Cracking catalyst and process

Claim 2

A cracking process comprising the step of contacting a hydrocarbon-containing feed stream having an initial boiling point of at least about 400° F., measured at atmospheric pressure conditions, with a cracking catalyst composition comprising (a) zeolite and (b) a matrix material, in which said zeolite is embedded, comprising aluminum phosphate, wherein said matrix material is substantially free of alumina and magnesia, under such cracking conditions as to obtain at least one liquid product stream having a lower initial boiling point and a higher API gravity than said feed stream.

Claim 3

A cracking process in accordance with claim 1 wherein said feed stream has a boiling range of from about 400° to about 1300° F. and an API 60 gravity of from about 5 to about 40.

Claim 4

A cracking process in accordance with claim 2 wherein said boiling range is about 600° to about 1200° F.

Claim 5

A cracking process in accordance with claim 1 wherein said feed stream is a hydrotreated residuum.

Claim 6

A cracking process in accordance with claim 1 wherein said zeolite (a) is a zeolite Y having a BET/N 2 surface area in the range of from about 200 to about 1000 m 2 /g.

Claim 7

A cracking process in accordance with clain 1 wherein said matrix material (b) consists essentially of aluminum phosphate.

Claim 8

A cracking process in accordance with clain 1 wherein said matrix material (b) consists essentially of aluminum phosphate.

Claim 9

A cracking process in accordance with claim 1 wherein the BET/N 2 surface area of said matrix material (b) exceeds about 50 m 2 /g.

Claim 10

A cracking process in accordance with claim 1 wherein the BET/N 2 surface area of said matrix material (b) is in the range of from about 50 to about 300 m 2 /g.

Claim 11

A cracking process in accordance with claim 1 wherein the atomic ratio of Al to P in said aluminum phosphate is in the range of from about 0.9:1 to about 1:1.

Claim 12

A cracking process in accordance with claim 1 wherein the weight ratio of said zeolite (a) to said matrix material (b) is in the range of from about 1:30 to about 1:1.

Claim 13

A cracking process in accordance with claim 1, wherein said cracking catalyst composition has a BET/N 2 surface area in the range of from about 50 to about 800 m 2 /g.

Claim 14

A cracking process in accordance with claim 1 wherein said cracking process is carried out in a fluidized-bed cracking reactor.

Claim 15

A cracking process in accordance with claim 1 wherein said contacting conditions comprise a cracking temperature of about 800°-1200° F., a contact time between said feed stream and said cracking catalyst composition of about 0.2-3 seconds and a weight ratio of said catalyst composition to said feed stream of about 2:1 to about 10:1.

Claim 16

A cracking process in accordance with claim 13 wherein said cracking conditions further comprise the presence of steam at a weight ratio of said steam to said feed steam of about 0.01:1 to about 0.5:1.

Claim 17

A cracking process comprising the steps of (A) contacting a hydrocarbon-containing feed stream having an initial boiling point of at least about 400° F., measured at atmospheric pressure conditions, with a cracking catalyst composition comprising (a) zeolite and (b) a matrix material, in which said zeolite is embedded, comprising aluminum phosphate, wherein said matrix material is substantially free of alumina and magnesia, under such cracking conditions as to obtain at least one liquid product stream having a lower initial boiling point and a higher API gravity than said feed stream; (B) separating the cracking catalyst composition, which has been used in step (A), from formed gases and said at least one liquid product; (C) exposing the separated cracking catalyst composition obtained in step (B) to flowing steam under such conditions as to strip liquids which are adhered to said separated catalyst composition; (D) heating the steam-stripped cracking catalyst composition obtained in step (C) in a free oxygen containing gas under such conditions as to burn off substantially all coke deposited on said steam-stripped cracking catalyst composition; and (E) recycling at least a portion of the regenerated catalyst composition obtained in step (D) to the cracking zone of step (A).

Claim 18

A cracking process comprising the steps of (A) contacting a hydrocarbon-containing feed stream having an initial boiling point of at least about 400° F., measured at atmospheric pressure conditions, with a cracking catalyst composition comprising (a) zeolite and (b) a matrix material, in which said zeolite is embedded, comprising aluminum phosphate, wherein said matrix material is substantially free of alumina and magnesia, under such cracking conditions as to obtain at least one liquid product stream having a lower initial boiling point and a higher API gravity than said feed stream; (B) separating the cracking catalyst composition, which has been used in step (A), from formed gases and said at least one liquid product; (C) exposing the separated cracking catalyst composition obtained in step (B) to flowing steam under such conditions as to strip liquids which are adhered to said separated catalyst composition; (D) heating the steam-stripped cracking catalyst composition obtained in step (C) in a free oxygen containing gas under such conditions as to burn off substantially all coke deposited on said steam-stripped cracking catalyst composition; and (E) recycling at least a portion of the regenerated catalyst composition obtained in step (D) to the cracking zone of step (A).

Claim 19

A process in accordance with claim 1 wherein said cracking catalyst composition has been exposed to steam before said contacting with said hydrocarbon-containing feed stream under said cracking conditions.

Claim 20

A process in accordance with claim 1 wherein said cracking catalyst composition has been exposed to steam at about 700°-1500° F. before said contacting with said hydrocarbon-containing feed stream under said cracking conditions.

Claim 21

A process in accordance with claim 1 where steam is present during said contacting under cracking conditions.

Claim 22

A process in accordance with claim 18 wherein the weight ratio of steam to said hydrocarbon containing feed stream is in the range of from about 0.01:1 to about 0.5:1.

Claim 23

A process in accordance with claim 1 wherein said catalyst composition has been prepared by a process comprising the steps of (i) mixing a slurry of a zeolite in a liquid with a slurry of aluminum phosphate in a liquid, (ii) separating the obtained mixture of dispersed zeolite and aluminum phosphate from the liquid portion of the mixture of the two slurries obtained in step (i), (iii) at least partially drying the separated mixture of zeolite and alumina phosphate obtained in step (ii), and (iv) calcining the at least partially dried mixture obtained in step (iii).

Claim 24

A process in accordance with claim 20 wherein drying step (iii) is carried out at about 100°-200° C., and calcining step (iv) is carried out at about 600°-900° C.

Claim 25

A process in accordance with claim 15 wherein said steam in step (C) has a temperature of about 700°-1500° F.

Claim 26

A process in accordance with claim 16 wherein said heating in step (D) is carried out at a temperature of about 1100°-1400° F.

Claim 27

A process in accordance with claim 15 wherein fresh, unused catalyst composition is added to said portion of the regenerated catalyst composition before being recycled to said cracking zone.