US4472267A — Catalyst and process for conversion of hydrocarbo…

Claim 1

Independent Claim 257 words

In a hydrocarbon conversion process for converting a sulfur-containing hydrocarbon feedstock which comprises (1) contacting said feedstock with solid 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 solid particles thereby forming deposit-containing particles; (2) contacting said deposit-containing particles 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 solid particles and to form a regeneration zone flue gas containing sulfur trioxide; and (3) repeating steps (1) and (2) periodically, the improvement which comprises: using, in intimate admixture with said solid particles, a minor amount of discrete entities having a composition different from said solid particles and comprising at least one alkaline earth metal-containing spinel including alkaline earth metal and a second metal having a valence higher than the valence of said alkaline earth metal, the atomic ratio of said alkaline earth metal to said second metal in said spinel being at least about 0.25 and said spinel having a surface area in the range of about 25 m 2 /gm. to about 600 m 2 /gm., and a minor amount of at least one rare earth metal component, said discrete entities being present in an amount sufficient to reduce the amount of sulfur oxides in said flue gas.

Claim 2

Dependent Claim 257 words

In a hydrocarbon conversion process for converting a sulfur-containing hydrocarbon feedstock which comprises (1) contacting said feedstock with solid 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 solid particles thereby forming deposit-containing particles; (2) contacting said deposit-containing particles 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 solid particles and to form a regeneration zone flue gas containing sulfur trioxide; and (3) repeating steps (1) and (2) periodically, the improvement which comprises: using, in intimate admixture with said solid particles, a minor amount of discrete entities having a composition different from said solid particles and comprising at least one alkaline earth metal-containing spinel including alkaline earth metal and a second metal having a valence higher than the valence of said alkaline earth metal, the atomic ratio of said alkaline earth metal to said second metal in said spinel being at least about 0.25 and said spinel having a surface area in the range of about 25 m 2 /gm. to about 600 m 2 /gm., and a minor amount of at least one rare earth metal component, said discrete entities being present in an amount sufficient to reduce the amount of sulfur oxides in said flue gas.

Claim 3

Dependent Claim 37 words

The process of claim 1 wherein said conversion comprises hydrocarbon cracking in the substantial absence of added molecular hydrogen, said solid particles and discrete entities being fluidizable and circulating between said reaction zone and said regeneration zone.

Claim 4

Dependent Claim 19 words

The process of claim 2 wherein said hydrocarbon feedstock contains about 0.01% to about 5.0% by weight of sulfur.

Claim 5

Dependent Claim 44 words

The process of claim 2 wherein said discrete entities further comprise a minor amount of at least one material selected from the group consisting of alumina, silica, zirconia, magnesia, aluminosilicate capable of promoting hydrocarbon cracking at the conditions of step (1) and mixtures thereof.

Claim 6

Dependent Claim 19 words

The process of claim 2 wherein said discrete entities contain at least about 70% by weight of said spinel.

Claim 7

Dependent Claim 60 words

The process of claim 2 wherein said spinel includes magnesium and aluminum, the atomic ratio of magnesium to aluminum in said spinel is in the range of about 0.25 to about 0.75, and said rare earth metal component comprises at least one cerium component present in an amount of about 1% to about 25% by weight of said discrete entities.

Claim 8

Dependent Claim 50 words

The process of claim 2 wherein said solid particles are separate from said discrete entities and the relative amounts of said solid particles and said discrete entities 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

Dependent Claim 26 words

The process of claim 2 wherein said solid particles comprise at least one crystalline aluminosilicate capable of promoting hydrocarbon cracking at the conditions of step (1).

Claim 10

Dependent Claim 28 words

The process of claim 2 wherein said rare earth metal component is present in an amount of about 1% to about 25% by weight of said discrete entities.

Claim 11

Dependent Claim 19 words

The process of claim 2 wherein said discrete entities contain at least about 90% by weight of said spinel.

Claim 12

Dependent Claim 47 words

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

Claim 13

Dependent Claim 47 words

The process of claim 6 wherein at least one of said solid particles and discrete entities further comprise a minor, catalytically effective amount of at least one additional metal component capable of promoting the conversion of sulfur dioxide to sulfur trioxide at the conditions of step (2).

