Abstract: A process for cracking high metals content feedstocks which comprises contacting said feedstocks under catalytic cracking conditions with a novel catalytic cracking composition comprising a solid cracking catalyst and a magnesium oxide diluent.

Abstract: This invention comprises improvements to processes for the catalytic cracking of hydrocarbon feedstocks. One such improvement to catalytic cracking processes provides compositions comprising metals passivating agents having an increased degree of stability. These compositions comprise aqueous suspensions of antimony by vinyl copolymers, aqueous suspensions of antimony oxide by diesters of phosphoric acid, or aqueous suspensions of antimony oxide by cellulose derivatives. Another improvement to catalytic cracking processes provides a process for reducing the viscosity of liquid suspensions of metals passivating agents without substantially reducing the stability of the liquid suspension by the utilization of at least two different particle ranges of metals passivating agents. A further improvement to catalytic cracking processes provides an efficient utilization of metals passivating agents by introducing the selected agent into the catalyst regeneration cycle of a catalytic cracking unit.

Abstract: A catalytic cracking catalyst and process which tolerates high levels of vanadium and coke precursors in the feed is disclosed. A zeolite in an alumina free binder or coating, preferably silica, is used as the cracking catalyst. RE-USY in silica is especially preferred as it has a low affinity for vanadium, low coking characteristics and high stability. Preferably a vanadium getter additive is present as separate particles to act as a vanadium sink. The catalyst and process may be used in fluidized bed catalytic cracking (FCC) or in moving bed catalytic cracking units. A method of making a coated catalyst, by adding a layer of an alumina free material to a core of alumina containing cracking catalyst is also disclosed.

Abstract: A process for reactivating a spent, metal-contaminated zeolite-containing cracking catalyst composition comprises the substantially simultaneous contacting with a fluorine compound (preferably HH.sub.4 F) and a metals passivating agent (preferably a compound of Sb or Ca). The thus reactivated cracking catalyst composition is employed in a catalytic cracking process.

Abstract: This invention comprises improvements to processes for the catalytic cracking of hydrocarbon feedstocks. One such improvement to catalytic cracking processes provides compositions comprising metals passivating agents having an increased degree of stability. These compositions comprise aqueous suspensions of antimony by vinyl copolymers, aqueous suspensions of antimony oxide by diesters of phosphoric acid, or aqueous suspensions of antimony oxide by cellulose derivatives. Another improvement to catalytic cracking processes provides a process for reducing the viscosity of liquid suspensions of metals passivating agents without substantially reducing the stability of the liquid suspension by the utilization of at least two different particle ranges of metals passivating agents. A further improvement to catalytic cracking processes provides an efficient utilization of metals passivating agents by introducing the selected agent into the catalyst regeneration cycle of a catalytic cracking unit.

Abstract: A process for reactivating a spent, metal-contaminated zeolite-containing catalytic cracking catalyst composition comprises contacting the spent catalyst composition with an acidified aqueous NH.sub.4 NO.sub.3 solution, thereafter with a suitable fluorine compound (preferably dissolved NH.sub.4 F), and, optionally, additionally with an antimony compound. The thus prepared reactivated cracking catalyst composition is used in a process for catalytically cracking a liquid hydrocarbon-containing feed.

Abstract: This invention comprises improvements to processes for the catalytic cracking of hydrocarbon feedstocks. One such improvement to catalytic cracking processes provides compositions comprising metals passivating agents having an increased degree of stability. These compositions comprise aqueous suspensions of antimony by vinyl copolymers, aqueous suspensions of antimony oxide by diesters of phosphoric acid, or aqueous suspensions of antimony oxide by cellulose derivatives. Another improvement to catalytic cracking processes provides a process for reducing the viscosity of liquid suspensions of metals passivating agents without substantially reducing the stability of the liquid suspension by the utilization of at least two different particle ranges of metals passivating agents. A further improvement to catalytic cracking processes provides an efficient utilization of metals passivating agents by introducing the selected agent into the catalyst regeneration cycle of a catalytic cracking unit.

