50% specificity, more preferably, the propylene to butylene ratio is at least 2:1 or a propylene to ethylene ratio of at least 4:1. The olefinic hydrocarbon feedstock consists essentially of hydrocarbons boiling within the range of 18° to 220° C.

Abstract: A catalytic cracking process is disclosed for feedstock containing hydrocarbons having at least 5 carbon atoms. The feedstock is contacted, under catalytic cracking conditions, with a 9-member ring catalyst composition and, optionally, a large pore molecular sieve, such as zeolite Y.

Abstract: The invention relates to a process for the catalytic dewaxing of a hydrocarbon feed containing waxy molecules by contacting the hydrocarbon feed under catalytic dewaxing conditions with a catalyst composition having metallosilicate crystallites, a binder and a hydrogenation component, wherein the weight ratio of the metallosilicate crystallites and the binder is between 5:95 and 35:65. The invention also relates to a catalyst composition having at least a low acidity refractory oxide binder, which binder is essentially free of aluminum, metallosilicate crystallites and a hydrogenation component, wherein the weight ratio of the metallosilicate crystallites and the binder is between 5:95 and 35:65.

Abstract: A composition comprises silicon, aluminum, zirconium, and boron. A process for producing the composition comprises contacting a silicon compound, an aluminum compound, a zirconium compound, and a boron compound under a condition sufficient to effect the production of a composition comprising silicon, aluminum, zirconium, and boron. Also disclosed is a process for catalytically cracking a hydrocarbon-containing fluid which comprises contacting said hydrocarbon-containing fluid with a catalyst composition which comprises silicon, aluminum, zirconium, and boron.

Abstract: The invention deals with a microporous crystalline material, with a characteristic X-ray diffractogram, comprised of oxygen tetrahedra and a metal (T+4 and T+3) with the possibility of introducing surface acidity produced by the substitution in the lattice of some T+4 cations by T+3 cations, which gives rise to a structural charge deficiency that may be compensated by protons, Brönsted acidity, and/or high ratio radium charge cations, Lewis acidity; and the obtaining method thereof, based on the preparation of a gel, its hydrothermal treatment under controlled conditions and the treatment of the resulting laminar material with a solution of an organic compound, a swollen material being obtained, which is subjected to a treatment for the formation of interlaminar pillars of polymeric oxides, obtaining a pillared material that maintains the separation between the sheets, even after calcination.

Abstract: A catalyst component, a catalyst, and a process for making the component and catalyst are disclosed herein. Also disclosed herein is a fluid catalytic cracking process for converting petroleum feedstocks to lower boiling products wherein the feedstock is contacted with the catalyst. The catalyst component is a crystalline microporous oxide catalyst to which a compound for promoting dehydrogenation and increasing Lewis acidity is effectively added. This catalyst component can be included in an inorganic oxide matrix material and used as a catalyst. Preferably, the compound for promoting dehydrogenation and increasing Lewis acidity is effectively added to a non-framework portion of the crystalline microporous oxide.

Abstract: This invention relates to a new synthetic porous crystalline material, designated MCM-67, a method for its preparation and use thereof in catalytic conversion of organic compounds. MCM-67 appears to be closely related in structure to VPI-8 and SSZ-41 but is synthesized without zinc and in the presence of manganese and/or cobalt ions.

Abstract: Disclosed are silicoaluminophosphates (SAPOs) having unique silicon distributions and high catalytic cracking activity a method for their preparation and their use as FCC catalysts. More particularly, the new SAPOs have a high silica:alumina ratio and favorable Si atom distribution. The new SAPOs may have a small crystal size and may be synthesized from a single-phase synthesis solution.

Abstract: The propylene production of a fluid catalytic cracking unit employing a large pore zeolite cracking catalyst, produces more propylene by adding a naphtha cracking riser and a medium pore zeolite catalytic component to the unit, and recycling at least a portion of the naphtha crackate to the naphtha riser. The large pore size zeolite preferably comprises a USY zeolite and the medium pore size is preferably ZSM-5. Propylene production per unit of naphtha feed to the naphtha riser is maximized, by using the 60-300° F. naphtha crackate as the feed.

Abstract: A process for making a calcined, oxide material by at least partially delaminating a swollen, layered oxide material prior to calcination, and the product thereof having an increased active surface area that corresponds to an adsorption capacity for 1,3,5-trimethylbenzene of at least 0.50 mmol/g at a temperature of 42° C. and a pressure of 173.3 Pa. The calcined, oxide material retains a porous shape although non-pillared.