Claim 14

Dependent Claim 18 words

The process of claim 11 wherein said additional metal component is at least one platinum group metal component.

Claim 15

Dependent Claim 18 words

The process of claim 12 wherein said additional metal component is at least one platinum group metal component.

Claim 16

Dependent Claim 77 words

The process of claim 2 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 17

Dependent Claim 77 words

The process of claim 6 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 18

Dependent Claim 33 words

The process of claim 2 wherein said spinel includes magnesium and aluminum and the atomic ratio of magnesium to aluminum in said spinel is in the range of about 0.35 to about 0.65.

Claim 19

Dependent Claim 26 words

The process of claim 17 wherein the atomic ratio of magnesium to aluminum in said spinel is in the range of about 0.45 to about 0.55.

Claim 20

Dependent Claim 57 words

The process of claim 8 wherein said discrete entities further comprise at least one platinum component in an amount of about 0.05 ppm. to about 1% by weight of said discrete entities, calculated as elemental metal, said platinum component being capable of promoting the conversion of sulfur dioxide to sulfur trioxide at the conditions of step (2).

Claim 21

Dependent Claim 24 words

The process of claim 1 wherein said discrete entities further comprise about 0.1% to about 25% by weight of free magnesia, calculated as MgO.

Claim 22

Dependent Claim 24 words

The process of claim 2 wherein said discrete entities further comprise about 0.1% to about 25% by weight of free magnesia, calculated as MgO.

Claim 23

Dependent Claim 24 words

The process of claim 6 wherein said discrete entities further comprise about 0.1% to about 25% by weight of free magnesia, calculated as MgO.

Claim 24

Dependent Claim 24 words

The process of claim 7 wherein said discrete entities further comprise about 0.1% to about 25% by weight of free magnesia, calculated as MgO.

Claim 25

Dependent Claim 24 words

The process of claim 11 wherein said discrete entities further comprise about 0.1% to about 25% by weight of free magnesia, calculated as MgO.

Claim 26

Dependent Claim 27 words

The process of claim 6 wherein said spinel has a surface area in the range of about 40 m 2 /gm. to about 400 m 2 /gm.

Claim 27

Dependent Claim 27 words

The process of claim 9 wherein said spinel has a surface area in the range of about 50 m 2 /gm. to about 300 m 2 /gm.

Claim 28

Dependent Claim 19 words

The process of claim 1 wherein said solid particles and said discrete entities are both present in combined particles.

Claim 29

Dependent Claim 137 words

In a process for combusting solid, sulfur-containing material by contacting said material with a gaseous oxygen in a combustion zone at combustion conditions to produce combustion products including at least one sulfur oxide, the improvement comprising carrying out said contacting in the presence of discrete particles containing an alkaline earth metal-containing spinel including alkaline earth metal and a second metal having a valence higher than the valence of said alkaline earth metal, the atomic ratio of said alkaline earth metal to said second metal in spinel being at least about 0.25 and said spinel has a surface area in the range of about 25 m 2 /gm. to about 600 m 2 /gm., and a minor amount of at least one rare earth metal component, thereby reducing the amount of sulfur oxide emitted from said combustion zone.

Claim 30

Dependent Claim 137 words

In a process for combusting solid, sulfur-containing material by contacting said material with a gaseous oxygen in a combustion zone at combustion conditions to produce combustion products including at least one sulfur oxide, the improvement comprising carrying out said contacting in the presence of discrete particles containing an alkaline earth metal-containing spinel including alkaline earth metal and a second metal having a valence higher than the valence of said alkaline earth metal, the atomic ratio of said alkaline earth metal to said second metal in spinel being at least about 0.25 and said spinel has a surface area in the range of about 25 m 2 /gm. to about 600 m 2 /gm., and a minor amount of at least one rare earth metal component, thereby reducing the amount of sulfur oxide emitted from said combustion zone.

