US4828679A — Octane improvement with large size ZSM-5 catalyti…

Claim 1

Independent Claim 105 words

In a process for catalytic cracking of a petroleum fraction in the presence of a conventional cracking catalyst, under cracking conditions and wherein the catalyst is contacted with steam, the improvement comprising adding to said catalyst an additive catalyst comprising zeolite characterized by a Constraint Index of from about 1 to about 12 and a silica/alumina mole ratio greater than about 12 in an amount which provides the zeolite component of said additive catalyst at from about 0.1 wt. percent to about 50 wt. percent of said conventional cracking catalyst, said additive catalyst zeolite having a crystal size of from 0.2 micron to 10 microns.

Claim 2

Dependent Claim 105 words

In a process for catalytic cracking of a petroleum fraction in the presence of a conventional cracking catalyst, under cracking conditions and wherein the catalyst is contacted with steam, the improvement comprising adding to said catalyst an additive catalyst comprising zeolite characterized by a Constraint Index of from about 1 to about 12 and a silica/alumina mole ratio greater than about 12 in an amount which provides the zeolite component of said additive catalyst at from about 0.1 wt. percent to about 50 wt. percent of said conventional cracking catalyst, said additive catalyst zeolite having a crystal size of from 0.2 micron to 10 microns.

Claim 3

Dependent Claim 18 words

The process of claim 1 wherein said catalysts are fluidizable microspheres and said process is fluid catalytic cracking.

Claim 4

Dependent Claim 19 words

The process of claim 1 wherein said catalysts are beads or pellets and said process is Thermofor catalytic cracking.

Claim 5

Dependent Claim 20 words

The process of claim 1 wherein the additive catalyst zeolite has a crystal size of from 0.2 to 5 micron.

Claim 6

Dependent Claim 20 words

The process of claim 1 wherein the additive catalyst zeolite has a crystal size of from 0.3 to 3 micron.

Claim 7

Dependent Claim 39 words

The process of claim 1 wherein said additive catalyst is added in an amount which provides the zeolite component of said additive catalyst at from about 0.1 wt. percent to about 20 wt. percent of the conventional cracking catalyst.

Claim 8

Dependent Claim 28 words

The process of claim 1 wherein said additive catalyst zeolite is at least one member selected from the group consisting of ZSM-5, ZSM-11, ZSM-12, ZSM-23, ZSM-35 and ZSM-38.

Claim 9

Dependent Claim 15 words

The process of claim 1 wherein said additive catalyst zeolite has the structure of ZSM-5.

Claim 10

Dependent Claim 27 words

The process of claim 1 wherein said conventional cracking catalyst comprises a zeolite selected from the group consisting of zeolite X, zeolite Y, and naturally occurring faujasite.

Claim 11

Dependent Claim 17 words

The process of claim 9 wherein said conventional cracking catalyst zeolite has the structure of zeolite Y.

Claim 12

Dependent Claim 49 words

The process of claim 1 wherein a metal selected from the group consisting of platinum, palladium, iridium, osmium, rhodium, ruthenium and rhenium is added in an amount of from about 0.01 ppm to about 100 ppm, based on the total catalyst inventory, in order to enhance carbon monoxide conversion.

Claim 13

Dependent Claim 111 words

A process for catalytically cracking a petroleum fraction comprising: (A) contacting said petroleum fraction as feed, under cracking conditions, with a catalyst composition comprising (1) a large pore zeolite and (2) an additive component comprising a zeolite having a Constraint Index of about 1 to about 12, having a silica to alumina mole ratio greater than about 12 and having a crystal size from 0.2 to 10 microns and exhibiting hydrothermal stability to steam, wherein the catalyst composition is exposed to contact with steam during the cracking process, whereby the gasoline octane number and gasoline plus alkylate yield are improved by the use of said additive component of improved hydrothermal stability.

Claim 14

Dependent Claim 111 words

A process for catalytically cracking a petroleum fraction comprising: (A) contacting said petroleum fraction as feed, under cracking conditions, with a catalyst composition comprising (1) a large pore zeolite and (2) an additive component comprising a zeolite having a Constraint Index of about 1 to about 12, having a silica to alumina mole ratio greater than about 12 and having a crystal size from 0.2 to 10 microns and exhibiting hydrothermal stability to steam, wherein the catalyst composition is exposed to contact with steam during the cracking process, whereby the gasoline octane number and gasoline plus alkylate yield are improved by the use of said additive component of improved hydrothermal stability.

Claim 15

Dependent Claim 30 words

The process of claim 12, wherein said zeolite of Constraint Index of about 1 to about 12 comprises from about 0.1 to about 50 weight percent of said catalyst composition.

Claim 16

Dependent Claim 24 words

The process of claim 12 wherein the catalyst composition is exposed to contact with said steam when said steam is present in the feed.

Claim 17

Dependent Claim 25 words

The process of claim 12 wherein the catalyst composition is exposed to contact with said steam when said steam is produced under said cracking conditions.

Claim 18

Dependent Claim 30 words

The process of claim 12, wherein the catalyst composition is exposed to contact with said steam when said steam is added to remove products and unreacted feed from said catalyst.