Abstract: An additive catalyst for the cracking of heavy oil, characterized in that the additive catalyst includes: (i) a mixed metal oxide composed of an acidic metal oxide and a basic metal oxide, in which the proportion of the basic metal oxide is from 5 to 50 mole %, (ii) clay, and (iii) silica.

Abstract: Disclosed are silicoaluminophosphates (SAPOs) having unique silicon distributions, a method for their preparation and their use as catalysts for the catalytic cracking of hydrocarbon feedstocks. More particularly, the new SAPOs have a high silica:alumina ratio, and are prepared from microemulsions containing surfactants.

Abstract: An FCC catalyst containing zeolite particles at least 50% of the outer surface of which is coated with a layer of pre-formed inorganic oxide is used in fluidized catalytic cracking of hydrocarbon feeds. The inorganic oxide layer has a thickness in the range of 10 nm to 5 &mgr;m and the ratio between the particle size of the oxide and the mean particle size of the zeolite particles is in the range of 0.001:1 to 0.5:1. The zeolite particles may be coated by contacting uncoated zeolite particles having a mean particle size in the range of 0.1 to 10 &mgr;m with an aqueous medium containing particles of the oxide having a particle size in the range of 10 to 5,000 nm, after which the particles are optionally dried or calcined. The oxide is preferably alumina. The FCC catalysts are less rapidly deactivated by contaminant metals present in heavy feeds and are less susceptible to blocking of the zeolite pores by coke.

Abstract: The invention relates to a fluid catalytic cracking process for the preparation of good quality hydrocarbon fractions with a high octane number starting from heavy hydrocarbon fractions of a poorer quality characterized in that the heavy hydrocarbon fraction is put in contact, under cracking conditions, with a catalytic composition comprising a conventional FCC catalyst and a quantity of between 3-60% of a hydrothermally stable microporous material containing titanium.

Abstract: This invention relates to a new synthetic porous crystalline material, designated MCM-67, a method for its preparation and use thereof in catalytic conversion of organic compounds. MCM-67 appears to be closely related in structure to VPI-8 and SSZ-41 but is synthesized without zinc and in the presence of manganese and/or cobalt ions.

Abstract: A catalytic cracking catalyst, which comprises (1) a zeolite, (2) a silica.cndot.alumina or an alumina and (3) a kaolin, has a pore diameter distribution having a peak at a pore diameter of 450 to 3,000 .ANG., and has 40 to 75% of a pore volume of pores of not less than 200 .ANG. and less than 2,000 .ANG. in pore diameter and 5 to 45% of a pore volume of pores of not less than 2,000 .ANG. and less than 18,000 .ANG. in pore diameter, both based on a pore volume of pores of 40 to 18,000 .ANG. in pore diameter.

Abstract: A process for producing liquid fuels from heavy hydrocarbons such as residual oil in which the cracking temperatures are in the range of 800.degree. F. to 1200.degree. F., and the residence times are between 0.05 seconds and 0.50 seconds.

Abstract: A process for producing a high VI/low volatility lubricating oil basestock. The process comprises subjecting the raffinate from a solvent extraction step to a two step, single stage hydroconversion process wherein the first step involves severe hydroconversion of the raffinate followed by a cold hydrofinishing step.

Abstract: A process for producing a high VI/low volatility lubricating oil basestock. The process comprises subjecting the raffinate from a solvent extraction step to a two-step, single-stage hydroconversion process wherein the first step involves severe hydroconversion of the raffinate followed by a cold hydrofinishing step. The effluent from the cold hydrofinishing step is then catalytically dewaxed or in the alternative, solvent dewaxed followed by catalytic dewaxing.

Abstract: A catalytic cracking catalyst and catalytic cracking process for cracking the 650.degree. F.+ portion in a heavy feed to lighter products. The catalytic cracking catalyst contains a Y zeolite in a silica binder that is substantially free of catalytically active alumina. The silica binder contains silica gel as a component.

Abstract: A process for deasphalting a residua feedstock by use of a short vapor contact time thermal process unit comprised of a horizontal moving bed of fluidized hot particles. It is preferred that a mechanical means be used to fluidize a bed of hot particles.

