Alumina matrix modification in FCC catalyst compositions

Abstract

The present technology provides a fluid catalytic cracking (FCC) catalyst composition comprising a Y zeolite, wherein the Y zeolite comprises a rare earth element or an oxide thereof and an alumina matrix, and the alumina matrix comprises y-AhCb or pseudo-boehmite and a dopant; and the dopant is selected from a Group IIIB metal, a Group IVB metal, a Group IVA element, a Group VA element, an oxide thereof, or a combination of any two or more thereof.

Description

Technical Field

[0001] This technology generally relates to fluid catalytic cracking (FCC) catalyst compositions. In particular, this technology relates to FCC catalysts having a modified alumina matrix.

Summary of the Invention

Means for Solving the Problems

[0002] In one aspect, the technology is a fluid catalytic cracking (FCC) catalyst composition comprising Y zeolite, wherein the Y zeolite comprises rare earth elements or their oxides and an alumina matrix, and the alumina matrix comprises γ-Al2O3 or pseudo-boehmite and a dopant; the dopant is selected from Group IIIB metals, Group IVB metals, Group IVA elements, Group VA elements, their oxides, or combinations of any two or more thereof, to provide an FCC catalyst composition.

[0003] In a related aspect, the technology is a process for preparing an FCC catalyst, comprising: grinding a first slurry containing an alumina matrix material to a D90 particle size distribution of about 8 microns or less, or grinding a second slurry containing Y zeolite having rare earth elements or their oxides to a D90 particle size distribution of about 5 microns or less; or co-grinding a slurry mixture containing Y zeolite containing rare earth elements or their oxides and an alumina matrix material to a D90 particle size distribution of about 5 microns or less; combining the alumina matrix and Y zeolite with one or more additional components to obtain a mixture; spray drying the mixture to form microspheres; firing the microspheres to obtain an FCC catalyst and The present invention provides a process in which an alumina matrix comprises γ-Al2O3 or pseudo-boehmite and a dopant; the dopant is selected from group IIIB metals, group IVB metals, group IVA elements, group VA elements, their oxides, or any two or more combinations thereof.

[0004] In another embodiment, the Technology provides, in any embodiment, an incorporated FCC catalyst prepared according to the process described herein.

[0005] In another embodiment, the present technology provides a catalyst composition comprising: a first FCC catalyst comprising a Y zeolite and alumina matrix material having a rare earth element or an oxide thereof; a second FCC catalyst different from the first FCC catalyst; and optionally, an additional FCC catalyst different from the first and second FCC catalysts, wherein the alumina matrix comprises γ-Al2O3 or pseudo-boehmite and a dopant; and the dopant is selected from group IIIB metals, group IVB metals, group IVA elements, group VA elements, oxides thereof, or any two or more combinations thereof.

[0006] In another related embodiment, the Art provides a method for decomposing a hydrocarbon feedstock, comprising contacting the feedstock with an FCC catalyst, which in any embodiment includes an FCC catalyst described herein. [Modes for carrying out the invention]

[0007] Various embodiments are described below. It should be noted that specific embodiments are not intended to be exhaustive or to limit the broader embodiments discussed herein. One embodiment described in relation to a particular embodiment is not necessarily limited to that embodiment and can be implemented in any other embodiment.

[0008] As used herein, "approximately" will be understood by those skilled in the art and will vary to some extent depending on the context in which it is used. Where a term not apparent to those skilled in the art is used, "approximately" means within ±10% of the specific term, given the context in which it is used.

[0009] The use of terms such as “a, an,” “the,” and similar demonstrative pronouns in the context of describing elements (particularly in the context of the claims below) shall be interpreted as including both singular and plural, unless otherwise indicated herein or unless clearly contradicted by the context. The enumeration of value ranges herein is intended solely as a simplification of referring individually to each individual value included within the range, unless otherwise indicated herein, and each individual value is incorporated herein as as it is individually enumerated herein. All methods described herein may be carried out in any preferred order, unless otherwise indicated herein or unless clearly contradicted by the context. The use of any and all examples or illustrative words provided herein (e.g., “etc.”) is intended solely to better describe embodiments and shall not limit the scope of the claims unless otherwise stated. No word herein should be interpreted as indicating an element not claimed as essential.

[0010] As used herein, the term "catalyst" refers to a material that facilitates a reaction.

[0011] As used herein, the terms “fluid catalytic cracking” or “FCC” refer to the refinery conversion process that converts high-boiling-point, high-molecular-weight hydrocarbon fractions of crude oil into higher-value gasoline, olefin gases, and other products.

[0012] "Cracking" refers to typical FCC process conditions. A typical FCC process is carried out at reaction temperatures of 450°C to 650°C and catalyst regeneration temperatures of 600°C to 850°C. Catalytic cracking is a petroleum refining process that is applied on a very large scale commercially. Catalytic cracking, and in particular fluid catalytic cracking (FCC), is routinely used to convert heavy hydrocarbon feedstocks into lighter products such as gasoline and to distill range fractions. The cracked products are separated into a range of products including gas, gasoline, light gas oil, and heavy cycle gas oil. Some of the heavier hydrocarbons may be recycled back into the reactor.

[0013] As used herein, the term “feed” refers to the portion of crude oil having a high boiling point and high molecular weight. In the FCC process, the hydrocarbon feed is injected into the riser section of the FCC unit, where it is broken down into lighter, more valuable products upon contact with a high-temperature catalyst that is circulated from the catalyst regenerator to the riser reactor.

[0014] As used herein, the term "zeolite" refers to a crystalline aluminosilicate having a framework based on a broad three-dimensional network of oxygen ions and a substantially uniform pore distribution.

[0015] As used herein, the term “microsphere” refers to catalyst particles that can be obtained by pre-forming kaolin clay and other materials (such as transition alumina) by spray drying and optionally by calcination. As understood by the parties, the microspheres do not necessarily have to be perfectly spherical. In addition, the microspheres disclosed herein can be used in fluid contact processes.

[0016] Refined products of gasoline, light olefins, and light cycle oils are always more beneficial than bottom fractions. Catalyst compositions capable of selectively producing one of the beneficial fractions are desirable for refineries. While Y-zeolite is generally known to be more selective for gasoline fractions, matrix components such as clay or alumina matrices are generally known to be more selective for light olefins and soft cycle oils (LCOs). However, different matrix components with varying properties in composition, phase, acidity, and porosity can play a significant role in product selectivity.

[0017] This technology provides modified alumina matrices with various properties for incorporation into fluid catalytic cracking (FCC) catalysts containing Y zeolite. Examples of alumina matrices include boehmite, baierite, gibbsite, single or mixed phases of γ-alumina, and / or other transition-Al2O3 phases, where the alumina matrix is ​​doped with one or more elements selected from group IIIB metals, group IVB metals, group IVA elements, group VA elements (or their oxides). In particular, the alumina matrix may be doped with La, Ce, and / or Si. Surprisingly, FCC catalysts containing the modified alumina matrices described herein have been found to limit coke and bottom fractions. Furthermore, these FCC catalysts have been found to selectively produce more of either gasoline or light olefins for refineries, where one product is more advantageous than the other.