Claim 19

Dependent Claim 24 words

The process of claim 12, wherein the catalyst composition is exposed to contact with said steam when said steam is present during catalyst regeneration.

Claim 20

Dependent Claim 102 words

A process for catalytically cracking a petroleum fraction comprising (A) contacting said petroleum fraction as feed, under cracking conditions, with a catalyst composition comprising (1) a large pore zeolite and (2) zeolite of ZSM-5 structure having a silica to alumina mole ratio greater than about 12 and having a crystal size from 0.2 to 10 microns and thereby exhibiting hydrothermal stability to steam, wherein the catalyst composition is exposed to contact with steam during the cracking process, whereby the gasoline octane number and gasoline plus alkylate yield are improved by the use of said zeolite of ZSM-5 structure of improved hydrothermal stability.

Claim 21

Dependent Claim 102 words

A process for catalytically cracking a petroleum fraction comprising (A) contacting said petroleum fraction as feed, under cracking conditions, with a catalyst composition comprising (1) a large pore zeolite and (2) zeolite of ZSM-5 structure having a silica to alumina mole ratio greater than about 12 and having a crystal size from 0.2 to 10 microns and thereby exhibiting hydrothermal stability to steam, wherein the catalyst composition is exposed to contact with steam during the cracking process, whereby the gasoline octane number and gasoline plus alkylate yield are improved by the use of said zeolite of ZSM-5 structure of improved hydrothermal stability.

Claim 22

Dependent Claim 21 words

The process of claim 18, wherein said ZSM-5 comprises from about 0.1 to about 50 weight percent of said catalyst composition.

Claim 23

Dependent Claim 24 words

The process of claim 18, wherein the catalyst composition is exposed to contact with said steam when said steam is present in the feed.

Claim 24

Dependent Claim 25 words

The process of claim 18, wherein the catalyst composition is exposed to contact with said steam when said steam is produced under said cracking conditions.

Claim 25

Dependent Claim 30 words

The process of claim 18, wherein the catalyst composition is exposed to contact with said steam when said steam is added to remove products and unreacted feed from said catalyst.

Claim 26

Dependent Claim 24 words

The processes of claim 18, where the catalyst composition is exposed to contact with said steam when said steam is present during catalyst regeneration.

Claim 27

Dependent Claim 112 words

A process for catalytically cracking a petroleum fraction comprising (A) contacting said petroleum fraction as feed, under cracking conditions, with a catalyst composition comprising (1) zeolite X or zeolite Y (2) an additive component comprising a zeolite having a Constraint Index of about 1 to about 12, having a silica to alumina mole ratio greater than about 12 and having a crystal size from 0.2 to 10 microns and thereby exhibiting hydrothermal stability to steam, wherein the catalyst composition is exposed to contact with steam during the cracking process, whereby the gasoline octane number and gasoline plus alkylate yield are improved by the use of said additive component of improved hydrothermal stability.

Claim 28

Dependent Claim 112 words

A process for catalytically cracking a petroleum fraction comprising (A) contacting said petroleum fraction as feed, under cracking conditions, with a catalyst composition comprising (1) zeolite X or zeolite Y (2) an additive component comprising a zeolite having a Constraint Index of about 1 to about 12, having a silica to alumina mole ratio greater than about 12 and having a crystal size from 0.2 to 10 microns and thereby exhibiting hydrothermal stability to steam, wherein the catalyst composition is exposed to contact with steam during the cracking process, whereby the gasoline octane number and gasoline plus alkylate yield are improved by the use of said additive component of improved hydrothermal stability.

Claim 29

Dependent Claim 31 words

The process of claim 24, wherein said zeolite having a Constraint Index of about 1 to about 12 comprises from about 0.1 to about 50 weight percent of said catalyst composition.

Claim 30

Dependent Claim 22 words

The process of claim 24, wherein said zeolite of Constraint Index of about 1 to about 12 has the structure of ZSM-5.

Claim 31

Dependent Claim 14 words

The process of claim 24, wherein said zeolite Y is in its ultrastable form.

Claim 32

Dependent Claim 14 words

The process of claim 26, wherein said zeolite Y is in its ultrastable form.

Claim 33

Dependent Claim 24 words

The process of claim 24, wherein the catalyst composition is exposed to contact with said steam when said steam is present in the feed.

Claim 34

Dependent Claim 25 words

The process of claim 24, wherein the catalyst composition is exposed to contact with said steam when said steam is produced under said cracking conditions.

Claim 35

Dependent Claim 30 words

The process of claim 24, wherein the catalyst composition is exposed to contact with said steam when said steam is added to remove products and unreacted feed from said catalyst.

Claim 36

Dependent Claim 24 words

The process of claim 24, wherein the catalyst composition is exposed to contact with said steam when said steam is present during catalyst regeneration.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1992-05-08	1992-11-07	1993-05-09	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1996-05-08	1996-11-07	1997-05-09	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2000-05-08	2000-11-07	2001-05-09	$7700.00	Window Closed / Lapsed

Octane improvement with large size ZSM-5 catalytic cracking

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