Abstract: A class of highly stable supergallery pillared clay compositions that have a basal spacing up to 55 .ANG. corresponding a gallery height of 35 .ANG. for samples dried at room temperature and a basal spacing up to 45 .ANG. corresponding a gallery height of 255 .ANG. for samples steamed at 800.degree. C. for 17 hours. Said compositions are prepared by special procedures including pillaring reaction in presence of poly (vinyl alcohol) as a pillaring precursor, an aging process at pH of around 4 to 9, and a calcinating or steaming treatment at high temperature. The new compositions exhibit catalytic properties and adsorption properties superior to prior art pillared clays. Said compositions are useful as catalysts for carbonium-ion reaction, and as adsorbents and catalyst carriers. They are especially suitable for preparing microspheric cracking catalysts for heavy oil or residual feedstock.

Abstract: The present invention relates to new crystalline zeolite SSZ-41 which comprises oxides of (1) silicon or a mixture of silicon and germanium, and (2) zinc, said zinc being present in an amount from about 2 wt % to about 5 wt % of zinc metal based on the total weight of metals in said zeolite. Zeolite SSZ-41 may also optionally contain oxides of aluminum, iron, gallium or mixtures thereof. Zeolite SSZ-41 has the X-ray diffraction lines of Table I and has an argon adsorption capacity of at least about 0.06 cc/gm at 87.degree. K. Also disclosed are methods of making and using zeolite SSZ-41.

Abstract: An improved "magnetic hook"-promoted catalytic process, catalyst and method of manufacture for heavy hydrocarbon conversion, optionally in the presence of nickel and vanadium on the catalyst and in the feed stock to produce lighter molecular weight fractions, including more gasoline, lower olefins and higher isobutane than normally produced. This process is based on the discovery that two "magnetic hook" elements, namely manganese and chromium, previously employed as magnetic enhancement agents to facilitate removal of old catalyst, or to selectively retain expensive catalysts, can also themselves function as selective cracking catalysts, particularly when operating on feeds containing significant amounts of nickel and vanadium, and especially where economics require operating with high nickel- and vanadium-contaminated and containing catalysts.

Abstract: An apparatus for the catalytic cracking in the fluid state of hydrocarbon feedstocks which comprises a riser-type column (2); at the top of the riser (2) and concentric therewith, a chamber (1) for separation of the hydrocarbon vapors and the coke-laden catalyst particles; directly above the upper opening of the riser (2) and in the interior of said chamber (1), a ballistic separator (3); at least one unit for regeneration of the spent catalyst, fed by stripped particles received from said chamber. The chamber (1) for separation of the coke-laden catalyst particles and the stripping thereof comprises, at a level intermediate between the bed (6) of particles being stripped and the opening of the riser (2), a means (11) adapted to form a baffle for locally reducing the diameter of said chamber (1) and the free passage at the periphery of the riser (2), thereby reducing recirculating streams of hydrocarbon vapors in separation chamber (1) of the FCC unit thus avoiding overcracking.

Abstract: Hydrocarbon conversion processes such as alkylation and hydrocracking are described which use as the catalyst a novel beidellite clay. The clay has the empirical formulaA.sub.x (Al.sub.4)(Si.sub.8-x Al.sub.x)(O.sub.20)(OH).sub.4-u F.sub.uwhere A is a cation such as an alkali metal, x is the moles of A and varies from about 0.1 to about 2, and u varies from about 0.1 to about 3.5. The clay is prepared from a reaction mixture containing reactive sources of aluminum and silicon, a cation salt, a fluoride source and water.

Abstract: The present invention relates to new crystalline zeolite SSZ-35 prepared by processes for preparing crystalline molecular sieves, particularly large pore zeolites, using conformationally constrained aza-polycyclic ring system templating agents.

Abstract: Catalytic dewaxing of distillate feedstock is carried out concurrently with upgrading of olefins by oligomerization to produce fuel products.

Abstract: A process for converting feedstock comprising hydrocarbon compounds to product comprising hydrocarbon compounds of lower molecular weight than said feedstock hydrocarbon compounds which comprises contacting said feedstock at conditions for said conversion with catalyst comprising crystals having a framework topology after heating at 110.degree. C. or higher giving an X-ray diffraction pattern with interplanar d-spacings at 16.4.+-.0.2 Angstroms, 8.2.+-.0.1 Angstroms, 6.21.+-.0.05 Angstroms, 6.17.+-.0.05 Angstroms, 5.48.+-.0.05 Angstroms and 4.74.+-.0.05 Angstroms, and without a significant interplanar d-spacing at 13.6-13.3 Angstroms.

Abstract: Middle distillates can be produced efficiently in high yields by catalytically cracking petroleum hydrocarbons by contacting the petroleum hydrocarbons at cracking conditions with a catalyst composition comprising a cation-exchanged stevensite.

