Cracking catalyst improvement with gallium compounds

Claim 2

In a catalytic cracking process wherein a zeolite-containing catalyst is circulated in a cracking unit between a cracking zone and a regeneration zone in a cyclic fashion, said process comprising: (a) introducing the cracking catalyst and a hydrocarbon feedstock into the cracking zone, said hydrocarbon feedstock containing contaminants selected from the group consisting of nickel, vanadium, and iron; (b) contacting the cracking catalyst with the hydrocarbon feedstock in the cracking zone under cracking conditions including the absence of added hydrogen wherein at least a portion of the contaminants in the feedstock become deposited on the cracking catalyst; (c) withdrawing an effluent of cracking catalyst and cracked hydrocarbon feedstock from the cracking zone; (d) separating the cracking catalyst from the effluent; (e) introducing the cracking catalyst into a regeneration zone; (f) regenerating the cracking catalyst under elevated temperatures and in the presence of free oxygen-containing gas wherein contaminants deposited on the catalyst from the feedstock prevent complete regeneration of the cracking catalyst; and (g) recycling the cracking catalyst to the cracking zone; the improvement comprising circulating a gallium-treated cracking catalyst in the cracking unit, said gallium-treated cracking catalyst having been contacted with a gallium-containing treating agent under conditions to deposit thereon a passivating amount of gallium or a gallium compound.

Claim 3

A process as in claim 1 further comprising introducing into the hydrocarbon feedstock at least one of gallium and a gallium compound.

Claim 4

A process as in claim 2 further comprising introducing into the hydrocarbon feedstock at least one of antimony and an antimony compound.

Claim 5

A process as in claim 2 wherein the cracking conditions include a temperature within the range of about 427°-649° C. and wherein the regeneration conditions include a temperature within the range of about 538°-816° C. and wherein the free oxygen-containing gas comprises air.

Claim 6

A process as in claim 3 wherein the cracking conditions include a temperature within the range of about 482°-538° C. and a contact time between cracking catalyst and feedstock within the range of from about 1 to about 10 seconds, and wherein the regeneration conditions include a temperature within the range of about 620°-677° C.

Claim 7

A process as in claim 5 wherein the hydrocarbon feedstock has an end boiling point above about 400° C.

Claim 8

A process as in claim 1 wherein the cracking catalyst has a particle size in the range of from about 10 to about 100 microns, and wherein the regenerating is carried out in a regeneration zone apart from the cracking zone.

Claim 9

A process as in claim 7 wherein the cracking catalyst comprises from about 0.0001 to about 10 weight percent of gallium deposited thereon.

Claim 10

A process as in claim 8 wherein the cracking catalyst comprises about 0.001 to about 1 weight percent of gallium deposited thereon.

Claim 11

A process as in claim 2 wherein a sufficient amount of gallium and antimony are introduced into the hydrocarbon feedstock to impart to the cracking catalyst a concentration of antimony of from about 0.01 to about 1 weight percent and a concentration of gallium of from about 0.001 to about 0.25 weight percent.

Claim 12

A process as in claim 9 wherein the gallium is introduced into the hydrocarbon feedstock in the form of a finely divided particulate suspended in a hydrocarbon oil.

Claim 13

A process as in claim 11 wherein the gallium is introduced into the hydrocarbon feedstock in the form of a solution of gallium compound in a suitable solvent.

Claim 14

A process as in claim 11 wherein a sufficient amount of gallium is introduced into the feedstock so as to impart to the feedstock a concentration of gallium of between about 1 and about 200 parts per million based on weight of feedstock entering the cracking zone.

Claim 15

A process as in claim 12 wherein a sufficient amount of gallium is introduced into the feedstock so as to impart to the feedstock a concentration of gallium of between about 1 and about 200 parts per million based on weight of feedstock entering the cracking zone.

Claim 16

A process as in claim 12 wherein a sufficient amount of gallium is introduced into the feedstock so as to impart to the feedstock a concentration of gallium of between about 5 and about 50 parts per million based on weight of feedstock entering the cracking zone.