[0018] While not bound by theory, zeolites and matrices are thought to play a role in product selectivity in fluid catalytic cracking. The presence of rare earth elements in Y zeolites, also expressed as unit cell size (UCS) numbers, may also affect product selectivity. Higher rare earth content or high UCS leads to greater hydride migration, resulting in lower olefin yield and higher gasoline yield. Conversely, lower rare earth content or low UCS may result in a product with higher olefinicity. Matrices with a large surface area and a low Z / M ratio may enhance olefin selectivity / yield. The inventors have found that the FCC catalyst incorporating this technology has a low Z / M ratio favorable for olefin formation, and that different alumina matrices, as described herein, also exhibit different product selectivity.

[0019] In one embodiment, a fluid catalytic cracking (FCC) catalyst composition is provided comprising a Y zeolite, wherein the Y zeolite comprises a rare earth element or an oxide thereof and an alumina matrix, the alumina matrix comprising γ-Al2O3 or pseudo-boehmite and a dopant; and the dopant is selected from a group IIIB metal, a group IVB metal, a group IVA element, a group VA element, an oxide thereof, or a combination of two or more thereof. In any embodiment described herein, the FCC catalyst is an incorporated catalyst.

[0020] In any embodiment disclosed herein, the catalyst may contain about 5 weight percent ("wt%") to about 30 weight percent of Y zeolite based on the total weight of the catalyst. For example, in any embodiment disclosed herein, the catalyst may contain Y zeolite in amounts of about 5 weight percent, about 10 weight percent, about 15 weight percent, about 20 weight percent, about 25 weight percent, about 30 weight percent, or any two of the aforementioned values ​​and / or any amount in between. In any embodiment disclosed herein, Y zeolite may be present in amounts ranging from about 5 weight percent to about 30 weight percent, about 10 weight percent to about 25 weight percent, about 10 weight percent to about 22 weight percent, about 12 weight percent to about 20 weight percent, or any two of the aforementioned values ​​and / or any range in between.

[0021] The Y zeolite of the FCC catalyst may contain rare earth elements or their oxides, where the rare earth elements are yttrium, scandium, praseodymium, neodymium, promethium, samarium, europium, terbium, dysprosium, holmium, erbium, thulium, lutetium, ytterbium, gadolinium, cerium, lanthanum, or a mixture of two or more of these. In any embodiment disclosed herein, the Y zeolite may contain lanthanum or its oxide.

[0022] In any embodiment, the Y zeolite may contain about 0.1% to about 12% by weight of rare earth elements or their oxides, based on the total weight of the Y zeolite. For example, Y zeolite may contain rare earth elements or their oxides in amounts including and / or any two of the aforementioned values: about 0.1% by weight, about 0.5% by weight, about 1.0% by weight, about 1.5% by weight, about 2% by weight, about 2.5% by weight, about 3.0% by weight, about 3.5% by weight, about 4.0% by weight, about 4.5% by weight, about 5.0% by weight, about 5.5% by weight, about 6.0% by weight, about 6.5% by weight, about 7.0% by weight, about 7.5% by weight, about 8.0% by weight, about 8.5% by weight, about 9.0% by weight, about 9.5% by weight, about 10.0% by weight, about 10.5% by weight, about 11.0% by weight, about 11.5% by weight, about 12.0% by weight, or any amount including and / or any range in between. In any embodiment disclosed herein, the Y zeolite may contain rare earth elements or their oxides in amounts including and / or any two of the aforementioned values, such as about 0.1% to about 12% by weight, about 1% to about 12% by weight, about 3% to about 10% by weight, about 4% to about 9% by weight, or any range between those values.

[0023] The FCC catalyst may contain an alumina matrix, which may be present in an amount of about 15% to about 65% by weight based on the total weight of the catalyst. For example, the FCC catalyst may contain the alumina matrix in an amount including and / or any range between about 15% by weight, about 20% by weight, about 25% by weight, about 30% by weight, about 35% by weight, about 40% by weight, about 45% by weight, about 50% by weight, about 55% by weight, about 60% by weight, about 65% by weight, or any two of the aforementioned values. In any embodiment disclosed herein, the FCC catalyst may contain the alumina matrix in an amount including and / or any range between about 15% to about 65% by weight, about 25% to about 60% by weight, about 30% to about 50% by weight, or any two of the aforementioned values.

[0024] In any embodiment, the dopant may be a Group IIIB metal, a Group IVB metal, an oxide thereof, or a combination of two or more thereof. Suitable Group IIIB metals, Group IVB metals, or oxides thereof may include, but are not limited to, rare earth elements, titanium (Ti), zirconium (Zr), or mixtures thereof. Rare earth element dopants in any embodiment disclosed herein may include lanthanide elements. For example, in any embodiment disclosed herein, the dopant may be yttrium (Y), scandium (Sc), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium (Gd), cerium (Ce), lanthanum (La), or a mixture of two or more thereof. In any embodiment disclosed herein, the dopant may be a Group IIIB metal or an oxide thereof. For example, in any embodiment disclosed herein, the Group IIIB metal or an oxide thereof may be lanthanum.

[0025] The alumina matrix may contain a dopant that is a Group IIIB metal, a Group IVB metal, or an oxide thereof, where the alumina matrix contains the dopant in an amount of about 0.01 wt% to about 10 wt% based on the total weight of the alumina matrix. Suitable amounts of the dopant of a Group IIIB metal, a Group IVB metal, or an oxide thereof in the alumina matrix are about 0.01 wt%, about 0.05 wt%, about 0.1 wt%, about 0.5 wt%, about 1.0 wt%, about 1.5 wt%, about 2.0 wt%, about 2.5 wt%, about 3.0 wt%, about 3.5 wt%, about 4.0 wt%, about 4.5 wt%, about 5.0 wt%, about 5.5 wt%, about 6.0 wt%, about 6.5 wt%, about 7.0 wt%, about 7.5 wt%, about 8.0 wt%, about 8.5 wt%, about 9.0 wt%, about 9.5 wt%, about 10.0 wt%, or any two of the foregoing values and / or any range therebetween. In any of the embodiments disclosed herein, the amount of the dopant selected from a Group IIIB metal, a Group IVB metal, or an oxide thereof in the alumina matrix is about 0.01 wt% to about 10 wt%, about 0.1 wt% to about 10 wt%, about 1 wt% to about ⑥ wt%, or any two of the foregoing values and / or any range therebetween.

[0026] The alumina matrix in any of the embodiments disclosed herein may contain a dopant that is a Group IVA element, a Group VA element, an oxide thereof, or a combination of any two or more thereof. Suitable Group IVA elements, Group VA elements, or oxides thereof include, but are not limited to, silicon (Si), germanium (Ge), tin (Sn), phosphorus (P), bismuth (Bi), or a mixture of any two or more thereof. In any of the embodiments disclosed herein, the dopant may be a Group IVA element or an oxide thereof. For example, in any of the embodiments disclosed herein, the Group IVA element or an oxide thereof may be silicon. [[ID=⑥]]

[0027] It should be noted that there seems to be a typo in the original text where "about 1 wt% to about ⑥ wt%" should likely be a correct value. Also, the tags ,

[0026] , etc. are kept as they are as per the requirement.In any of the embodiments disclosed herein, the alumina matrix may contain a dopant selected from Group IVA elements, Group VA elements, or their oxides, where the alumina matrix contains the dopant in an amount of about 0.01 wt% to about 35 wt% based on the total weight of the alumina matrix. Suitable amounts of dopants selected from Group IIIB metals, Group IVB metals, or their oxides in the alumina matrix are about 0.01 wt%, about 0.05 wt%, about 0.1 wt%, about 0.5 wt%, about 1 wt%, about 3 wt%, about 5 wt%, about 7 wt%, about 9 wt%, about 11 wt%, about 13 wt%, about 15 wt%, about 17 wt%, about 19 wt%, about 21 wt%, about 23 wt%, about 25 wt%, about 27 wt%, about 29 wt%, about 31 wt%, about 33 wt%, about 35 wt%, or any two of the foregoing values and / or may include any range therebetween. In any of the embodiments disclosed herein, Group IIIB metals, Group IVB metals, or their oxides in the alumina matrix may be about 0.01 wt% to about 35 wt%, about 0.1 wt% to about 35 wt%, about 3 wt% to about 25 wt%, or any two of the foregoing values and / or any range therebetween.

