Processes and bimetallic cracking additives for steam enhanced catalytic cracking of crude oil to produce light olefins and aromatics
A process for upgrading a hydrocarbon feed comprises contacting the hydrocarbon feed with steam in the presence of a cracking catalyst composition at reaction conditions sufficient to cause at least a portion of hydrocarbons in the hydrocarbon feed to undergo one or more cracking reactions to produce a steam catalytic cracking effluent comprising light olefins, light aromatic compounds, or both, where: the cracking catalyst composition comprises a cracking additive comprising a ZSM-5 zeolite, a first metal species, and a second metal species, where the first metal species and the second metal species are impregnated onto the ZSM-5 zeolite, the first metal species comprises a metal or metal oxide comprising a first metal, the second metal species comprises a metal or metal oxide comprising a second metal, and the second metal is different from the first metal.
1 . A process for upgrading a hydrocarbon feed, the process comprising: contacting the hydrocarbon feed with steam in the presence of a cracking catalyst composition at reaction conditions sufficient to cause at least a portion of hydrocarbons in the hydrocarbon feed to undergo one or more cracking reactions to produce a steam catalytic cracking effluent comprising light olefins, light aromatic compounds, or both, where:
the hydrocarbon feed is a whole crude oil having an API gravity between 25 and 50;
the cracking catalyst composition comprises a cracking additive;
the cracking additive comprises a ZSM-5 zeolite, a first metal species, and a second metal species;
the first metal species and the second metal species are impregnated onto the ZSM-5 zeolite;
the first metal species comprises a metal or metal oxide comprising cerium;
the second metal species comprises a metal or metal oxide comprising iron; and
the cracking additive is essentially free of phosphorus.
2 . The process of claim 1 , where the ZSM-5 zeolite has a molar ratio of silica to alumina of from 20 to 80.
3 . The process of claim 1 , where a concentration of the first metal species in the cracking additive is from 0.1 weight percent (wt. %) to 10 wt. % based on the total weight of the cracking additive.
4 . The process of claim 1 , where a concentration of the second metal species in the cracking additive is from 0.1 wt. % to 10 wt. % based on the total weight of the cracking additive.
5 . The process of claim 1 , where the cracking additive comprises cerium oxide and iron oxide impregnated on the ZSM-5 zeolite the ZSM-5 zeolite has a molar ratio of silica to alumina of 30.
6 . A process for upgrading a hydrocarbon feed, the process comprising: contacting the hydrocarbon feed with steam in the presence of a cracking catalyst composition at reaction conditions sufficient to cause at least a portion of hydrocarbons in the hydrocarbon feed to undergo one or more cracking reactions to produce a steam catalytic cracking effluent comprising light olefins, light aromatic compounds, or both, where:
the hydrocarbon feed is a whole crude oil having an API gravity between 25 and 50;
the cracking catalyst composition comprises a cracking additive; and
the cracking additive consists of cerium oxide and iron oxide impregnated on a ZSM-5 zeolite.
7 . The process of claim 1 , where an amount of the cracking additive in the cracking catalyst composition is from 20 wt. % to 30 wt. % based on the cracking catalyst composition.
8 . The process of claim 1 , where the cracking catalyst composition further comprises an equilibrium catalyst.
9 . The process of claim 8 , where an amount of the equilibrium catalyst in the cracking catalyst composition is from 70 wt. % to 80 wt. % based on the cracking catalyst composition.
10 . The process of claim 1 , wherein the hydrocarbon feed has not undergone any substantial separation before being contacted with steam in the presence of the cracking catalyst composition.
11 . The process of claim 1 , wherein a concentration of the first metal species in the cracking additive is from 1 weight percent (wt. %) to 2 wt. % based on the total weight of the cracking additive.
12 . The process of claim 1 , wherein the cracking additive comprises less than or equal to 0.1 wt. % phosphorus based on the total weight of the cracking additive.
13 . The process of claim 1 , wherein the cracking additive comprises less than or equal to 0.01 wt. % phosphorus based on the total weight of the cracking additive.