Abstract: Unclouded solutions of antimony hydrocarbylthiolate suitable for metals passivation are produced utilizing an amine. In one embodiment of the invention the amine is included with the antimony oxide and hydroxyhydrocarbylthiol reactants to produce the passivating agent. In another embodiment of the invention, the metals passivation additive is produced by combining antimony oxide with a hydroxyhydrocarbylthiol to produce a reaction mixture which is thereafter contacted with an amine. The resulting product is useful for the passivation of metals deposited on cracking catalysts.

Abstract: An improved method for passivating metals in a hydrocarbon feedstock during catalytic cracking has been discovered. The method involves contacting the feedstock with a passivating agent comprising a precipitated porous rare earth oxide, alumina, and aluminum phosphate precipitate. The passivating agent may be coated on a cracking catalyst, be part of the matrix of a cracking catalyst, or be added to the cracking operation as discrete particles.

Abstract: The present invention is directed to a method of using cerium and/or cerium contaning compounds to passivate nickel contaminants in hydrocarbon feedstocks which are used in catalytic cracking processes.

Abstract: Hydrocarbon feedstocks containing relatively high levels of vanadium contaminants are converted by catalytic cracking to products of lower average molecular weight by contacting the feedstock with a catalyst comprising (1) a crystalline aluminosilicate zeolite dispersed in a matrix and (2) a vanadium passivating agent selected from the group consisting of cerium, praseodymium, neodymium, gadolinium and compounds thereof. The passivating agent is present in the catalyst in an amount greater than about 1.0 weight percent, calculated as the oxide of the vanadium passivating agent and based on the carbon-free weight of the catalyst. The passivating agent is also present in an amount such that the weight ratio of the passivating agent to any lanthanum present in the catalyst, calculated based on the respective oxides, is greater than about 1.0. The total weight of all rare earths present in the catalyst is greater than about 2.

Abstract: This application is directed to a process and apparatus for regenerating an elutriable mixture of fluidized catalytic cracking (FCC) catalyst and a demetallizing additive. Deactivated catalyst and coke containing additive are added to a single dense bed regenerator. Within the regenerator, differences in settling velocity segregate the elutriable mixture into a lower dense bed containing most of the additive and a contiguous upper dense bed containing most of the FCC catalyst. Some regeneration gas is added to the lower dense bed to at least partially decoke the additive, while additional regeneration gas is added to the upper dense bed. Decoked additive and regenerated FCC catalyst are preferably withdrawn separately and charged to a riser reactor for demetallizing and catalytic cracking of heavy feed. Flue gas is withdrawn from the regenerator from a dilute phase vapor space above the single dense bed.

Abstract: An FCC or fluidized catalytic cracking process and apparatus for converting heavy metals laden crudes is disclosed. The heavy feed, conventional catalyst and an additive or vanadium getter contact the feed in a riser reactor. The additive is segregated from conventional FCC catalyst upstream of the conventional FCC regenerator. An elutriating, upflow riser reactor may be used with a coarse, rapidly settling getter. A fine, slowly settling getter may be used, with getter segregation achieved by using an elutriating cyclone on the riser outlet, an elutriating catalyst stripper, a sieve, or the like. The spent getter may be used once through, regenerated in a separate getter regenerator, or used as a source of fuel. Alumina and sponge coke are preferred getters.

Abstract: A process is disclosed for passivating sodium contaminants in FCC feed using tin or tin compounds.

Abstract: A catalytic cracking process especially useful for the catalytic cracking of high metals content feeds including resids in which the feed is cracked in the presence of a catalyst additive comprising a dehydrated magnesium-aluminum hydrotalcite which acts as a trap for vanadium as well as an agent for reducing the content of sulfur oxides in the regenerator flue gas. The additive is used in the form of a separate additive from the cracking catalyst particles in order to keep the vanadium away from the cracking catalyst and so preserve the activity of the catalyst.