[0028] In any of the embodiments disclosed herein, the dopant may be a Group IIIB metal or its oxide, a Group IVA element or its oxide, or a combination thereof. For example, the dopant may be silicon, lanthanum, or a mixture thereof.

[0029] In any of the embodiments disclosed herein, the alumina matrix may contain about 50 wt% to about 99 wt% of γ-Al2O3 or a pseudo-boehmite phase based on the total weight of the alumina matrix. For example, in any of the embodiments disclosed herein, the alumina matrix may contain γ-Al2O3 or a pseudo-boehmite phase in an amount of about 50 wt%, about 55 wt%, about 60 wt%, about 65 wt%, about 70 wt%, about 75 wt%, about 80 wt%, about 85 wt%, about 90 wt%, about 95 wt%, about 99 wt%, or any two of the foregoing values and / or any range therebetween.

[0030] In any embodiment disclosed herein, the FCC catalyst may include a calcined alumina matrix or an uncalcined alumina matrix. In some embodiments, the alumina matrix may be calcined. In some embodiments, the alumina matrix may be uncalcined.

[0031] The FCC catalyst may further comprise one or more additional materials. For example, in any embodiment disclosed herein, the FCC catalyst may further comprise a binder, an alumina gel, papillating boehmite, pseudoboehmite, kaolin, transition alumina, or two or more combinations thereof.

[0032] In any embodiment disclosed herein, the catalyst may further comprise a binder. Any such binder may be present in an amount of about 5% to about 25% by weight based on the total weight of the FCC catalyst. Other suitable amounts of the binder may include about 5% by weight, about 7% by weight, about 9% by weight, about 11% by weight, about 13% by weight, about 15% by weight, about 17% by weight, about 19% by weight, about 21% by weight, about 23% by weight, about 25% by weight, or any two of the aforementioned values ​​and / or any range in between. Suitable binders may include, but are not limited to, colloidal silica, silica hydrosol, alkali silicates (e.g., sodium silicate), or mixtures thereof.

[0033] In any embodiment disclosed herein, the FCC catalyst may comprise an alumina gel, a gelatinized boehmite gel, or a mixture thereof. For example, in any embodiment disclosed herein, the FCC catalyst may comprise an alumina gel or gelatinized boehmite gel in an amount of 0% to about 10% by weight based on the total weight of the FCC catalyst. Preferred amounts of alumina gel and / or dissociative boehmite gel may include, but are not limited to, about 0.01% by weight, about 0.05% by weight, about 0.1% by weight, about 0.5% by weight, about 1.0% by weight, about 1.5% by weight, about 2.0% by weight, about 2.5% by weight, about 3.0% by weight, about 3.5% by weight, about 4.0% by weight, about 4.5% by weight, about 5.0% by weight, about 5.5% by weight, about 6.0% by weight, about 6.5% by weight, about 7.0% by weight, about 7.5% by weight, about 8.0% by weight, about 8.5% by weight, about 9.0% by weight, about 9.5% by weight, about 10.0% by weight, or any range including and / or any two of the aforementioned values. In any embodiment disclosed herein, in addition to γ-Al2O3, the alumina matrix may further include, but is not limited to, other transition alumina phases, including η-Al2O3, δ-Al2O3, θ-Al2O3, κ-Al2O3, χ-Al2O3, or combinations of two or more thereof. Furthermore, or in some embodiments, the alumina matrix may further include a single or mixed phase of bayerite, gibbsite, boehmite, or mixtures thereof.

[0034] In any embodiment disclosed herein, the FCC catalyst may have a zeolite-to-matrix (Z / M) ratio of about 0.1 to about 0.7. As described herein, the term “Z / M” (or “zeolite-to-matrix ratio”) refers to the ratio of the surface area of ​​the zeolite to the surface area of ​​the matrix. In any embodiment disclosed herein, the FCC catalyst may have a Z / M of about 0.1, about 0.2, about 0.3, about 0.4, about 0.5, about 0.6, about 0.7, or any two of these values ​​and / or any range in between.

[0035] In any embodiment disclosed herein, the FCC catalyst may be provided in any convenient form. For example, in any embodiment, the FCC catalyst may be formed into microspheres. In any embodiment disclosed herein, the microspheres may have an average particle size of about 65 microns to about 120 microns. Suitable particle sizes for microspheres may include, but are not limited to, about 65 microns, about 70 microns, about 75 microns, about 80 microns, about 85 microns, about 90 microns, about 95 microns, about 100 microns, about 105 microns, about 110 microns, about 115 microns, about 120 microns, or any range including and / or any two of these values.

[0036] In related embodiments, the technology is a process for preparing an FCC catalyst: The first slurry containing an alumina matrix material is pulverized to a D90 particle size distribution of approximately 8 microns or less, or the second slurry containing a Y zeolite having a rare earth element or its oxide is pulverized to a D90 particle size distribution of approximately 5 microns or less; or A slurry mixture containing Y zeolite containing rare earth elements or their oxides and an alumina matrix material is co-ground to a D90 particle size distribution of approximately 5 microns or less; A mixture is obtained by combining an alumina matrix and Y zeolite with one or more additional components; The mixture is spray-dried to form microspheres; Obtaining an FCC catalyst by calcining microspheres Includes, The present invention provides a process in which an alumina matrix comprises γ-Al2O3 or pseudo-boehmite and a dopant; the dopant is selected from group IIIB metals, group IVB metals, group IVA elements, group VA elements, their oxides, or any two or more combinations thereof.

[0037] In any embodiment disclosed herein, the process may include grinding the first slurry to a D90 particle size of less than about 8 microns, less than about 7.5 microns, less than about 7 microns, less than about 6.5 microns, less than about 6 microns, less than about 5.5 microns, less than about 5 microns, less than about 4.5 microns, less than about 4 microns, less than about 3.5 microns, less than about 3 microns, less than about 2.5 microns, less than about 2 microns, or any range including and / or any two of these values. In any embodiment disclosed herein, the process may include grinding the first slurry to a D90 particle size of less than about 8 microns to about 2 microns, less than about 5 microns to about 2 microns, less than about 4 microns to about 2 microns, or any range including and / or any two of these values.