Claim 31

Dependent Claim 239 words

In a hydrocarbon conversion process for converting a sulfur-containing hydrocarbon feedstock which comprises (1) contacting said feedstock with solid 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 solid particles thereby forming deposit-containing particles; (2) contacting said deposit-containing particles 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 solid particles and to form a regeneration zone flue gas containing sulfur trioxide; and (3) repeating steps (1) and (2) periodically, the improvement which comprises: using, in intimate admixture with said solid particles, a minor amount of discrete entities having a composition different from said solid particles and comprising a major amount of at least one alkaline earth metal-containing spinel including alkaline earth metal and a second metal having a valence higher than the valence of said alkaline earth metal, the atomic ratio of said alkaline earth metal to said second metal in said spinel being at least about 0.25, and a minor amount of at least one rare earth metal component, said discrete entities being present in an amount sufficient to reduce the amount of sulfur oxides in said flue gas.

Claim 32

Dependent Claim 239 words

In a hydrocarbon conversion process for converting a sulfur-containing hydrocarbon feedstock which comprises (1) contacting said feedstock with solid 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 solid particles thereby forming deposit-containing particles; (2) contacting said deposit-containing particles 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 solid particles and to form a regeneration zone flue gas containing sulfur trioxide; and (3) repeating steps (1) and (2) periodically, the improvement which comprises: using, in intimate admixture with said solid particles, a minor amount of discrete entities having a composition different from said solid particles and comprising a major amount of at least one alkaline earth metal-containing spinel including alkaline earth metal and a second metal having a valence higher than the valence of said alkaline earth metal, the atomic ratio of said alkaline earth metal to said second metal in said spinel being at least about 0.25, and a minor amount of at least one rare earth metal component, said discrete entities being present in an amount sufficient to reduce the amount of sulfur oxides in said flue gas.

Claim 33

Dependent Claim 37 words

The process of claim 29 wherein said conversion comprises hydrocarbon cracking in the substantial absence of added molecular hydrogen, said solid particles and discrete entities being fluidizable and circulating between said reaction zone and said regeneration zone.

Claim 34

Dependent Claim 19 words

The process of claim 30 wherein said hydrocarbon feedstock contains about 0.01% to about 5.0% by weight of sulfur.

Claim 35

Dependent Claim 44 words

The process of claim 31 wherein said discrete entities further comprise a minor amount of at least one material selected from the group consisting of alumina, silica, zirconia, magnesia, aluminosilicate capable of promoting hydrocarbon cracking at the conditions of step (1) and mixtures thereof.

Claim 36

Dependent Claim 19 words

The process of claim 31 wherein said discrete entities contain at least about 70% by weight of said spinel.

Claim 37

Dependent Claim 60 words

The process of claim 31 wherein said spinel includes magnesium and aluminum, the atomic ratio of magnesium to aluminum in said spinel is in the range of about 0.25 to about 0.75, and said rare earth metal component comprises at least one cerium component present in an amount of about 1% to about 25% by weight of said discrete entities.

Claim 38

Dependent Claim 50 words

The process of claim 31 wherein said solid particles are separate from said discrete entities and the relative amounts of said solid particles and said discrete entities are in the range of about 80 parts to about 99 parts and about 1 part to about 20 parts by weight, respectively.

Claim 39

Dependent Claim 26 words

The process of claim 31 wherein said solid particles comprise at least one crystalline aluminosilicate capable of promoting hydrocarbon cracking at the conditions of step (1).

Claim 40

Dependent Claim 28 words

The process of claim 31 wherein said rare earth metal component is present in an amount of about 1% to about 25% by weight of said discrete entities.

Claim 41

Dependent Claim 19 words

The process of claim 31 wherein said discrete entities contain at least about 90% by weight of said spinel.

Claim 42

Dependent Claim 47 words

The process of claim 31 wherein at least one of said solid particles and discrete entities further comprise a minor, catalytically effective amount of at least one additional metal component capable of promoting the conversion of sulfur dioxide to sulfur trioxide at the conditions of step (2).

Claim 43

Dependent Claim 47 words

The process of claim 34 wherein at least one of said solid particles and discrete entities further comprise a minor, catalytically effective amount of at least one additional metal component capable of promoting the conversion of sulfur dioxide to sulfur trioxide at the conditions of step (2).