Abstract: A process and apparatus for cracking heavy hydrocarbons using a mixture of fluid cracking catalyst and a demetallizing additive differing in physical characteristics from the cracking catalyst is described. A heavy, metals containing feed such as a resid contacts demetallizing additive in the base of a riser reactor. The demetallized resid is cracked by contact with a stream of hot, regenerated catalyst. A mixture of metal containing additive, deactivated cracking catalyst, and cracked products is discharged from the riser. The metal containing additive and deactivated catalyst are stripped, preferably with steam, and charged to a two-stage regenerator. The first stage of the regenerator partially regenerates the cracking catalyst and separates it by elutriation from the demetallizing additive, which accumulates as a dense phase fluidized bed in a lower portion of the first stage regenerator.

Abstract: A process in which coke is reduced and volatile products yield increased in a catalytic cracking system wherein spent cracking catalyst is stripped in the presence of a hydrogen donor.

Abstract: A process for catalytically cracking deep cut vacuum gas oils, resids, or other reduced crudes containing metal contaminants to increase gasoline octane. Hydrocarbon feedstocks which include vanadium and sodium contaminants are introduced into the reaction zone of a catalytic cracking unit. Catalytic cracking catalysts which include a ZSM-5 type catalytic component are contacted in the reaction zone with the metals-containing hydrocarbon feedstock. The hydrocarbon feedstock is cracked at high temperature by the cracking catalysts, resulting in increased gasoline octane, and surprising tolerance of the ZSM-5 type catalytic component to poisoning from the usually expected synergistically destructive combination of sodium and vanadium on Y-type zeolites.

Abstract: Method for treating particulate used oil-coated catalysts to provide a rejuvenated catalyst material in a rejuvention vessel assembly. The pressurizable vertically-oriented vessel assembly has inlet and outlet openings for the catalyst and washing fluids, and has a removable lower sub-assembly head portion which contains a conical shaped grid unit located therein. The vessel assembly is arranged to permit solvent washing, vacuum drying and acid treatment and gas drying of the used catalyst in a bed supported above the conical grid, by upward flow and recycle of the washing liquids and fluidization of the catalyst. Following rejuvenation of the catalyst, it is withdrawn from the vessel downwardly through the conical shaped grid and out through a central withdrawal conduit containing a slide valve unit for further processing or use as desired.

Abstract: The formation of carbon on metals exposed to hydrocarbons in a thermal cracking process is reduced by contacting such metals with an antifoulant selected from the group consisting of an organic compound of chromium, a combination of tin and elemental chromium or an organic compound of chromium, a combination of antimony and elemental chromium or an organic compound of chromium and a combination of tin, antimony and elemental chromium or an organic compound of chromium.

Abstract: A composition of matter, suitable as cracking catalyst, comprises zeolite, silica matrix and vanadium oxide(s) at a level of at least 0.2 weight-% V. A process for preparing the above composition of matter comprises the steps of contacting zeolite in a silica matrix with at least one vanadium compound and calcining the thus contacted material. A process for cracking substantially liquid hydrocarbon-containing feed streams, which contain at least about 5 ppmw vanadium, in the presence of the above composition of matter as catalyst, is provided.

Abstract: A system is provided for passivating metals, such as vanadium, deposited on a catalyst during a conversion reaction. Spent catalyst particles containing the metal deposits are introduced into a regenerator, and passivating particles containing the passivating materials are also introduced into the regenerator. The passivating particles and the catalyst particles are separated after they have exited from the regenerator. At least a portion of the separated passivating particles are recycled to the regenerator, and the regenerated, separated catalyst particles are reintroduced into a reaction zone, such as a riser conversion zone.

Abstract: Unclouded solutions of antimony hydrocarbylthiolate suitable for metals passivation are produced utilizing an amine. In one embodiment of the invention the amine is included with the antimony oxide and hydroxyhydrocarbylthio reactants to produce the passivating agent. In another embodiment of the invention, the metals passivation additive is produced by combining antimony oxide with a hydroxhydrocarbylthiol to produce a reaction mixture which is thereafter contacted with an amine. The resulting product is useful for the passivation of metals deposited on cracking catalysts.