[0038] In any embodiment disclosed herein, the process may include grinding the second slurry to a D90 particle size of less than about 5 microns, less than about 4.5 microns, less than about 4 microns, less than about 3.5 microns, less than about 3 microns, less than about 2.5 microns, less than about 2 microns, or any range including any two of these values ​​and / or in between. In any embodiment disclosed herein, the process may include grinding the first slurry to a D90 particle size of less than about 5 microns to about 2 microns, less than about 4 microns to about 2 microns, less than about 3.5 microns to about 2 microns, or any range including any two of these values ​​and / or in between.

[0039] In any embodiment disclosed herein, the process may further include combining the first slurry and the second slurry or slurry mixture with an acid to adjust the pH to about 5.0 or less. For example, in any embodiment disclosed herein, the pH may be adjusted to a range of pH including and / or any two of these values, such as about 5.0, about 4.5, about 4.0, about 3.5, about 3.0, or any two of these values. In any embodiment disclosed herein, the mixing of the first slurry and the second slurry or slurry mixture with an acid may adjust the pH to about 3.0 to about 5.0. Suitable acids may include, but are not limited to, formic acid, HNO3, HCl, other monobasic acids, or mixtures thereof.

[0040] The microspheres may have an average particle size of about 65 microns to about 120 microns. Preferred average particle sizes of microspheres may include, but are not limited to, about 65 microns, about 70 microns, about 75 microns, about 80 microns, about 85 microns, about 90 microns, about 95 microns, about 100 microns, about 105 microns, about 110 microns, about 115 microns, about 120 microns, or any range including and / or any two of these values. In any embodiment disclosed herein, the microspheres may have an average particle size of about 65 microns to about 120 microns, about 75 microns to about 105 microns, or any range including and / or any two of these values.

[0041] Firing can be carried out at temperatures ranging from approximately 950°F (510°C) to approximately 1650°F (899°C). For example, in any embodiment disclosed herein, the temperature may be about 950°F (510°C), about 1000°F (538°C), about 1050°F (566°C), about 1100°F (593°C), about 1150°F (621°C), about 1200°F (649°C), about 1250°F (677°C), about 1300°F (704°C), about 1350°F (732°C), about 1400°F (760°C), about 1450°F (788°C), about 1500°F (816°C), about 1550°F (843°C), about 1600°F (871°C), about 1650°F (899°C), or any range including and / or any two of these values. In any embodiment disclosed herein, the firing temperature may be in the range of about 950°F (510°C) to about 1650°F (899°C), about 1050°F (566°C) to about 1350°F (732°C), or any range including any two of these values ​​and / or any range in between.

[0042] The processes described herein form FCC catalysts as described. The formed FCC catalyst may contain about 5% to about 30% by weight of Y zeolite based on the total weight of the FCC catalyst. For example, in any embodiment disclosed herein, the FCC catalyst obtained according to the process may contain Y zeolite in amounts of about 5% by weight, about 10% by weight, about 15% by weight, about 20% by weight, about 25% by weight, about 30% by weight, or any two of the aforementioned values ​​and / or any amount in between. In any embodiment disclosed herein, Y zeolite may be present in amounts of about 5% to about 30% by weight, about 10% to about 25% by weight, about 10% to about 22% by weight, about 12% to about 20% by weight, or any two of the aforementioned values ​​and / or any range in between.

[0043] The formed FCC catalyst contains an alumina matrix in an amount of about 15% to about 65% by weight based on the total weight of the FCC catalyst. For example, in any embodiment disclosed herein, the FCC catalyst may contain an alumina matrix in an amount including and / or any range between about 15% by weight, about 20% by weight, about 25% by weight, about 30% by weight, about 35% by weight, about 40% by weight, about 45% by weight, about 50% by weight, about 55% by weight, about 60% by weight, about 65% by weight, or any two of the aforementioned values.

[0044] The alumina matrix may contain dopants which are Group IIIB metals, Group IVB metals, or oxides thereof, wherein the alumina matrix contains the dopants in an amount of about 0.01% to about 10% by weight based on the total weight of the alumina matrix. Preferred amounts of the dopant may be approximately 0.01% by weight, approximately 0.05% by weight, approximately 0.1% by weight, approximately 0.5% by weight, approximately 1.0% by weight, approximately 1.5% by weight, approximately 2.0% by weight, approximately 2.5% by weight, approximately 3.0% by weight, approximately 3.5% by weight, approximately 4.0% by weight, approximately 4.5% by weight, approximately 5.0% by weight, approximately 5.5% by weight, approximately 6.0% by weight, approximately 6.5% by weight, approximately 7.0% by weight, approximately 7.5% by weight, approximately 8.0% by weight, approximately 8.5% by weight, approximately 9.0% by weight, approximately 9.5% by weight, approximately 10.0% by weight, or any range including and / or any two of the aforementioned values. In any embodiment disclosed herein, the amount of dopant may be in the range of about 0.01% to about 10% by weight, about 0.1% to about 10% by weight, about 1% to about 6% by weight, or any two of the aforementioned values ​​and / or any range in between.

[0045] The alumina matrix may contain dopants which are IVA elements, VA elements, or oxides thereof, wherein the alumina matrix contains the dopants in amounts ranging from about 0.01% to about 35% by weight based on the total weight of the alumina matrix. Preferred amounts of such dopants may include about 0.01% by weight, about 0.05% by weight, about 0.1% by weight, about 0.5% by weight, about 1% by weight, about 3% by weight, about 5% by weight, about 7% by weight, about 9% by weight, about 11% by weight, about 13% by weight, about 15% by weight, about 17% by weight, about 19% by weight, about 21% by weight, about 23% by weight, about 25% by weight, about 27% by weight, about 29% by weight, about 31% by weight, about 33% by weight, about 35% by weight, or any two of the aforementioned values ​​and / or any range in between. In any embodiment disclosed herein, the IVA group elements, VA group elements, or oxides thereof in the alumina matrix may include and / or any two of the aforementioned values, in amounts ranging from about 0.01% to about 35% by weight, about 0.1% to about 35% by weight, about 3% to about 25% by weight, or any range between them.

[0046] In any embodiment disclosed herein, the dopant may be a group IIIB metal or an oxide thereof, a group IVA element or an oxide thereof, or a combination of two or more thereof. For example, the dopant may be selected from silicon, lanthanum, or a mixture thereof.

[0047] In any embodiment disclosed herein, the alumina matrix may contain about 50% to about 99% by weight of γ-Al2O3 or pseudo-boehmite phase, based on the total weight of the alumina matrix. For example, the alumina matrix may contain γ-Al2O3 or pseudo-boehmite phase in amounts including about 50% by weight, about 55% by weight, about 60% by weight, about 65% by weight, about 70% by weight, about 75% by weight, about 80% by weight, about 85% by weight, about 90% by weight, about 95% by weight, about 99% by weight, or any two of the aforementioned values ​​and / or any range in between.

[0048] In any embodiment disclosed herein, the FCC catalyst prepared according to the process described herein may include a calcined alumina matrix or an uncalcined alumina matrix. In some embodiments, the alumina matrix may be calcined. In some embodiments, the alumina matrix may be uncalcined.

[0049] The process may further include combining one or more additional materials with the first slurry or second slurry or mixture of slurries. For example, in any embodiment disclosed herein, the first slurry or second slurry or mixture of slurries may further include a binder, alumina gel, pectinated boehmite, pseudoboehmite, kaolin, transition alumina, or two or more combinations thereof.