Claim 44

Dependent Claim 18 words

The process of claim 39 wherein said additional metal component is at least one platinum group metal component.

Claim 45

Dependent Claim 18 words

The process of claim 40 wherein said additional metal component is at least one platinum group metal component.

Claim 46

Dependent Claim 77 words

The process of claim 31 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 47

Dependent Claim 77 words

The process of claim 34 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 48

Dependent Claim 33 words

The process of claim 31 wherein said spinel includes magnesium and aluminum and the atomic ratio of magnesium to aluminum in said spinel is in the range of about 0.35 to about 0.65.

Claim 49

Dependent Claim 26 words

The process of claim 45 wherein the atomic ratio of magnesium to aluminum in said spinel is in the range of about 0.45 to about 0.55.

Claim 50

Dependent Claim 57 words

The process of claim 36 wherein said discrete entities further comprise at least one platinum component in an amount of about 0.05 ppm. to about 1% by weight of said discrete entities, calculated as elemental metal, said platinum component being capable of promoting the conversion of sulfur dioxide to sulfur trioxide at the conditions of step (2).

Claim 51

Dependent Claim 24 words

The process of claim 29 wherein said discrete entities further comprise about 0.1% to about 25% by weight of free magnesia, calculated as MgO.

Claim 52

Dependent Claim 24 words

The process of claim 30 wherein said discrete entities further comprise about 0.1% to about 25% by weight of free magnesia, calculated as MgO.

Claim 53

Dependent Claim 24 words

The process of claim 34 wherein said discrete entities further comprise about 0.1% to about 25% by weight of free magnesia, calculated as MgO.

Claim 54

Dependent Claim 19 words

The process of claim 29 wherein said solid particles and said discrete entities are both present in combined particles.

Claim 55

Dependent Claim 119 words

In a process for combusting solid, sulfur-containing material by contacting said material with a gaseous oxygen in a combustion zone at combustion conditions to produce combustion products including at least one sulfur oxide, the improvement comprising carrying out said contacting in the presence of discrete particles containing a major amount of an alkaline earth metal-containing spinel including alkaline earth metal and a second metal having a valence higher than the valence of said alkaline earth metal, the atomic ratio of said alkaline earth metal to said second metal in spinel being at least about 0.25, and a minor amount of at least one rare earth metal component, thereby reducing the amount of sulfur oxide emitted from said combustion zone.

Claim 56

Dependent Claim 119 words

In a process for combusting solid, sulfur-containing material by contacting said material with a gaseous oxygen in a combustion zone at combustion conditions to produce combustion products including at least one sulfur oxide, the improvement comprising carrying out said contacting in the presence of discrete particles containing a major amount of an alkaline earth metal-containing spinel including alkaline earth metal and a second metal having a valence higher than the valence of said alkaline earth metal, the atomic ratio of said alkaline earth metal to said second metal in spinel being at least about 0.25, and a minor amount of at least one rare earth metal component, thereby reducing the amount of sulfur oxide emitted from said combustion zone.

Claim 57

Dependent Claim 38 words

The process of claim 29 wherein said discrete particles further comprise a minor catalytically effective amount of at least one additional metal component capable of promoting the conversion of sulfur dioxide to sulfur trioxide at said combustion conditions.

Claim 58

Dependent Claim 24 words

The process of claim 29 wherein said discrete particles further comprise about 0.1% to about 25% by weight of free magnesia, calculated as MgO.

Claim 59

Dependent Claim 38 words

The process of claim 52 wherein said discrete particles further comprise a minor catalytically effective amount of at least one additional metal component capable of promoting the conversion of sulfur dioxide to sulfur trioxide at said combustion conditions.

Claim 60

Dependent Claim 24 words

The process of claim 52 wherein said discrete particles further comprise about 0.1% to about 25% by weight of free magnesia, calculated as MgO.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1987-09-18	1988-03-19	1988-09-18	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1991-09-18	1992-03-19	1992-09-18	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1995-09-18	1996-03-19	1996-09-18	$7700.00	Window Closed / Lapsed

Catalyst and process for conversion of hydrocarbons

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