Process for the catalytic cracking of feedstocks containing high levels of nitrogen

Claim 2

A process for the catalytic cracking of a hydrocarbon feedstock containing greater than about 0.25 weight percent total nitrogen, calculated as the element, which comprises contacting said feedstock with a cracking catalyst under cracking conditions in the substantial absence of added molecular hydrogen in a cracking zone to convert components of said feedstock into lower molecular weight constituents, wherein said cracking catalyst has a surface area of at least 150 m 2 /gm and comprises greater than about 25 weight percent of a rare earth exchanged Y zeolite dispersed in a matrix comprising a clay and a synthetic silica-alumina component in which component the weight ratio of silica-to-alumina is equal to or greater than about 0.5 and wherein individual concentrations of nickel and vanadium in said hydrocarbon feedstock are less than about 1.0 ppmw.

Claim 3

A process as defined by claim 1 wherein said clay comprises kaolin.

Claim 4

A process as defined by claim 2 wherein said cracking catalyst comprises between about 30 weight percent and about 40 weight percent of said rare earth exchanged Y zeolite.

Claim 5

A process as defined by claim 3 wherein the weight ratio of silica-to-alumina in said synthetic silica-alumina component is between about 1.0 and about 5.0.

Claim 6

A process as defined by claim 4 wherein said weight ratio is between about 2.0 and about 4.0.

Claim 7

A process as defined by claim 3 wherein said hydrocarbon feedstock contains between about 0.25 and 0.80 weight percent total nitrogen, calculated as the element.

Claim 8

A process as defined by claim 1 wherein said cracking catalyst further comprises a Y zeolite that has not been exchanged with rare earth metal cations.

Claim 9

A process as defined by claim 1 wherein the source of alumina in said synthetic silica-alumina component is aluminum chlorhydrol.

Claim 10

A process as defined by claim 1 wherein said synthetic silica-alumina component comprises at least 10 weight percent of said matrix other than said synthetic silica-alumina component.

Claim 11

A process as defined by claim 1 wherein said hydrocarbon feedstock contains between about 0.30 and about 0.75 weight percent total nitrogen, calculated as the element.

Claim 12

A process as defined by claim 1 wherein said hydrocarbon feedstock contains greater than about 0.50 weight percent total nitrogen, calculated as the element.

Claim 13

A process for the catalytic cracking of a hydrocarbon feedstock containing between about 0.25 and about 0.80 weight percent total nitrogen, calculated as the element, which comprises contacting said feedstock with a cracking catalyst under cracking conditions in the substantial absence of added molecular hydrogen in a cracking zone to convert components of said feedstock into lower molecular weight weight constituents, wherein said cracking catalyst has a surface area of at least 150 m 2 /gm and comprises between about 25 weight percent and about 40 weight percent of a rare earth exchanged Y zeolite dispersed in a matrix comprising a clay and a synthetic silica-alumina component in which component the weight ratio of silica-to-alumina is greater than or equal to about 0.50 and wherein individual concentrations of nickel and vanadium in said hydrocarbon feedstock are less than about 1.0 ppmw.

Claim 14

A process for the catalytic cracking of a hydrocarbon feedstock containing between about 0.25 and about 0.80 weight percent total nitrogen, calculated as the element, which comprises contacting said feedstock with a cracking catalyst under cracking conditions in the substantial absence of added molecular hydrogen in a cracking zone to convert components of said feedstock into lower molecular weight weight constituents, wherein said cracking catalyst has a surface area of at least 150 m 2 /gm and comprises between about 25 weight percent and about 40 weight percent of a rare earth exchanged Y zeolite dispersed in a matrix comprising a clay and a synthetic silica-alumina component in which component the weight ratio of silica-to-alumina is greater than or equal to about 0.50 and wherein individual concentrations of nickel and vanadium in said hydrocarbon feedstock are less than about 1.0 ppmw.

Claim 15

A process as defined by claim 12 wherein said clay comprises kaolin.

Claim 16

A process as defined by claim 13 wherein the weight ratio of silica-to-alumina in said synthetic silica-alumina component ranges between about 2.0 and 4.0.

Claim 17

A process as defined by claim 14 wherein the surface area of said cracking catalyst is greater than about 200 m 2 /gm.

Claim 18

A process as defined by claim 12 wherein said cracking catalyst further comprises a zeolite selected from the group consisting of a stabilized Y zeolite, an ultrastable Y zeolite, LZ-210 zeolite, ZSM-5 zeolite, offretite, mordenite and ferrierite.

Claim 19

A process as defined by claim 13 wherein said cracking catalyst comprises between about 30 weight percent and about 40 weight percent of said rare earth exchanged Y zeolite.

Claim 20

A process for the catalytic cracking of a hydrocarbon feedstock containing greater than about 0.10 weight percent total nitrogen, calculated as the element, which comprises contacting said feedstock with a cracking catalyst under cracking conditions in the substantial absence of added molecular hydrogen in a cracking zone to convert components of said feedstock into lower molecular weight constituents, wherein said cracking catalyst comprises greater than about 25 weight percent of a rare earth exchanged Y zeolite dispersed in a matrix comprising a synthetic silica-alumina component in which component the weight ratio of silica-to-alumina is equal to or greater than about 0.50 and wherein individual concentrations of nickel and vanadium in said hydrocarbon feedstock are less than about 1.0 ppmw.

Claim 21

A process for the catalytic cracking of a hydrocarbon feedstock containing greater than about 0.10 weight percent total nitrogen, calculated as the element, which comprises contacting said feedstock with a cracking catalyst under cracking conditions in the substantial absence of added molecular hydrogen in a cracking zone to convert components of said feedstock into lower molecular weight constituents, wherein said cracking catalyst comprises greater than about 25 weight percent of a rare earth exchanged Y zeolite dispersed in a matrix comprising a synthetic silica-alumina component in which component the weight ratio of silica-to-alumina is equal to or greater than about 0.50 and wherein individual concentrations of nickel and vanadium in said hydrocarbon feedstock are less than about 1.0 ppmw.

Claim 22

A process as defined by claim 18 wherein said cracking catalyst has a surface area of at least 150 m 2 /gram and comprises between about 30 weight percent and about 40 weight percent of said rare earth exchanged Y zeolite and wherein the weight ratio of silica-to-alumina in said synthetic silica-alumina component is greater than about 1.0.

Claim 23

A process as defined by claim 18 wherein said hydrocarbon feedstock contains greater than about 0.25 weight percent total nitrogen, calculated as the element.