Alumina matrix modification in FCC catalyst composition

1 . A fluid catalytic cracking (FCC) catalyst composition comprising a Y-zeolite, wherein the Y-zeolite comprises a rare earth element or oxide thereof, and a modified alumina matrix,

wherein:

the modified alumina matrix comprises γ-Al 2 O 3 or pseudo-boehmite and a dopant; and

wherein the dopant comprises yttrium (Y), scandium (Sc), praseodymium (Pr), neodymium (Nd), samarium (Sm), europium (Eu), gadolinium (Gd), cerium (Ce), lanthanum (La), titanium (Ti), zirconium (Zr), an oxide thereof, or a combination of any two or more thereof, in an amount of about 0.01 wt % to about 10 wt % based on total weight of the alumina matrix;

or,

wherein the dopant comprises germanium (Ge), tin (Sn), bismuth (Bi), an oxide thereof, or a combination of any two or more thereof, in an amount from about 0.01 wt % to about 35 wt % based on total weight of the alumina matrix,

wherein the catalyst comprises about 15 wt % to about 65 wt % of the modified alumina matrix based on total weight of the catalyst.

2 . The FCC catalyst of claim 1 , wherein the catalyst comprises about 5 wt. % to about 30 wt. % of the Y-zeolite based on total weight of the catalyst.

3 . The FCC catalyst of claim 1 , wherein the catalyst comprises about 10 wt. % to about 25 wt. % of the Y-zeolite based on total weight of the catalyst.

4 . The FCC catalyst of claim 1 , wherein the rare earth element is lanthanum or an oxide thereof.

5 . The FCC catalyst of claim 1 , wherein the Y-zeolite comprises from about 0.1 wt. % to about 12 wt. % of the rare earth element or oxide thereof based on total weight of the Y-zeolite.

6 . The FCC catalyst of claim 1 , wherein the catalyst comprises about 30 wt % to about 50 wt % of the modified alumina matrix based on total weight of the catalyst.

7 . The FCC catalyst of claim 1 , wherein the dopant comprises yttrium (Y), scandium (Sc), praseodymium (Pr), neodymium (Nd), samarium (Sm), europium (Eu), gadolinium (Gd), cerium (Ce), lanthanum (La), titanium (Ti), zirconium (Zr), an oxide thereof, or a combination of any two or more thereof.

8 . The FCC catalyst of claim 1 , wherein the dopant comprises germanium (Ge), tin (Sn), bismuth (Bi), an oxide thereof, or a combination of any two or more thereof.

9 . The FCC catalyst of claim 1 , wherein the dopant is selected from La, Ce, an oxide thereof, or a combination of any two or more thereof.

10 . The FCC catalyst of claim 1 , wherein the dopant present in the modified alumina matrix is selected from lanthanum, an oxide thereof, or a combination thereof.

11 . The FCC catalyst of claim 1 , wherein the modified alumina matrix comprises from about 50 wt. % to about 99 wt. % of γ-Al 2 O 3 or pseudo-boehmite phase.

12 . The FCC catalyst of claim 1 , further comprising a binder, alumina gel, peptized boehmite, pseudo-boehmite, kaolin, transitional alumina, or combinations thereof.

13 . A process for preparing the FCC catalyst composition of claim 1 , the process comprising:

milling a first slurry comprising an alumina matrix material to a D90 particle size distribution of about 8 microns or less, and milling a second slurry comprising a Y-zeolite comprising a rare earth element or oxide thereof to a D90 particle size distribution of about 5 microns or less;

or co-milling a slurry mixture comprising the Y-zeolite comprising a rare earth element or oxide thereof and the alumina matrix material to a D90 particle size distribution of about 5 microns or less;

combining the alumina matrix and the Y-zeolite with one or more additional components to obtain a mixture;

spray drying the mixture to form microspheres; and

calcining the microspheres to obtain the FCC catalyst.

14 . The process according to claim 13 , further comprising combining the first slurry and the second slurry or the slurry mixtures with an acid to adjust the pH to about 5 or less.

15 . The process according to claim 14 , wherein the pH is about 3 to about 5.

16 . The process of according to claim 14 , wherein the acid is selected from formic acid, HNO 3 , HCl, or any other monoprotic acids.

17 . A catalyst composition comprising:

a first FCC catalyst in accordance with claim 1 ;

a second FCC catalyst that is different from the first FCC catalyst; and

optionally additional FCC catalyst that are different from the first and second FCC catalyst.