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EP-3737499-B1 - FCC CATALYST PREPARED BY A PROCESS INVOLVING MORE THAN ONE SILICA MATERIAL

EP3737499B1EP 3737499 B1EP3737499 B1EP 3737499B1EP-3737499-B1

Inventors

  • SABAHI, Amir
  • LOEBL, ANDREW J.
  • GAVALDA, Sandra
  • FRANCIS, JULIE ANN
  • IYYAMPERUMAL, Eswaramoorthi
  • LI, MIN
  • MARCINKOVA, Andrea

Dates

Publication Date
20260506
Application Date
20190111

Claims (7)

  1. A process for manufacturing an FCC catalyst comprising: a. Adding, clay, 10 to 45 wt% quasi-crystalline boehmite and 0 to 35 wt% micro-crystalline boehmite, wherein the wt% is the dry base wt%, based upon the total dry base weight of the final FCC catalyst, sodium stabilized colloidal silica to form a slurry; b. Digesting the slurry with a monoprotic acid to a pH of less than 4; c. Adding one or more zeolites to the slurry; d. Adding an ammonia stabilized colloidal silica at any time during or after steps (a) - (c) but before step (e); e. Mixing the slurry and then destabilizing the slurry by raising the pH to above 4.0; f. Shaping and collecting the resulting FCC Catalyst.
  2. The process of Claim 1 further comprising adding 5 to 60 wt% one or more zeolites, wherein the wt% is the dry base wt%, based upon the total dry base weight of the FCC catalyst.
  3. The process of Claims 1 further comprising adding greater than 0 to 15 wt% silica from sodium stabilized basic colloidal silica, wherein the wt% is the dry base wt%, based upon the total dry base weight of the FCC catalyst.
  4. The process of Claims 1 further comprising adding greater than 0.5 wt% to 10 wt% silica from sodium stabilized colloidal silica, wherein the wt% is the dry base wt%, based upon the total dry base weight of the FCC catalyst.
  5. The process of Claim 1 further comprising adding greater than 0 to 30 wt% ammonia stabilized colloidal silica, wherein the wt% is the dry base wt%, based upon the total dry base weight of the FCC catalyst.
  6. The process of Claim 1 further comprising adding greater than 1 wt% to 25 wt% silica from ammonia stabilized colloidal silica, wherein the wt% is the dry base wt%, based upon the total dry base weight of the FCC catalyst.
  7. The process of Claim 1 further comprising adding greater than 5 wt% to 20 wt% silica from ammonia stabilized colloidal silica, wherein the wt% is the dry base wt%, based upon the total dry base weight of the FCC catalyst.

Description

FIELD OF THE INVENTION The present invention pertains to a process for manufacturing a catalyst composition for use in a process for the cracking or conversion of a feed comprised of hydrocarbons, such as, for example, those obtained from the processing of crude petroleum, the catalyst having better physical properties and performance. BACKGROUND A common challenge in the design and production of heterogeneous catalysts is to find a good compromise between the effectiveness and/or accessibility of the active sites and the effectiveness of the immobilising matrix in giving the catalyst particles sufficient physical strength, i.e. attrition resistance. The preparation of attrition resistant catalysts is disclosed in several prior art documents. US 4,086,187 discloses a process for the preparation of an attrition resistant catalyst by spray-drying an aqueous slurry prepared by mixing (i) a faujasite zeolite with a sodium content of less than 5 wt% with (ii) kaolin, (iii) peptised pseudoboehmite, and (iv) ammonium polysilicate. The attrition resistant catalysts according to US 4,206,085 are prepared by spray-drying a slurry prepared by mixing two types of acidified pseudoboehmite, zeolite, alumina, clay, and either ammonium polysilicate or silica sol. EP 1 863 588 B1 describes a process for the preparation of an attrition resistant FCC catalyst from a single silica source. It is not disclosed to use a combination of silica components comprising an ammonia stabilized colloidal silica component for preparing the FCC catalyst. WO 02/098563 discloses a process for the preparation of an FCC catalyst having both a high attrition resistance and a high accessibility. The catalyst is prepared by slurrying zeolite, clay, and boehmite, feeding the slurry to a shaping apparatus, and shaping the mixture to form particles, characterised in that just before the shaping step the mixture is destabilised. This destabilisation is achieved by, e.g., temperature increase, pH increase, pH decrease, or addition of gel-inducing agents such as salts, phosphates, sulphates, and (partially) gelled silica. Before destabilisation, any peptisable compounds present in the slurry must have been well peptised. WO 06/067154 describes an FCC catalyst, its preparation and its use. It discloses a process for the preparation of an FCC catalyst having both a high attrition resistance and a high accessibility. The catalyst is prepared by slurrying a clay, zeolite, a sodium-free silica source, quasi-crystalline boehmite, and micro-crystalline boehmite, provided that the slurry does not comprise peptised quasi-crystalline boehmite, b) adding a monovalent acid to the slurry, c) adjusting the pH of the slurry to a value above 3, and d) shaping the slurry to form particles. BRIEF DESCRIPTION OF THE INVENTION The present invention relates to a process for manufacturing an FCC catalyst meant to be employed in the process for cracking, a hydrocarbon feed over a particular catalyst composition to produce conversion product hydrocarbon compounds of lower molecular weight than feed hydrocarbons, e.g., product comprising a high gasoline fraction. A unique feature of the invention is the use of more than one silica source. Thus, not encompassed by the wording of the claim is a particulate FCC catalyst comprising about 5 to about 60 wt% one or more zeolites, about 10 to about 45 wt% quasi crystalline boehmite (QCB), about 0 to about 35 wt% microcrystalline boehmite (MCB), greater than about 0 to about 15 wt% silica from sodium stabilized colloidal silica, greater than about 0 to about 30 wt% silica from ammonia stabilized or lower sodium colloidal silica, and the balance clay. Provided is a process for manufacturing an FCC catalyst, wherein the process comprises: (a) Adding, clay, 10 to 45 wt% quasi-crystalline boehmite and 0 to 35 wt% micro-crystalline boehmite, wherein the wt% is the dry base wt%, based upon the total dry base weight of the final FCC catalyst, sodium stabilized colloidal silica to form a slurry;(b) Digesting the slurry with a monoprotic acid to a pH of less than 4;(c) Adding one or more zeolites to the slurry;(d) Adding the ammonia stabilized colloidal silica at any time during or after steps (a) - (c) but before step (e);(e) Mixing the slurry and then destabilizing the slurry by raising the pH to above 4.0;(f) Shaping and collecting the resulting FCC Catalyst. The resulting catalyst shows improved benefits over that known in the art. It is evident from the physical properties (ABD and attrition) that the catalysts of the present invention showed similar attributes as to the catalysts known in the art. However, each of the catalysts showed performance advantages, particularly on bottoms or coke. Outside the scope of the claims is a process for cracking a petroleum fraction feedstock said process comprising the steps of: a) providing an FCC catalyst composition comprising about 5 to about 60 wt% one or more zeolites, about 10 to about 45 wt% quas