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NOx reduction compositions for use in FCC processes

a technology of nox reduction composition and composition, which is applied in the direction of catalyst activation/preparation, physical/chemical process catalyst, metal/metal-oxide/metal-hydroxide catalyst, etc., can solve the problem of nosub>x/sub>evolution from the regenerator, 300%), and undesirable gas evolution, etc., to achieve the effect of superior nox control performan

Inactive Publication Date: 2005-09-22
PETERS ALAN W +4
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0005] The invention provides compositions suitable for use in FCC processes which are capable of providing superior NOx control performance.

Problems solved by technology

While FCC processes are efficient from the point of catalyst use, the regeneration step typically results in the evolution of undesirable gases such as SOx, CO, and NOx.
Unfortunately, the additives used to control CO emissions typically cause a dramatic increase (e.g., 300%) in NOx evolution from the regenerator.
Some of the spinel-based (SOx reduction) additives act to lessen the amount of NOx emission, but with limited success.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0027] An amorphous silica alumina particulate support containing 6 wt. % silica was impregnated with a sodium carbonate solution, dried and calcined to achieve a 3.6 wt. % Na content measured as Na2O based on the weight of the silica alumina The Na-containing silica alumina particles were then impregnated with a solution of cerium nitrate and then dried to achieve a ceria content of about 1 wt. % based on the weight of the silica alumina particles. The Ce-containing composition was then impregnated with a silver nitrate solution to achieve a silver content of about 5 wt. % (oxide basis) based on the weight of the silica alumina particles. The impregnated particles were then dried and calcined at about 704° C. to form a particulate composition in accordance with the invention.

example 2

[0028] An amorphous silica alumina particulate support containing 6 wt. % silica was impregnated with a sodium carbonate solution, dried and calcined to achieve a 6 wt. % Na content measured as Na2O based on the weight of the silica alumina. The Na-containing silica alumina particles were then impregnated with a solution of cerium nitrate and then dried to achieve a ceria content of about 22 wt. % based on the weight of the silica alumina particles. The Ce-containing composition was then impregnated with a copper nitrate solution to achieve a copper content of about 2 wt. % (oxide basis) based on the weight of the silica alumina particles. The impregnated particles were then dried and calcined at about 704° C. to form a particulate composition in accordance with the invention.

example 3

[0029] The 152 g of the composition of example 1 was admixed with 2908 grams of a commercial FCC catalyst (Grace Davison Orion® 842 equilibrium catalyst (ECAT)) and 10 g of a combustion promoter (Grace Davison CP-5). The admixture was then used to crack a hydrocarbon feedstock containing 0.3 wt. % nitrogen in a DCR pilot plant FCC unit. The cracking was performed at a 75% conversion rate and 1000 g / hr catalyst feed rate. As a control example, the same catalyst admixture was run without the composition of example 1. The NOx emission measured from the FCC unit regenerator was 65% less when the composition of example 1 was used compared to the control example.

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Abstract

Compositions comprising a component containing (i) an acidic oxide support, (ii) an alkali metal and / or alkaline earth metal or mixtures thereof, (iii) a transition metal oxide having oxygen storage capability, and (iv) a transition metal selected from Groups Ib and / or IIb of the Periodic Table provide NOx control performance in FCC processes. The acidic oxide support preferably contains silica alumina. Ceria is the preferred oxygen storage oxide. Cu and Ag are preferred Group I / IIb transition metals. The compositions are especially useful in the cracking of hydrocarbon feedstocks having above average nitrogen content.

Description

BACKGROUND OF THE INVENTION [0001] Public policy and cost / benefit pressures have created an increasing desire to reduce the amount of polluting gases released by industrial processes. As a result, there has been a drive to find ways of decreasing pollution by modifying industrial processes. [0002] In the petroleum refining industry, fluid catalytic cracking (FCC) of hydrocarbons is a commonly used petroleum refining method. In an FCC process, catalyst particles (inventory) are repeatedly circulated between a catalytic cracking zone and a catalyst regeneration zone. In regeneration, coke deposits (from the cracking reaction) on the catalyst particles are removed at elevated temperatures by oxidation. The removal of coke deposits restores the activity of the catalyst particles to the point where they can be reused in the cracking reaction. [0003] While FCC processes are efficient from the point of catalyst use, the regeneration step typically results in the evolution of undesirable ga...

Claims

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Application Information

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IPC IPC(8): B01J23/00B01J23/10B01J23/66B01J23/83B01J35/00B01J37/02C10G11/00C10G11/02C10G11/18
CPCB01J23/002B01J23/10B01J23/66B01J23/83C10G11/187B01J37/0205B01J2523/00C10G11/02C10G11/18B01J35/0006B01J2523/12B01J2523/17B01J2523/31B01J2523/3712B01J2523/41B01J2523/18B01J35/19
Inventor PETERS, ALAN W.RUDESILL, JOHN A.WEATHERBEE, GORDON DEANRAKIEWICZ, EDWARD F.BARBATO-GRAUSO, MARY JANE A.
Owner PETERS ALAN W