[0050] In any embodiment disclosed herein, the FCC catalyst prepared according to the process described herein may further contain a binder. For example, in any embodiment disclosed herein, the FCC catalyst may contain a binder in an amount of about 5% to about 25% by weight based on the total weight of the FCC catalyst. Preferred amounts of the binder may include about 5% by weight, about 7% by weight, about 9% by weight, about 11% by weight, about 13% by weight, about 15% by weight, about 17% by weight, about 19% by weight, about 21% by weight, about 23% by weight, about 25% by weight, or any two of the aforementioned values ​​and / or any range in between. Suitable binders may include, but are not limited to, colloidal silica, silica hydrosol, alkali silicates, or mixtures thereof.

[0051] In any embodiment disclosed herein, the FCC catalyst prepared according to the process described herein may comprise an alumina gel, a papular boehmite gel, or a mixture thereof. For example, in any embodiment disclosed herein, the FCC catalyst may comprise an alumina gel or papular boehmite gel in an amount of 0% to about 10% by weight based on the total weight of the FCC catalyst. Preferred amounts of alumina gel and / or dissociative boehmite gel may include, but are not limited to, about 0.01% by weight, about 0.05% by weight, about 0.1% by weight, about 0.5% by weight, about 1.0% by weight, about 1.5% by weight, about 2.0% by weight, about 2.5% by weight, about 3.0% by weight, about 3.5% by weight, about 4.0% by weight, about 4.5% by weight, about 5.0% by weight, about 5.5% by weight, about 6.0% by weight, about 6.5% by weight, about 7.0% by weight, about 7.5% by weight, about 8.0% by weight, about 8.5% by weight, about 9.0% by weight, about 9.5% by weight, about 10.0% by weight, or any range including and / or any two of the aforementioned values.

[0052] In any embodiment disclosed herein, the FCC catalyst prepared according to the process described herein may have a Z / M ratio of about 0.1 to about 0.7. In any embodiment disclosed herein, the FCC catalyst may have a Z / M ratio of about 0.1, about 0.2, about 0.3, about 0.4, about 0.5, about 0.6, about 0.7, or any two of these values ​​and / or any range in between.

[0053] In any embodiment disclosed herein, the microspheres may have an average particle size of about 65 microns to about 120 microns. Preferred particle sizes for microspheres may include, but are not limited to, about 65 microns, about 70 microns, about 75 microns, about 80 microns, about 85 microns, about 90 microns, about 95 microns, about 100 microns, about 105 microns, about 110 microns, about 115 microns, about 120 microns, or any range including and / or any two of these values.

[0054] In another embodiment, the Technology provides, in any embodiment, an incorporated FCC catalyst prepared according to the process described herein.

[0055] In another embodiment, the present technology provides a catalyst composition comprising: a first FCC catalyst comprising a Y zeolite and alumina matrix material having a rare earth element or an oxide thereof; a second FCC catalyst different from the first FCC catalyst; and optionally, an additional FCC catalyst different from the first and second FCC catalysts, wherein the alumina matrix comprises γ-Al2O3 or pseudo-boehmite and a dopant; and the dopant comprises a group IIIB metal, a group IVB metal, a group IVA element, a group VA element, an oxide thereof, or a combination of any two or more thereof.

[0056] In any embodiment disclosed herein, the composition may comprise about 1% to about 99% by weight of a first FCC catalyst based on the total weight of the catalyst composition. Preferred amounts of the first FCC catalyst may include about 1% by weight, about 2% by weight, about 3% by weight, about 4% by weight, about 5% by weight, about 6% by weight, about 7% by weight, about 8% by weight, about 9% by weight, about 10% by weight, about 15% by weight, about 20% by weight, about 25% by weight, about 30% by weight, about 35% by weight, about 40% by weight, about 45% by weight, about 50% by weight, about 55% by weight, about 60% by weight, about 65% by weight, about 70% by weight, about 75% by weight, about 80% by weight, about 85% by weight, about 90% by weight, about 95% by weight, about 99% by weight, or any range including any two of the aforementioned values ​​and / or any range in between. For example, the first catalyst may be present in an amount including and / or any range in between, based on the total weight of the composition, of about 1% to about 99% by weight, about 5% to about 85% by weight, about 10% to about 70% by weight, about 15% to about 60% by weight, about 20% to about 50% by weight, or any of these values. In any embodiment disclosed herein, the first FCC catalyst is the FCC catalyst described herein in any embodiment.

[0057] In any embodiment disclosed herein, the composition may comprise about 1% to about 99% by weight of a second FCC catalyst based on the total weight of the composition. Preferred amounts of one or more additional FCC catalysts may include about 1% by weight, about 2% by weight, about 3% by weight, about 4% by weight, about 5% by weight, about 6% by weight, about 7% by weight, about 8% by weight, about 9% by weight, about 10% by weight, about 15% by weight, about 20% by weight, about 25% by weight, about 30% by weight, about 35% by weight, about 40% by weight, about 45% by weight, about 50% by weight, about 55% by weight, about 60% by weight, about 65% by weight, about 70% by weight, about 75% by weight, about 80% by weight, about 85% by weight, about 90% by weight, about 95% by weight, about 99% by weight, or any range including any two of the aforementioned values ​​and / or any range in between. For example, one or more additional FCC catalysts may be present in amounts including and / or any range in between, based on the total weight of the composition, approximately 1% to approximately 99% by weight, approximately 5% to approximately 85% by weight, approximately 10% to approximately 70% by weight, approximately 15% to approximately 60% by weight, approximately 20% to approximately 50% by weight, or any of these values.

[0058] In any embodiment disclosed herein, the composition may optionally contain an additional FCC catalyst in an amount of about 1% to about 99% by weight based on the total weight of the composition. Preferred amounts of the optional additional FCC catalyst may include about 1% by weight, about 2% by weight, about 3% by weight, about 4% by weight, about 5% by weight, about 6% by weight, about 7% by weight, about 8% by weight, about 9% by weight, about 10% by weight, about 15% by weight, about 20% by weight, about 25% by weight, about 30% by weight, about 35% by weight, about 40% by weight, about 45% by weight, about 50% by weight, about 55% by weight, about 60% by weight, about 65% by weight, about 70% by weight, about 75% by weight, about 80% by weight, about 85% by weight, about 90% by weight, about 95% by weight, about 99% by weight, or any two of the aforementioned values ​​and / or any range in between. For example, optional additional FCC catalysts may be present in amounts including and / or any range in between, based on the total weight of the composition, approximately 1% to approximately 99% by weight, approximately 5% to approximately 85% by weight, approximately 10% to approximately 70% by weight, approximately 15% to approximately 60% by weight, approximately 20% to approximately 50% by weight, or any of these values.

[0059] In another related embodiment, the Art provides a method for decomposing a hydrocarbon feedstock, comprising contacting the feedstock with an FCC catalyst, which in any embodiment includes an FCC catalyst described herein.

[0060] The present invention, as generally described herein, can be more readily understood by referring to the following examples, which are provided for illustrative purposes only and are not intended to limit the invention. [Examples]

[0061] Example 1: Preparation and evaluation of FCC catalysts incorporated into calcined alumina matrices. Table 1 provides the properties of two alumina matrix materials (AM1 and AM2) used to create the FCC catalysts described in Samples A-C. AM1 and AM2 are calcined at high temperatures with a large portion of the alumina phase as γ-(γ)-Al2O3 and small amounts of several other phases such as χ- and α-Al2O3.