Claim 17

A process as in claim 14 wherein a sufficient amount of gallium is introduced into the feedstock so as to impart to the feedstock a concentration of gallium of between about 5 and 50 parts per million by weight.

Claim 18

A process as in claim 15 wherein the cracking catalyst comprises from about 0.005 to about 0.25 weight percent of gallium.

Claim 19

In a catalyst cracking process wherein a zeolite-containing cracking catalyst is circulated in a cracking unit between a cracking zone and a regeneration zone in a cyclic fashion, said process comprising: (a) introducing the cracking catalyst and a hydrocarbon feedstock into the cracking zone, said hydrocarbon feedstock containing contaminants selected from the group consisting of nickel, vanadium, and iron; (b) contacting the cracking catalyst with the hydrocarbon feedstock in the cracking zone under cracking conditions including the absence of added hydrogen wherein at least a portion of the contaminants in the feedstock become deposited on the cracking catalyst; (c) withdrawing an effluent of cracking catalyst and cracked hydrocarbon feedstock including a gasoline fraction from the cracking zone; (d) separating the cracking catalyst from the effluent; (e) introducing the cracking catalyst into a regeneration zone; (f) regenerating the cracking catalyst under elevated temperatures and in the presence of free oxygen-containing gas wherein contaminants deposited on the catalyst from the feedstock prevent complete regeneration of the cracking catalyst; and (g) recycling the cracking catalyst to the cracking zone; wherein an antimony-treated cracking catalyst is circulated in the cracking unit, said antimony-treated cracking catalyst having been contacted with an antimony-containing treating agent under conditions to deposit thereon a sufficient amount of antimony or an antimony-compound to at least partially passivate the at least one contaminant deposited on the catalyst from the feedstock; the improvement comprising contacting the cracking catalyst with a treating agent selected from the group consisting of gallium and a compound of gallium, whereby the portion of the cracked hydrocarbon feedstock forming the gasoline fraction is increased.

Claim 20

In a catalyst cracking process wherein a zeolite-containing cracking catalyst is circulated in a cracking unit between a cracking zone and a regeneration zone in a cyclic fashion, said process comprising: (a) introducing the cracking catalyst and a hydrocarbon feedstock into the cracking zone, said hydrocarbon feedstock containing contaminants selected from the group consisting of nickel, vanadium, and iron; (b) contacting the cracking catalyst with the hydrocarbon feedstock in the cracking zone under cracking conditions including the absence of added hydrogen wherein at least a portion of the contaminants in the feedstock become deposited on the cracking catalyst; (c) withdrawing an effluent of cracking catalyst and cracked hydrocarbon feedstock including a gasoline fraction from the cracking zone; (d) separating the cracking catalyst from the effluent; (e) introducing the cracking catalyst into a regeneration zone; (f) regenerating the cracking catalyst under elevated temperatures and in the presence of free oxygen-containing gas wherein contaminants deposited on the catalyst from the feedstock prevent complete regeneration of the cracking catalyst; and (g) recycling the cracking catalyst to the cracking zone; wherein an antimony-treated cracking catalyst is circulated in the cracking unit, said antimony-treated cracking catalyst having been contacted with an antimony-containing treating agent under conditions to deposit thereon a sufficient amount of antimony or an antimony-compound to at least partially passivate the at least one contaminant deposited on the catalyst from the feedstock; the improvement comprising contacting the cracking catalyst with a treating agent selected from the group consisting of gallium and a compound of gallium, whereby the portion of the cracked hydrocarbon feedstock forming the gasoline fraction is increased.

Claim 21

A process as in claim 18 further comprising introducing into the hydrocarbon feedstock at least one of gallium and a gallium compound.

Claim 22

A process as in claim 19 further comprising introducing into the hydrocarbon feedstock at least one of antimony and an antimony compound.

Claim 23

A process as in claim 20 wherein a sufficient amount of gallium and antimony are introduced into the hydrocarbon feedstock to impart to the cracking catalyst a concentration of antimony of from about 0.01 to about 1 weight percent and a concentration of gallium of from about 0.001 to about 0.25 percent.