Abstract: In the cataytic cracking of gas oils or heavier feeds, retarded catalyst aging is achieved by adding lighter saturated hydrocarbons such as paraffins and/or cycloparaffins to the feed together with employing a highly siliceous zeolite as the cracking catalyst. The unconverted light hydrocarbon may be recovered and recycled. The invention is applicable to fluid catalytic cracking for the manufacture of gasoline and light fuel oil, and also to the catalytic dewaxing process wherein normal paraffins are selectively cracked to reduce the pour point of a fuel oil or of a lubricant based stock.

Abstract: Combustible carbonaceous particles such as particles of sponge coke or coal are incorporated with the circulating inventory of cracking catalyst in a fluid catalytic cracking unit. The carbonaceous particles selectively sorb metal contaminants in the feed, thereby extending catalyst life, and they also serve to reduce NO.sub.x emissions in certain instances. The sorbed metals values may be recovered as the carbonaceous particles are burned.

Abstract: A process for the production of molecular hydrogen and demetallization of solid particles comprising:(a) contacting hydrogen sulfide at conditions effective to convert at least a portion of the hydrogen sulfide into molecular hydrogen, the contacting being conducted in the presence of solid particles comprising at least one metallic component effective to promote hydrogen sulfide conversion;(b) separating the molecular hydrogen from elemental sulfur formed in step (a) and unconverted hydrogen sulfide and recovering a product enriched in molecular hydrogen; and(c) demetallizing at least a portion of the solid particles from step (a) to produce demetallized solid particles having a reduced content of the metallic component.

Abstract: A process for treating a catalyst useful to promote the conversion of a substantially hydrocarbon feedstock containing at least one first metal at least a portion of which is deposited on the catalyst forming a first metal-containing catalyst, which process comprises:contacting the catalyst with at least one component of at least one second metal selected from the group consisting of antimony, tin, gallium, indium, zinc, tellurium and mixtures thereof to increase the second metal content of the catalyst, anddemetallizing the first metal-containing catalyst to provide a demetallized catalyst having a reduced first metal content.

Abstract: This invention relates to a catalyst suitable for use in a fluid catalytic process and a method of using the catalyst on hydrocarbons containing one or more poison metal of vanadium or nickel to convert the hydrocarbons to lower boiling fractions. The catalyst contains a particulate and substantially water-insoluble strontium compound (in addition to a conventional zeolite and catalyst matrix) which reacts with and traps the metal poison to preserve the structure of the zeolite and, in addition, lowers the coke make and hydrogen production.

Abstract: A method for making a catalyst containing a vanadium passivating agent in the form of anatase crystalline TiO.sub.2 including a method for processing hydrocarbon feeds containing vanadium.

Abstract: A spent zeolite-containing catalytic cracking catalyst composition is reactivated by a process comprising the steps of contacting the catalyst composition with a solution of a suitable ammonium compound (preferably an aqueous solution of NH.sub.4 NO.sub.3) and thereafter contacting the ammonium-exchanged cracking catalyst composition with a suitable fluorine compound (preferably a aqueous solution of NH.sub.4 F). A catalytic cracking process employs the reactivated cracking catalyst composition.

Abstract: A process for treating a catalyst contaminated with at least one metal which was so contaminated while promoting conversion of a substantially hydrocarbon feedstock containing the metal comprising at least one of the following: (1) contacting the catalyst component to increase the ammonium ion-containing component to increase the ammonium ion content of the catalyst; and (2) contacting the catalyst with at least one rare earth metal ion-containing component to increase the rare earth metal ion content of the catalyst. Improved hydrocarbon conversion processes are also disclosed.

