Conversion of hydrocarbons with mixture of small and large pore crystalline zeolite catalyst compositions to accomplish cracking cyclization, and alkylation reactions

Claim 1

A METHOD FOR CONVERTING HYDROCARBONS WITH A DUAL FUNCTION CONVERSION CATALYST COMPRISING A LARGE PORE FAUJASITE TYPE CRYSTALLINE ZEOLITE CRACKING COMPONENT AND A CRYSTALLINE ALUMINOSILICATE OF THE ZSM-5 TYPE HAVING A PORE SIZE RESTRICTED TO WITHIN THE RANGE OF 5 TO 9 ANGSTROMS WHICH COMPRISES, CRACKING A GAS OIL FEED WITH SAID DUAL FUNCTION CATALYST PARTICLES IN A FIRST DISPERSED CATALYST PHASE CONVERSION ZONE AT A TEMPERATURE SELECTED FROM WITHIN THE RANGE OF 1000*F. TO 1200*F. AT A CATALYST RESIDENCE TIME OF NOT MORE THAN ABOUT 5 SECONDS, CONVERTING A C3 CONTAINING HYDROCARBON FEED IN A SECOND SEPARATE DISPERSED CATALYST PHASE CONVERSION ZONE IN THE PRESENCE OF SAID DUAL FUNCTION CATALYST PARTICLES, A PORTION OF WHICH WAS USED IN SAID FIRST CONVERSION ZONE AT A TEMPERATURE WITHIN THE RANGE OF 500* TO 1000*F. RELYING UPON A CATALYST RESIDEENCE TIME IN EXCESS OF 5 SECONDS, RECOVERING CATALYST PARTICLES SEPARATED FROM EACH OF SAID FIRST AND SECOND CONVERSION ZONES AS A DENSE FLUID BED OF CATALYST PARTICLES, STRIPPING THE DENSE FLUID BED OF CATALYST PARTICLES OF VAPOROUS HYDROCARBONS, REGENERATING THE STRIPPED CATALYST TO REMOVE DEPOSITED HYDROCARBONACEOUS MATERIAL, PASSING REGENERATED CATALYST TO AT LEAST SAID FIRST CONVERSION ZONE, AND CONTACTING PARTICLES OF CATALYST SEPARATED FROM SAID FIRST CONVERSION ZONE IN SAID SECOND CONVERSION ZONE AT A TEMPERATURE LESS THAN 1000*F. WITH A C3 CONTAINING HYDROCARBON MATERIAL OBTAINED AS A PORTION OF THE PRODUCT OF SAID FIRST CONVERSION ZONE.

Claim 2

A METHOD FOR CONVERTING HYDROCARBONS WITH A DUAL FUNCTION CONVERSION CATALYST COMPRISING A LARGE PORE FAUJASITE TYPE CRYSTALLINE ZEOLITE CRACKING COMPONENT AND A CRYSTALLINE ALUMINOSILICATE OF THE ZSM-5 TYPE HAVING A PORE SIZE RESTRICTED TO WITHIN THE RANGE OF 5 TO 9 ANGSTROMS WHICH COMPRISES, CRACKING A GAS OIL FEED WITH SAID DUAL FUNCTION CATALYST PARTICLES IN A FIRST DISPERSED CATALYST PHASE CONVERSION ZONE AT A TEMPERATURE SELECTED FROM WITHIN THE RANGE OF 1000*F. TO 1200*F. AT A CATALYST RESIDENCE TIME OF NOT MORE THAN ABOUT 5 SECONDS, CONVERTING A C3 CONTAINING HYDROCARBON FEED IN A SECOND SEPARATE DISPERSED CATALYST PHASE CONVERSION ZONE IN THE PRESENCE OF SAID DUAL FUNCTION CATALYST PARTICLES, A PORTION OF WHICH WAS USED IN SAID FIRST CONVERSION ZONE AT A TEMPERATURE WITHIN THE RANGE OF 500* TO 1000*F. RELYING UPON A CATALYST RESIDEENCE TIME IN EXCESS OF 5 SECONDS, RECOVERING CATALYST PARTICLES SEPARATED FROM EACH OF SAID FIRST AND SECOND CONVERSION ZONES AS A DENSE FLUID BED OF CATALYST PARTICLES, STRIPPING THE DENSE FLUID BED OF CATALYST PARTICLES OF VAPOROUS HYDROCARBONS, REGENERATING THE STRIPPED CATALYST TO REMOVE DEPOSITED HYDROCARBONACEOUS MATERIAL, PASSING REGENERATED CATALYST TO AT LEAST SAID FIRST CONVERSION ZONE, AND CONTACTING PARTICLES OF CATALYST SEPARATED FROM SAID FIRST CONVERSION ZONE IN SAID SECOND CONVERSION ZONE AT A TEMPERATURE LESS THAN 1000*F. WITH A C3 CONTAINING HYDROCARBON MATERIAL OBTAINED AS A PORTION OF THE PRODUCT OF SAID FIRST CONVERSION ZONE.

Claim 11

A method for converting hydrocarbons to form gasoline, aromatics and alkyl aromatics which comprises, cracking high boiling hydrocarbon material admixed with a ZSM-5 crystalline zeolite and a larger pore crystalline aluminosilicate catalyst composition of different activity and selectivity characteristic in a first dispersed phase riser reaction zone at a temperature above 1000*F. relying upon a catalyst residence time less than 5 seconds, separating the effluent of said first reaction zone into a catalyst phase, and a hydrocarbon phase comprising C3 hydrocarbons, passing a feed comprising monocyclic aromatics admixed with C3 hydrocarbons recovered from the hydrocarbon phase of said first reaction zone with said catalyst composition through a second separate reaction zone maintained at a temperature below 1000*F. relying upon a residence time sufficient to form cyclic compounds and alkyl aromatics therein, separating an effluent of said second reaction zone into a hydrocarbon phase and a catalyst phase, recovering catalyst from said first and second reaction zone as a fluid bed of catalyst, converting a third hydrocarbon feed comprising C3 hydrocarbons in said fluid bed of catalyst before regenerating the catalyst therein, and passing catalyst separated from said first reaction zone through said second and third reaction zones.

Claim 12

A method for converting hydrocarbons to form gasoline, aromatics and alkyl aromatics which comprises, cracking high boiling hydrocarbon material admixed with a ZSM-5 crystalline zeolite and a larger pore crystalline aluminosilicate catalyst composition of different activity and selectivity characteristic in a first dispersed phase riser reaction zone at a temperature above 1000*F. relying upon a catalyst residence time less than 5 seconds, separating the effluent of said first reaction zone into a catalyst phase, and a hydrocarbon phase comprising C3 hydrocarbons, passing a feed comprising monocyclic aromatics admixed with C3 hydrocarbons recovered from the hydrocarbon phase of said first reaction zone with said catalyst composition through a second separate reaction zone maintained at a temperature below 1000*F. relying upon a residence time sufficient to form cyclic compounds and alkyl aromatics therein, separating an effluent of said second reaction zone into a hydrocarbon phase and a catalyst phase, recovering catalyst from said first and second reaction zone as a fluid bed of catalyst, converting a third hydrocarbon feed comprising C3 hydrocarbons in said fluid bed of catalyst before regenerating the catalyst therein, and passing catalyst separated from said first reaction zone through said second and third reaction zones.