Catalyst and process for conversion of hydrocarbons

Claim 2

In a process for converting a hydrocarbon feedstock which comprises (1) contacting said feedstock in at least one reaction zone with catalyst particles capable of promoting the conversion of said feedstock at hydrocarbon conversion conditions to produce at least one hydrocarbon product and to cause deactivating carbonaceous material to be formed on said catalyst particles, thereby forming deposit-containing particles; (2) contacting said deposit-containing particles in at least one regeneration zone with an oxygen-containing vaporous medium at conditions to combust at least a portion of said carbonaceous deposit material to thereby regenerate at least a portion of the hydrocarbon conversion catalytic activity of said catalyst particles and to form at least one carbonaceous deposit material combustion product; and (3) repeating step (1) and (2) periodically, the improvement which comprises: circulating between said reaction zone and said regeneration zone, as at least a portion of said catalyst particles, combined particles comprising (1) a major amount of solid particles capable of promoting hydrocarbon conversion in said reaction zone and (2) a minor amount of discrete entities comprising (A) a major amount by weight of substantially accessible alumina, (B) a minor, catalytically effective amount of at least one platinum group metal component disposed on said alumina, and (C) a minor, catalytically effective amount of at least one crystalline aluminosilicate capable of promoting hydrocarbon conversion at the conditions in said reaction zone, said metal component being capable of promoting the oxidation of carbon monoxide to carbon dioxide at the conditions of step (2), thereby promoting the oxidation of carbon monoxide to carbon dioxide in said regeneration zone, said discrete entities having been calcined prior to being incorporated into said combined particles.

Claim 3

The process of claim 1 wherein said conversion comprises hydrocarbon cracking and said reaction zone and regeneration zone is a fluidized bed reaction zone and a fluidized bed regeneration zone.

Claim 4

The process of claim 2 wherein said platinum group metal component is present in an amount of about 0.05 ppm. to about 1% by weight of said discrete entities, calculated as elemental metal.

Claim 5

The process of claim 3 wherein said solid particles are about 60% to about 99% by weight of said combined particles and said discrete entities are about 1% to about 40% by weight of said combined particles.

Claim 6

The process of claim 4 wherein said alumina is gamma alumina.

Claim 7

The process of claim 5 wherein said discrete entities contain at least about 70% by weight of gamma alumina and said platinum group metal component comprises a metal selected from the group consisting of platinum, palladium and mixtures thereof and is present in an amount of about 0.05 ppm. to about 1000 ppm. by weight of the total discrete entities, calculated as elemental metal.

Claim 8

The process of claim 6 wherein said solid particles comprise a catalytically effective amount of at least one crystalline aluminosilicate capable of promoting said hydrocarbon cracking at the conditions in said reaction zone, said platinum group metal component is substantially uniformly disposed on said alumina of said discrete entities and the relative amounts of said solid particles and said discrete entities in said combined particles are in the range of about 80 parts to about 99 parts and about 1 part to about 20 parts by weight, respectively.

Claim 9

The process of claim 7 wherein the relative amounts of said solid particles and said discrete entities in said combined particles are in the range of about 90 parts to about 99 parts and about 1 part to about 10 parts by weight, respectively.

Claim 10

The process of claim 8 wherein said feedstock contains a minor amount of sulfur.

Claim 11

In a hydrocarbon conversion process for converting a sulfur-containing hydrocarbon feedstock which comprises (1) contacting said feedstock with catalyst particles capable of promoting the conversion of said feedstock at hydrocarbon conversion conditions in at least one reaction zone to produce at least one hydrocarbon product and to cause deactivating sulfur-containing carbonaceous material to be formed on said catalyst particles thereby forming deposit-containing particles; (2) contacting said deposit-containing with an oxygen containing vaporous medium at conditions to combust at least a portion of said carbonaceous deposit material in at least one regeneration zone to thereby regenerate at least a portion of the hydrocarbon conversion catalytic activity of said catalyst particles and to form a regeneration zone flue gas containing at least one sulfur-containing carbonaceous deposit material combustion product; and (3) repeating step (1) and (2) periodically, the improvement which comprises: reducing the amount of sulfur in said regeneration zone flue gas using, as at least a portion of said catalyst particles, combined particles comprising (1) a major amount of solid particles capable of promoting hydrocarbon conversion in said reaction zone and (2) a minor amount of discrete entities comprising a major amount by weight of substantially accessible alumina capable of associating with sulfur trioxide at the conditions of step (2) and capable of disassociating with sulfur trioxide at the conditions of step (1), and a minor, catalytically effective amount of at least one crystalline aluminosilicate capable of promoting hydrocarbon conversion at the conditions in said reaction zone, thereby associating at least a portion of said sulfur-containing combustion product with said discrete entities in said regeneration zone and disassociating at least a portion of said sulfur-containing combustion product from said discrete entities in said reaction zone to form H 2 S which exits said reaction zone with said hydrocarbon product, said discrete entities having been calcined prior to being incorporated into said combined particles.