[0062] [Table 1]

[0063] The incorporated FCC samples A-C were generally prepared by the following process: 1. Grind the alumina matrix material (AM1 or AM2) in the slurry until 90% of the material particles are reduced, i.e., the D90 is less than approximately 8 microns. 2. Grind the Y zeolite (REUSY) containing rare earth elements or their oxides in a slurry until the D90 is less than approximately 5 microns. 3. Before, during, or after grinding, adjust the pH of the slurry to less than approximately 5 using a monobasic acid (i.e., formic acid). 4. The pulverized alumina matrix material (AM1 or AM2) and REUSY are mixed with colloidal silica (Nalco 2326), papular alumina (PB950), kaolin slurry, and crystalline boehmite (Tor alumina). 5. The mixture is spray-dried to form microspheres with an average particle size of approximately 65 microns to 125 microns. 6. The obtained microspheres were fired at temperatures ranging from 950°F to 1650°F.

[0064] These slurry components can be mixed simultaneously or sequentially to produce a slurry mixture suitable for spray drying, which can then be formed into microspheres.

[0065] Table 2 below provides the formulations and characteristics of samples A to C.

[0066] [Table 2]

[0067] As shown in Table 2, samples A-C have different REO, UCS, and Y zeolite content, and different alumina matrices. After vapor inactivation at 1450°F / 24h / 100%, these samples have low sZ / M (0.4-0.6). Sample C has lower Z stability due to its high Na content in AM2. Both samples B and C have similar sZSA and sUCS. A CRU (circulating riser unit) test was used to evaluate these samples. The results at a constant conversion rate of 76% are summarized in Table 3 below, compared to a comparable in-situ Y zeolite FCC catalyst control.

[0068] [Table 3]

[0069] As shown in Table 3 above, exemplary incorporated FCC catalyst samples A-C showed improved coke selectivity compared to the control in situ FCC catalyst. The results showed that changes in Y zeolite content (Z / M) or REO(UCS) had only a small effect on the bottom upgrade. For the same AM1, changing Z / M and REO(UCS) in samples A and B affected the selectivity of other products. Compared to sample A, sample B showed higher UCS as well as higher selectivity for LPG and olefins. The product distribution results for samples A and B' compared to sample C showed that the properties of the alumina matrix affected product selectivity. In other words, FCC catalysts containing AM1 produced more LPG / olefins, and AM2 produced more gasoline. Therefore, AM1 (3.5 wt% La2O3 dopant) in the FCC catalyst composition is very beneficial in the case of C4=, and AM2 (0.2 wt% SiO2 dopant) produces excellent gasoline with low olefin / LPG. As shown above, prototype CRU testing demonstrated that exemplary FCC catalyst samples A-C showed 9-10% better bottom-up grading compared to the control in situ FCC catalyst.

[0070] Example 2: Preparation and evaluation of FCC catalyst incorporated into an uncalcined alumina matrix. An overview of the uncalcined alumina matrix, mainly containing a pseudo-boehmite phase, is shown in Table 4. Table 4 provides the formulations and properties of the alumina matrix materials (AM3 to AM8).

[0071] [Table 4]

[0072] The FCC catalysts incorporating samples D to I were prepared according to the procedure described in Example 1 above. As shown in Table 5 below, FCC catalyst samples D to I incorporate alumina matrix materials AM3 to AM8 having dopants (i.e., Si and / or La) modified in different concentrations.

[0073] [Table 5]

[0074] The ACE test results indicated that modification of the alumina matrix with high Si doping and / or some La doping affects the product selectivity of the same alumina phase. In particular, Si and / or La doping of the uncalcined alumina matrix reduces coke and hydrogen formation and improves bottom-up grading.

[0075] [Table 6]

[0076] While specific embodiments have been illustrated and described, it should be understood that these can be modified and altered in accordance with the ordinary art in the art without departing from the broader aspects of the art as defined in the appended claims.

[0077] Embodiments described herein exemplary can be suitably implemented in the absence of any elements or limitations not specifically disclosed herein. Therefore, terms such as “comprising,” “including,” and “containing” should be read broadly and without limitation. Furthermore, the terms and expressions used herein are descriptive and not restrictive, and in the use of such terms and expressions, there is no intention to exclude any equivalents of the shown or described features or parts thereof, and it is recognized that various modifications are possible within the scope of the claimed art. Furthermore, the phrase “essentially consisting of” is understood to include several elements specifically cited, and additional elements that do not substantially affect the fundamental and novel features of the claimed art. The phrase “consisting of” excludes any elements not explicitly stated.

[0078] This disclosure is not limited to the specific embodiments described in this application. Many modifications and changes can be made without departing from the spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods and compositions within the scope of this disclosure will be apparent to those skilled in the art from the above description, in addition to those enumerated herein. Such modifications and changes are intended to be included in the appended claims. This disclosure should be limited only by the appended claims and the entire scope of the equivalents to which such claims are granted. It should be understood that this disclosure is not limited to specific methods, reagents, compounds, or compositions, which may, of course, vary. It should also be understood that the terms used herein are for the purpose of describing specific embodiments and are not intended to be limiting.

[0079] In addition, where any feature or aspect of this disclosure is described in relation to the Markush Group, a person skilled in the art will recognize that this disclosure is also described in relation to any individual member of the Markush Group or a subgroup of any member thereof.

[0080] As will be understood by those skilled in the art, for all purposes, and especially in terms of providing written explanations, all scopes disclosed herein also encompass all possible sub-scopes and combinations thereof. Any enumeration of scopes can be readily recognized as adequately describing and enabling the same scope to be broken down into at least equal halves, thirds, quarters, fifths, tenths, etc. As a non-limiting example, each scope considered herein can readily be broken down into a lower third, an intermediate third, an upper third, etc. Also, as will be understood by those skilled in the art, all terms such as “maximum,” “at least,” “greater than,” and “less than” include the enumerated numbers and refer to scopes that can be subsequently broken down into the sub-scopes considered above. Finally, as will be understood by those skilled in the art, scopes include each individual member.

[0081] All publications, patent applications, issued patents, and other documents referenced herein are incorporated herein by reference in such a way that each individual publication, patent application, issued patent, or other document in its entirety is specifically and individually indicated as being incorporated herein by reference. Definitions contained in the text incorporated by reference are excluded to the extent that they conflict with the definitions in this disclosure.