Abstract: A novel cracking catalyst, a method of preparing same and an improved hydrocarbon cracking process are provided wherein adverse effects of metals such as nickel, vanadium, iron, copper and cobalt in the cracking catalyst are precluded or mitigated by contacting the cracking catalyst with an antimony treating agent comprising at least one of elemental antimony and compounds thereof and a lithium treating agent comprising at least one of elemental lithium and compounds thereof whereby there is added to said catalyst a modifying amount of each antimony treating agent and lithium treating agent with the weight ratio of antimonmy to lithium being such as to provide passivation of contaminating metals greater than the sum of the passivation effect of each of antimony treating agent and lithium treating agent individually.

Abstract: An improved catalyst demetallization process involves chlorinating the metal contaminated catalyst at elevated temperatures and contacting the chlorinated catalyst with a liquid aqueous composition to produce a demetallized catalyst. Improved catalytic activity is obtained utilizing a catalyst comprising at least one crystalline material capable of promoting the hydrocarbon conversion, and cooling the chlorinated catalyst prior to contact with the liquid aqueous composition. An improved hydrocarbon conversion process is also disclosed.

Abstract: Poisoning of a cracking catalyst by contaminant metals such as nickel, vanadium and iron during fluid catalytic cracking of hydrocarbon charge stock containing the contaminant metals is suppressed by depositing minor amounts of a bismuth-containing passivating agent on the catalyst, desirably, a weight ratio of bismuth to nickel equivalents (nickel+0.2 vanadium+0.1 iron) of about 0.01:1 to about 1:1. The passivating agent can also comprise mixtures of compounds of bismuth and antimony, bismuth and tin.

Abstract: This invention provides for a method of preparing zeolite A from spent metals-contaminated cracking catalyst while concomitantly removing at least a portion of one of the contaminant and catalytic metals from the spent catalyst by contacting the spent catalyst with a solution containing an alkali metal hydroxide and a sufficient amount of sodium aluminate under hydrothermal conditions for a specified period of time to form the zeolite A.

Abstract: A process for cracking hydrocarbon containing feed streams, which have an initial boiling point of at least 400.degree. F. and contain at least about 5 ppmw vanadium, is carried out in the presence of a catalyst composition comprising a physical mixture of (a) zeolite embedded in an inorganic refractory matrix material and (b) at least one oxide of Be, Mg, Ca, Sr, Ba or La, preferably MgO, on a silica containing support material.

Abstract: Improved noncatalytic nonreactive alumina-silica solid for removing carbonaceous and metallic contaminants including nickel and vanadium from hydrocarbon feedstock by short term, high temperature contact comprises mullite and crystalline silica. In the decarbonizing and demetallizing process, impurities are deposited on the particles of the solid and the major portion of the feedstock is vaporized. After burning carbonaceous deposit from the particles, the hot particles containing nickel and vanadium are recycled into contact with incoming charges of contaminated feedstock. Periodically metals are removed from coke-depleted particles by extraction with a mineral acid at elevated temperature without dissolving or otherwise destroying the alumina-silica particles. The particles are then reintroduced into the system.

Abstract: In a catalytic cracking process which includes contacting a hydrocarbon feedstock in a contacting zone in the presence of solid composition containing molecular sieve-containing catalyst capable of promoting hydrocarbon cracking at conditions effective to crack the hydrocarbon feedstock to lower boiling components, the improvement comprising conducting the contacting in the presence of at least one metal component, other than the catalyst, containing calcium and tin. A composition of matter comprising such catalyst and metal component is also disclosed.

Abstract: Solids e.g. catalysts are separated from suspensions in gases e.g. products from catalytic cracking of crude oil fractions a discharging of suspensions against a surface positioned above the outlet of a riser conduit through which the suspensions are flowing and collecting the displaced gases for passage to cyclones.

Abstract: An aqueous sol composition from the group consisting of antimony and tin sols useful in restoring the activity of metal contaminated molecular sieve cracking catalysts which comprises a major portion of an aqueous antimony sol or tin sol containing between 1-50% by weight of antimony oxide as Sb.sub.2 O.sub.5 or tin oxide as SnO.sub.2 and between 0.1-20% by weight of a compatable water-soluble surfactant which is capable of producing a water-in-oil emulsion and having an HLB of at least 6.0.