Claim 12

In a hydrocarbon conversion process for converting a sulfur-containing hydrocarbon feedstock which comprises (1) contacting said feedstock with catalyst particles capable of promoting the conversion of said feedstock at hydrocarbon conversion conditions in at least one reaction zone to produce at least one hydrocarbon product and to cause deactivating sulfur-containing carbonaceous material to be formed on said catalyst particles thereby forming deposit-containing particles; (2) contacting said deposit-containing with an oxygen containing vaporous medium at conditions to combust at least a portion of said carbonaceous deposit material in at least one regeneration zone to thereby regenerate at least a portion of the hydrocarbon conversion catalytic activity of said catalyst particles and to form a regeneration zone flue gas containing at least one sulfur-containing carbonaceous deposit material combustion product; and (3) repeating step (1) and (2) periodically, the improvement which comprises: reducing the amount of sulfur in said regeneration zone flue gas using, as at least a portion of said catalyst particles, combined particles comprising (1) a major amount of solid particles capable of promoting hydrocarbon conversion in said reaction zone and (2) a minor amount of discrete entities comprising a major amount by weight of substantially accessible alumina capable of associating with sulfur trioxide at the conditions of step (2) and capable of disassociating with sulfur trioxide at the conditions of step (1), and a minor, catalytically effective amount of at least one crystalline aluminosilicate capable of promoting hydrocarbon conversion at the conditions in said reaction zone, thereby associating at least a portion of said sulfur-containing combustion product with said discrete entities in said regeneration zone and disassociating at least a portion of said sulfur-containing combustion product from said discrete entities in said reaction zone to form H 2 S which exits said reaction zone with said hydrocarbon product, said discrete entities having been calcined prior to being incorporated into said combined particles.

Claim 13

The process of claim 10 wherein said conversion comprises hydrocarbon cracking, said solid particles being fluidizable and circulating between said reaction zone and said regeneration zone.

Claim 14

The process of claim 11 wherein said solid particles are about 60% to about 99% by weight of said combined particles and said discrete entities are about 1% to about 40% by weight of said combined particles.

Claim 15

The process of claim 12 wherein said alumina is gamma alumina.

Claim 16

The process of claim 13 wherein said discrete entities contain at least about 70% by weight of alumina and said alumina has a surface area of about 25 m. 2 /gm. to about 600 m. 2 /gm.

Claim 17

The process of claim 14 wherein said discrete entities further comprise a minor amount of at least one material selected from the group consisting of silica, zirconia, magnesia and mixtures thereof.

Claim 18

The process of claim 14 wherein said hydrocarbon feedstock contains about 0.01% to about 5% by weight of sulfur, said solid particles comprise a catalytically effective amount of at least one crystalline aluminosilicate capable of promoting said hydrocarbon cracking at the conditions in said reaction zone and the relative amounts of said solid particles and said discrete entities in said combined particles are in the range of about 80 parts to about 99 parts and about 1 part to about 20 parts by weight, respectively.

Claim 19

The process of claim 16 wherein the relative amounts of said solid particles and said discrete entities in said combined particles are in the range of about 90 parts to about 99 parts and about 1 part to about 10 parts by weight, respectively.

Claim 20

The process of claim 10 wherein said discrete entities further comprise a minor catalytically effective amount of at least one metal component capable of promoting the conversion of sulfur dioxide to sulfur trioxide at the conditions of step (2).

Claim 21

The process of claim 11 wherein said discrete entities further comprise a minor, catalytically effective amount of at least one platinum group metal component capable of promoting the conversion of sulfur dioxide to sulfur trioxide at the conditions of step (2).

Claim 22

The process of claim 11 wherein said discrete entities further comprise a minor, catalytically effective amount of at least one platinum group metal component capable of promoting the conversion of sulfur dioxide to sulfur trioxide at the conditions of step (2).

Claim 23

The process of claim 12 wherein said discrete entities further comprise at least one platinum group metal component in an amount of about 0.05 ppm. to about 1% by weight of said discrete entities, calculated as elemental metal, said platinum group metal component being capable of promoting the conversion of sulfur dioxide to sulfur trioxide at the conditions of step (2), said platinum group metal being selected from the group consisting of platinum, palladium and mixtures thereof.

Claim 24

The process of claim 13 wherein said discrete entities further comprise at least one platinum group metal component in an amount of about 0.05 ppm. to about 1% by weight of said discrete entities, calculated as elemental metal, said platinum group metal component being capable of promoting the conversion of sulfur dioxide to sulfur trioxide at the conditions of step (2), said platinum group metal being selected from the group consisting of platinum, palladium and mixtures thereof.

Claim 25

The process of claim 15 wherein said discrete entities further comprise at least one platinum group metal component in an amount of about 0.05 ppm. to about 1% by weight of said discrete entities, calculated as elemental metal, said platinum group metal component being capable of promoting the conversion of sulfur dioxide to sulfur trioxide at the conditions of step (2), said platinum group metal being selected from the group consisting of platinum, palladium and mixtures thereof.

Claim 26

The process of claim 17 wherein said discrete entities further comprise at least one platinum group metal component in an amount of about 0.05 ppm. to about 1% by weight of said discrete entities, calculated as elemental metal, said platinum group metal component being capable of promoting the conversion of sulfur dioxide to sulfur trioxide at the conditions of step (2), said platinum group metal being selected from the group consisting of platinum, palladium and mixtures thereof.