[0082] Other embodiments are described in the subsequent claims. The present invention includes the following embodiments. [Section 1] A fluid catalytic cracking (FCC) catalyst composition comprising Y zeolite, wherein the Y zeolite comprises rare earth elements or their oxides and an alumina matrix. The alumina matrix is ​​γ-Al 2 O 3 or including pseudo-boehmite and dopant; An FCC catalyst composition wherein the dopant comprises a group IIIB metal, a group IVB metal, a group IVA element, a group VA element, an oxide thereof, or a combination of two or more thereof. [Section 2] The FCC catalyst according to item 1, wherein the catalyst comprises about 5% to about 30% by weight of the Y zeolite based on the total weight of the catalyst. [Section 3] The FCC catalyst according to claim 1 or 2, wherein the catalyst comprises about 10% to about 25% by weight of the Y zeolite based on the total weight of the catalyst. [Section 4] The FCC catalyst according to any one of claims 1 to 3, wherein the rare earth element is lanthanum or an oxide thereof. [Section 5] The FCC catalyst according to any one of claims 1 to 4, wherein the Y zeolite contains about 0.1% to about 12% by weight of the rare earth element or its oxide based on the total weight of the Y zeolite. [Section 6] The FCC catalyst according to any one of claims 1 to 5, wherein the Y zeolite contains about 3% to about 10% by weight of the rare earth element or its oxide based on the total weight of the Y zeolite. [Section 7] The FCC catalyst according to any one of claims 1 to 6, wherein the catalyst comprises about 15% to about 65% by weight of the alumina matrix based on the total weight of the catalyst. [Section 8] The FCC catalyst according to any one of claims 1 to 7, wherein the catalyst comprises about 25% to about 60% by weight of the alumina matrix based on the total weight of the catalyst. [Section 9] The FCC catalyst according to any one of claims 1 to 8, wherein the catalyst comprises about 30% to about 50% by weight of the alumina matrix based on the total weight of the catalyst. [Section 10] The FCC catalyst according to any one of claims 1 to 9, wherein the dopant is the group IIIB metal, the group IVB metal, an oxide thereof, or a combination of two or more thereof. [Section 11] The FCC catalyst according to item 10, wherein the alumina matrix contains 0.01% to about 10% by weight of the dopant based on the total weight of the alumina matrix. [Section 12] The FCC catalyst according to item 10 or 11, wherein the alumina matrix contains about 0.1% to about 10% by weight of the dopant based on the total weight of the alumina matrix. [Section 13] The FCC catalyst according to any one of claims 10 to 12, wherein the alumina matrix contains about 1% to about 6% by weight of the dopant based on the total weight of the alumina matrix. [Section 14] The FCC catalyst according to any one of claims 1 to 9, wherein the dopant is the IVA element, the VA element, an oxide thereof, or a combination of two or more thereof. [Section 15] The FCC catalyst according to item 14, wherein the alumina matrix comprises 0.01% to about 35% by weight of the dopant based on the total weight of the alumina matrix. [Section 16] The FCC catalyst according to item 14 or 15, wherein the alumina matrix comprises about 0.1% to about 35% by weight of the dopant based on the total weight of the alumina matrix. [Section 17] The FCC catalyst according to any one of claims 14 to 16, wherein the alumina matrix contains about 3% to about 25% by weight of the dopant based on the total weight of the alumina matrix. [Section 18] The FCC catalyst according to any one of claims 1 to 9, wherein the dopant is selected from a group IIIB metal, a group IVA element, an oxide thereof, or a combination of two or more thereof. [Section 19] The FCC catalyst according to any one of claims 1 to 9, wherein the dopant present in the alumina matrix is ​​selected from silicon, lanthanum, oxides thereof, or combinations thereof. [Section 20] The alumina matrix consists of approximately 50% to 99% by weight of γ-Al 2 O 3 Or an FCC catalyst according to any one of items 1 to 18, comprising a pseudo-boehmite phase. [Section 21] The FCC catalyst according to any one of items 1 to 20, wherein the alumina matrix is ​​calcined. [Section 22] The FCC catalyst according to any one of claims 1 to 20, wherein the alumina matrix is ​​uncalcined. [Section 23] An FCC catalyst according to any one of claims 1 to 22, further comprising a binder, an alumina gel, pectinated boehmite, pseudo-boehmite, kaolin, transition alumina, or a combination thereof. [Section 24] The FCC catalyst according to claim 23, wherein the catalyst comprises about 5% to about 25% by weight of a binder based on the total weight of the catalyst. [Section 25] The FCC catalyst according to item 23 or 24, wherein the binder is colloidal silica. [Section 26] The FCC catalyst according to any one of claims 23 to 25, wherein the catalyst comprises 0% to about 10% by weight of alumina gel or gelatinized boehmite gel based on the total weight of the catalyst. [Section 27] The FCC catalyst according to any one of claims 1 to 26, wherein the catalyst has a zeolite-to-matrix (Z / M) ratio of about 0.1 to about 0.7. [Section 28] The FCC catalyst according to any one of claims 1 to 27, wherein the catalyst is in the form of microspheres. [Section 29] A process for preparing an FCC catalyst: The first slurry containing an alumina matrix material is pulverized to a D90 particle size distribution of approximately 8 microns or less, and the second slurry containing a Y zeolite containing rare earth elements or their oxides is pulverized to a D90 particle size distribution of approximately 5 microns or less; Alternatively, the slurry mixture containing the Y zeolite containing rare earth elements or their oxides and the alumina matrix material may be co-ground to a D90 particle size distribution of approximately 5 microns or less; The alumina matrix and the Y zeolite are combined with one or more additional components to obtain a mixture; The mixture is spray-dried to form microspheres; The FCC catalyst is obtained by calcining the aforementioned microspheres; Includes, The alumina matrix is ​​γ-Al 2 O 3 and including dopants; A process wherein the dopant comprises a group IIIB metal, a group IVB metal, a group IVA element, a group VA element, an oxide thereof, or a combination of two or more thereof. [Section 30] The process according to claim 29, further comprising combining the first slurry and the second slurry or the slurry mixture with an acid to adjust the pH to about 5 or less. [Section 31] The process according to item 30, wherein the pH is approximately 3 to approximately 5. [Section 32] The aforementioned acid is formic acid, HNO 3 The process according to item 30 or 31, selected from HCl or any other monobasic acid. [Section 33] The process according to any one of claims 29 to 32, wherein the microspheres have an average particle size of about 65 microns to about 125 microns. [Section 34] The process according to any one of items 29 to 33, wherein the microspheres are fired at a temperature of approximately 950°F to approximately 1650°F. [Section 35] The process according to any one of claims 29 to 34, wherein the catalyst comprises about 5% to about 30% by weight of the Y zeolite based on the total weight of the catalyst. [Section 36] The process according to any one of claims 29 to 35, wherein the catalyst comprises about 15% to about 65% by weight of the alumina matrix based on the total weight of the catalyst. [Section 37] The process according to any one of claims 29 to 36, wherein the dopant is the group IIIB metal, the group IVB metal, an oxide thereof, or a combination of two or more thereof. [Section 38] The process according to claim 37, wherein the alumina matrix comprises 0.01% to about 10% by weight of the dopant based on the total weight of the alumina matrix. [Section 39] The process according to any one of claims 29 to 38, wherein the dopant is one of the IVA elements, one of the VA elements, an oxide thereof, or a combination of two or more of them. [Section 40] The process according to claim 39, wherein the alumina matrix comprises 0.01% to about 35% by weight of the dopant based on the total weight of the alumina matrix. [Section 41] The process according to any one of claims 29 to 40, wherein the dopant is silicon, lanthanum, an oxide thereof, or a combination thereof. [Section 42] The process according to any one of claims 29 to 41, wherein the one or more additional components include a binder, an alumina gel, a gelatinous boehmite, pseudo-boehmite, kaolin, transition alumina, or a combination thereof. [Section 43] A catalyst composition: A first FCC catalyst comprising a Y zeolite containing rare earth elements or their oxides and an alumina matrix material; A second FCC catalyst, different from the first FCC catalyst; Optionally, an additional FCC catalyst different from the first and second FCC catalysts; Includes, The alumina matrix is ​​γ-Al 2 O3 or including pseudo-boehmite and dopant; A catalyst composition in which the dopant comprises a group IIIB metal, a group IVB metal, a group IVA element, a group VA element, an oxide thereof, or a combination of two or more thereof.