Abstract: A process and catalyst are provided for the catalytic cracking of a hydrocarbon feedstock to catalytic cracking conversion products comprising the steps of contacting the hydrocarbon feedstock at catalytic cracking conditions with a catalytic cracking catalyst. The catalytic cracking catalyst is prepared by modifying a base catalyst comprising a crystalline molecular sieve and a binder by combining the base catalyst with an ion exchange solution comprising at least one trivalent cation, a trivalent cation complexing agent, and a hydroxide-producing component, wherein the ion exchange solution has a pH ranging from about 4 to about 8, and producing an ion exchanged catalyst and excess ion exchange solution. The modified catalyst is then separated from said excess ion exchange solution.

Abstract: A layered catalyst contains a core of at least one, and preferably three, molecular sieve components within a shell layer of reduced molecular sieve content. A preferred catalyst consists of a core of a large pore molecular sieve, preferably a dealuminized Y-type zeolite, a shape selective paraffin cracking/isomerization component, preferably HZSM-5, and a shape selective aliphatic aromatization component, preferably gallium ZSM-5, within a shell of an alumina-rich, matrix. The shell can capture metals from the feeds being processed, it can act as a metals sink, and can remove metals form the unit by attrition. The catalyst is preferably prepared by forming the core and then coating or encapsulating the core with a shell having a reduced molecular sieve content. The shell may contain a pillared clay or other very large pore cracking component. The shell may be an attritable coating of an amorphous rare earth oxide, aluminum oxide and aluminum phosphate composite, which traps metals.

Abstract: The present invention provides a method for producing raw materials for a reformer by cracking and desulfurizing petroleum fuels, characterized by cracking and desulfurizing petroleum fuels in a desulfurizer in the fuel cell electricity generation process at a temperature of 300.degree.-600.degree. C., preferably 350.degree.-500.degree. C., a pressure of 1-10 kg/cm.sup.2, an H.sub.2 /oil of 500-2000, preferably 800-1000, and an SV of 0.5-4 hr.sup.-1 using a zeolite catalyst such as Y-type zeolite or a metallosilicate catalyst such as one having an Si/Me atomic ratio of 40-3200 where Me is Al, Ni, Co, Mo, W, Fe, Cr or Ga.

Abstract: A catalytic cracking composition comprising a physical blend of a cracking catalyst component with alcohol treated Sr(OH).sub.2 and alcohol is used to crack hydrocarbon-containing feedstocks that further contain quantities of vanadium.

Abstract: A process for naphtha cracking employing new synthetic catalyst of ultra-large pore crystalline material. The new crystalline material exhibits unusually large sorption capacity demonstrated by its benzene adsorption capacity of greater than about 15 grams benzene/100 grams at 50 torr and 25.degree. C., a hexagonal electron diffraction pattern that can be indexed with a d.sub.100 value greater than about 18 Angstrom Units and a hexagonal arrangement of uniformly sized pores with a maximum perpendicular cross section of at least about 13 Angstrom units.An improved cracking reaction is provided for catalytic conversion of hydrocarbon feedstock which comprises contacting the feedstock under catalytic conversion conditions with acid metallosilicate solid catalyst having the structure of MCM-41 with hexagonal honeycomb lattice structure consisting essentially of uniform pores in the range of about 20 to 100 Angstroms. The cracking reaction is very selective, especially when conducted at temperature of about 425.

Abstract: A catalytic cracking process for converting a hydrocarbon fraction, preferably boiling in the range of a heavy gas oil, is disclosed in which the cracking catalyst is a large crystal fully crystalline zeolite Beta having a broad range of silica-to-alumina mole ratios, i.e. 20->1000. The zeolite Beta catalyst is synthesized with a nitrogenous organic chelating agent, such as a tertiary alkanolamine, preferably triethanolamine, in the synthesis mixture along with at least one source of organic directing agent such as tetraethylammonium hydroxide, tetraethylammonium bromide and tetraethylammonium fluoride. The zeolite Beta can be used as a stand alone catalyst or an additive catalyst for hydrocarbon cracking reactions along with another molecular seive type catalyst such as a faujasite catalyst or ZSM-5. The large crystal zeolite Beta can also be treated with a source of phosphorus to enhance the properties of the zeolite.

Abstract: A novel shell-coated FCC catalyst is disclosed wherein the shell is a mixture of at least one refractory metal oxide or silicate or precursor thereof (preferably clay) having a particle size of 0.3 to 5 microns and an inorganic refractory binder (preferably silica) having a particle size of less than 0.01 microns and the core is a zeolite-containing microsphere.