Steam passivation of metal contaminants on cracking catalysts

Claim 2

A process to passivate metal contaminants on zeolitic cracking catalysts during the process of catalytic cracking of hydrocarbons without seriously affecting cracking activity, which process comprises contacting said metal contaminant-containing catalysts with steam under moderate steaming conditions sufficient to deactivate harmful metal activity present in said catalysts but insufficient to seriously adversely affect catalytic cracking activity, said steaming conditions including steam contact at a temperature between about 1000° F. and about 1400° F., for a period of time between about 1/2 hour and about 16 hours and at a partial pressure of steam between about 1/10 psia and about 1000 psia.

Claim 3

The process of claim 1 wherein the temperature is between about 1200° F. and about 1350° F.

Claim 4

The process of claim 1 wherein the period of time is between about 2 hours and about 12 hours.

Claim 5

The process of claim 1 wherein said cracking catalyst is zeolite Y in a suitable matrix.

Claim 6

The process of claim 1 wherein the process of catalytic cracking of hydrocarbons is fluid catalytic cracking.

Claim 7

A process for catalytic cracking of hydrocarbons wherein a. a metal-containing hydrocarbon feed is introduced into a cracking region; b. said feed is contacted with a zeolite cracking catalyst under cracking conditions whereby the feed is cracked; c. the cracked feed is removed from said cracking region for further processing; d. said catalyst which is now deposited with coke formed during cracking is contacted with oxygen in a regeneration zone in order to burn off a desired amount of coke; and e. metals deposited on said cracking catalyst from said feed and tending to deactivate said cracking catalyst are passivated by removing a slip stream of said cracking catalyst from the regeneration zone and contacting said slip stream with steam at a temperature between about 1000° F. and about 1400° F., for a period of time between about 1/2 hour and about 16 hours and then returning said catalyst back to the regeneration zone.

Claim 8

A process for catalytic cracking of hydrocarbons wherein a. a metal-containing hydrocarbon feed is introduced into a cracking region; b. said feed is contacted with a zeolite cracking catalyst under cracking conditions whereby the feed is cracked; c. the cracked feed is removed from said cracking region for further processing; d. said catalyst which is now deposited with coke formed during cracking is contacted with oxygen in a regeneration zone in order to burn off a desired amount of coke; and e. metals deposited on said cracking catalyst from said feed and tending to deactivate said cracking catalyst are passivated by removing a slip stream of said cracking catalyst from the regeneration zone and contacting said slip stream with steam at a temperature between about 1000° F. and about 1400° F., for a period of time between about 1/2 hour and about 16 hours and then returning said catalyst back to the regeneration zone.

Claim 9

The process of claim 6 wherein the temperature is between about 1200° F. and about 1350° F.

Claim 10

The process of claim 6 wherein the period of time is between about 2 hours and about 12 hours.

Claim 11

The process of claim 6 wherein said cracking catalyst is zeolite Y in a suitable matrix.

Claim 12

In a process which comprises contacting under cracking conditions, comprising a continuous cycle cracking reaction and catalyst regeneration procedure, a hydrocarbon feed boiling above about 450° F. with a zeolite cracking catalyst containing metal contaminants to produce a gasoline fraction, the improvement which comprises adding steam at a temperature between about 1000° F. and about 1400° F. during said regeneration in order to passivate said metal contaminants.

Claim 13

In a process which comprises contacting under cracking conditions, comprising a continuous cycle cracking reaction and catalyst regeneration procedure, a hydrocarbon feed boiling above about 450° F. with a zeolite cracking catalyst containing metal contaminants to produce a gasoline fraction, the improvement which comprises adding steam at a temperature between about 1000° F. and about 1400° F. during said regeneration in order to passivate said metal contaminants.

Claim 14

The process of claim 10 wherein the temperature is between about 1200° F. and about 1350° F.

Claim 15

The process of claim 10 wherein said cracking reaction and catalyst regeneration occur in a fluid catalytic cracking process.

Claim 16

The process of claim 10 wherein said cracking catalyst is zeolite Y in a suitable matrix.

Claim 17

In a fluid catalytic cracking process employing a hot catalyst storage hopper, which comprises contacting under cracking conditions a hydrocarbon feed boiling above about 450° F. with a zeolite cracking catalyst containing metal contaminants to produce a gasoline fraction, the improvement which comprises adding steam in said hot catalyst storage hopper at a temperature between about 1000° F. and about 1400° F.

Claim 18

In a fluid catalytic cracking process employing a hot catalyst storage hopper, which comprises contacting under cracking conditions a hydrocarbon feed boiling above about 450° F. with a zeolite cracking catalyst containing metal contaminants to produce a gasoline fraction, the improvement which comprises adding steam in said hot catalyst storage hopper at a temperature between about 1000° F. and about 1400° F.

Claim 19

The process of claim 14 wherein the temperature is between about 1200° F. and about 1350° F.

Claim 20

The process of claim 14 wherein said cracking catalyst is zeolite Y in a suitable matrix.

Claim 21

A process to achieve a predetermined level of passivation of metal contaminants on zeolite cracking catalysts during a catalytic cracking of hydrocarbons process, which comprises contacting said metal contaminant-containing catalysts with steam wherein steam temperature, steam partial pressure and steam-catalyst contact time are all simultaneously controlled in order to attain said predetermined degree of passivation.

Claim 22

A process to achieve a predetermined level of passivation of metal contaminants on zeolite cracking catalysts during a catalytic cracking of hydrocarbons process, which comprises contacting said metal contaminant-containing catalysts with steam wherein steam temperature, steam partial pressure and steam-catalyst contact time are all simultaneously controlled in order to attain said predetermined degree of passivation.

Claim 23

The process of claim 17 wherein the steam temperature is between about 1000° F. and about 1400° F.

Claim 24

The process of claim 18 wherein the steam temperature is between about 1200° F. and about 1350° F.

Claim 25

The process of claim 17 wherein the steam-catalyst contact time is between about 1/2 hour and about 16 hours.

Claim 26

The process of claim 20 wherein the steam-catalyst contact time is between about 2 hours and about 12 hours.

Claim 27

The process of claim 17 wherein said cracking catalyst is zeolite Y in a suitable matrix.

Claim 28

The process of claim 17 wherein the process of catalytic cracking of hydrocarbons is fluid catalytic cracking.

Claim 29

The process of claim 17 wherein said level of passivation is determined by the group of measurements consisting of total dry gas make, hydrogen molar yield and hydrogen factor.