Abstract: A strontium colloid system is introduced into a hydrocarbon conversion process to suppress the harmful effects of one or more metal contaminants in the hydrocarbon feedstock on the active component(s) of the catalyst used in said process. The strontium compound in the colloid system reacts with or traps the metal contaminants before they contact the active component(s) of said catalyst, thereby reducing catalyst deactivation, coke make and hydrogen production relative to that obtained had said compound been introduced into the process in non-colloid form. In a preferred embodiment, the strontium colloid system is introduced into the reaction zone of said process and, preferably, with at least a portion of the hydrocarbon feedstock to said process.

Abstract: A novel cracking catalyst, a method of preparing same and an improved hydrocarbon cracking process are provided wherein adverse effects of metals such as nickel, vanadium, iron, copper and cobalt in the cracking catalyst are precluded or mitigated by contacting the cracking catalyst with an antimony treating agent comprising at least one of elemental antimony and compounds thereof and a lithium treating agent comprising at least one of elemental lithium and compounds thereof whereby there is added to said catalyst a modifying amount of each antimony treating agent and lithium treating agent with the weight ratio of antimony to lithium being such as to provide passivation of contaminating metals greater than the sum of the passivation effect of each of antimony treating agent and lithium treating agent individually.

Abstract: The formation of carbon on metals exposed to hydrocarbons in a thermal cracking process is reduced by contacting such metals with an antifoulant selected from the group consisting of a combination of tin and silicon, a combination of antimony and silicon and a combination of tin, antimony and silicon.

Abstract: The formation of carbon on metals exposed to hydrocarbons in a thermal cracking process is reduced by contacting such metals with an antifoulant selected from the group consisting of a combination of elemental indium or an organic compound of indium and tin and a combination of elemental indium or an organic compound of indium and antimony.

Abstract: An improved catalyst demetallization process involves chlorinating the metal contaminated catalyst at elevated temperatures and contacting the chlorinated catalyst with a liquid aqueous composition to produce a demetallized catalyst. Improved catalytic activity is obtained utilizing a catalyst comprising at least one crystalline material capable of promoting the hydrocarbon conversion, and cooling the chlorinated catalyst prior to contact with the liquid aqueous composition. An improved hydrocarbon conversion process is also disclosed.

Abstract: The formation of carbon on metals exposed to hydrocarbons in a thermal cracking process is reduced by contacting such metals with an antifoulant selected from the group consisting of a combination of tin and aluminum, a combination of aluminum and antimony and a combination of tin, antimony and aluminum.

Abstract: This invention pertains to a new process for removing metals, especially contaminant metals, from spent catalysts. Also, this invention pertains to a catalyst composite with metals removed by the new process, and to several uses for the catalyst, including as a rejuvenated hydrotreating catalyst. The new process comprises (i) contacting the spent catalyst with a complexing agent with four or more coordinating groups, including at least two carboxylic acid type groups and at least one amino type group, and (ii) separating from the spent catalyst a mixture containing the complexing agent and the removed metals. By this process contaminant metals, like vanadium, are more selectively removed from the spent catalyst than are catalytic metals, like cobalt and molybdenum.

Abstract: A method and apparatus for passivating the adverse catalytic effects of metal contaminated hydrocarbon feedstocks is described. The method is directed at the use of control means to regulate the residence time of the catalyst in the passivation zone and to regulate the reducing gas flow rate to the passivation zone.

Abstract: A method to restore the activity of a cracking catalyst which has been deactivated at least partially by metals contamination which involves contacting the cracking catalyst with an aluminum containing treating agent.

Abstract: A process for cracking high metals content feedstocks which comprises contacting said feedstocks under catalytic cracking conditions with a novel catalytic cracking composition comprising a solid cracking catalyst and an alumina diluent.