Claims

1. A fluid catalytic cracking (FCC) catalyst composition comprising an alumina matrix and a Y zeolite, wherein the Y zeolite comprises a rare earth oxide, and the rare earth oxide is lanthanum oxide. The alumina matrix comprises a dopant and 50% to 99% by weight of γ-Al₂O₃ or a pseudo-boehmite phase based on the total weight of the alumina matrix; An FCC catalyst composition in which the dopant is selected from silicon, lanthanum, their oxides, or combinations thereof.

2. The FCC catalyst according to claim 1, wherein the catalyst contains 5% to 30% by weight of the Y zeolite based on the total weight of the catalyst.

3. The FCC catalyst according to claim 1 or 2, wherein the catalyst comprises 10% to 25% by weight of the Y zeolite based on the total weight of the catalyst.

4. The FCC catalyst according to any one of claims 1 to 3, wherein the Y zeolite contains 0.1% to 12% by weight of the rare earth oxide based on the total weight of the Y zeolite.

5. The FCC catalyst according to any one of claims 1 to 4, wherein the Y zeolite contains 3% to 10% by weight of the rare earth oxide based on the total weight of the Y zeolite.

6. The FCC catalyst according to any one of claims 1 to 5, wherein the catalyst comprises 15% to 65% by weight of the alumina matrix based on the total weight of the catalyst.

7. The FCC catalyst according to any one of claims 1 to 6, wherein the catalyst comprises 25% to 60% by weight of the alumina matrix based on the total weight of the catalyst.

8. The FCC catalyst according to any one of claims 1 to 7, wherein the catalyst comprises 30% to 50% by weight of the alumina matrix based on the total weight of the catalyst.

9. The FCC catalyst according to any one of claims 1 to 8, wherein the dopant is lanthanum, its oxide, or a combination thereof.

10. The FCC catalyst according to claim 9, wherein the alumina matrix contains 0.01% to 10% by weight of the dopant based on the total weight of the alumina matrix.

11. The FCC catalyst according to claim 9 or 10, wherein the alumina matrix contains 0.1% to 10% by weight of the dopant based on the total weight of the alumina matrix.

12. The FCC catalyst according to any one of claims 9 to 11, wherein the alumina matrix contains 1% to 6% by weight of the dopant based on the total weight of the alumina matrix.

13. The FCC catalyst according to any one of claims 1 to 8, wherein the dopant is silicon, its oxide, or a combination thereof.

14. The FCC catalyst according to claim 13, wherein the alumina matrix contains 0.01% to 35% by weight of the dopant based on the total weight of the alumina matrix.

15. The FCC catalyst according to claim 13 or 14, wherein the alumina matrix contains 0.1% to 35% by weight of the dopant based on the total weight of the alumina matrix.

16. The FCC catalyst according to any one of claims 13 to 15, wherein the alumina matrix contains 3% to 25% by weight of the dopant based on the total weight of the alumina matrix.

17. The FCC catalyst according to any one of claims 1 to 16, wherein the alumina matrix is ​​calcined.

18. The FCC catalyst according to any one of claims 1 to 16, wherein the alumina matrix is ​​uncalcined.

19. An FCC catalyst according to any one of claims 1 to 18, further comprising a binder, alumina gel, pectinated boehmite, pseudo-boehmite, kaolin, transition alumina, or a combination thereof.

20. The FCC catalyst according to claim 19, wherein the catalyst comprises 5% to 25% by weight of a binder based on the total weight of the catalyst.

21. The FCC catalyst according to claim 19 or 20, wherein the binder is colloidal silica.

22. The FCC catalyst according to any one of claims 19 to 21, wherein the catalyst comprises 0% to 10% by weight of alumina gel or papillate boehmite gel based on the total weight of the catalyst.

23. The FCC catalyst according to any one of claims 1 to 22, wherein the catalyst has a zeolite-to-matrix (Z / M) ratio of 0.1 to 0.

7.

24. The FCC catalyst according to any one of claims 1 to 23, wherein the catalyst is in the form of microspheres.

25. A process for preparing the FCC catalyst according to Claim 1, the following: A first slurry containing an alumina matrix material is pulverized to a D90 particle size distribution of 8 microns or less, and a second slurry containing a Y zeolite containing a rare earth element or its oxide, wherein the rare earth element is lanthanum, is pulverized to a D90 particle size distribution of 5 microns or less; Alternatively, a slurry mixture containing a rare earth element or its oxide, wherein the rare earth element is lanthanum, and the alumina matrix material, is co-ground to a D90 particle size distribution of 5 microns or less; The alumina matrix and the Y zeolite are combined with one or more additional components, including a binder, alumina gel, gelatinized boehmite, pseudo-boehmite, kaolin, transition alumina, or a combination thereof, to obtain a mixture; The mixture is spray-dried to form microspheres; The FCC catalyst is obtained by calcining the aforementioned microspheres; Includes, The alumina matrix is ​​γ-Al ２ O ３ and including dopants; The dopant is selected from silicon, lanthanum, their oxides, or combinations thereof. process.

26. The process according to claim 25, further comprising combining the first slurry and the second slurry or the slurry mixture with an acid and adjusting the pH to 5 or less.

27. The process according to claim 26, wherein the pH is 3 to 5.

28. The aforementioned acid is formic acid, HNO ３ The process according to claim 26 or 27, selected from HCl or any other monobasic acid.

29. The process according to any one of claims 25 to 28, wherein the microspheres have an average particle size of 65 microns to 125 microns.

30. The process according to any one of claims 25 to 29, wherein the microspheres are fired at a temperature of 950°F to 1650°F.

31. The process according to any one of claims 25 to 30, wherein the catalyst comprises 5% to 30% by weight of the Y zeolite based on the total weight of the catalyst.

32. The process according to any one of claims 25 to 31, wherein the catalyst comprises 15% to 65% by weight of the alumina matrix based on the total weight of the catalyst.

33. The process according to any one of claims 25 to 32, wherein the dopant is lanthanum, its oxide, or a combination thereof.

34. The process according to claim 33, wherein the alumina matrix comprises 0.01% to 10% by weight of the dopant based on the total weight of the alumina matrix.

35. The process according to any one of claims 25 to 34, wherein the dopant is silicon, its oxide, or a combination thereof.

36. The process according to claim 35, wherein the alumina matrix comprises 0.01% to 35% by weight of the dopant based on the total weight of the alumina matrix.

37. A catalyst composition: A first FCC catalyst comprising an alumina matrix and a Y zeolite containing a rare earth oxide, wherein the rare earth oxide is lanthanum oxide; A second FCC catalyst, different from the first FCC catalyst; Includes, The alumina matrix comprises a dopant and 50% to 99% by weight of γ-Al₂O₃ or a pseudo-boehmite phase based on the total weight of the alumina matrix; A catalyst composition in which the dopant is selected from silicon, lanthanum, their oxides, or combinations thereof.

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