FCC catalyst additive and binder
Provided is a process for manufacturing a Fluid Catalytic Cracking catalyst additive composition with a novel binder. The steps involve mixing an alumina source with water to make a slurry; adding to the alumina slurry an amount of P2O5 source; the slurry is then stirred and reacted under controlled temperature and time conditions to form an aluminum phosphate binder; adding to the aluminum phosphate binder a zeolite, an amount of silica binder and an amount of clay; and spray-drying the slurry to form catalyst additive particles. The catalyst additive composition comprises a about 35 wt % to about 65 wt % zeolite; about 0 wt % to about 10 wt % silica; about 15 wt % to about 50 wt % clay and an aluminum phosphate binder comprising about 2.5 wt % to 5 wt % amorphous or pseudo-boehmite alumina and about 7 wt % to 15 wt % phosphoric acid.
1. A process for the preparation of a catalyst additive comprising the following steps:
a. mixing an alumina source with water to make a slurry;
b. adding to the slurry of step (a) an amount of P 2 O 5 source;
c. the slurry of step (b) is then stirred and reacted at a temperature above 5° C. but not higher than 60° C. and under time conditions to form an aluminum phosphate binder;
d. adding to the aluminum phosphate binder a zeolite, an amount of silica binder and an amount of clay; and
e. spray-drying the slurry of step (d) to form catalyst additive particles.
2. The process of claim 1 further comprising the step of calcining the catalyst additive particles after step (e) at a temperature of between about 350° C. and about 700° C.
3. The process of claim 1 wherein the alumina source is amorphous or pseudoboehmite alumina added in an amount of less than about 5 wt %.
4. The process of claim 3 wherein the amorphous or pseudoboehmite alumina is added in amount of greater than about 2.5 wt % and less than about 5 wt %.
5. The process of claim 1 wherein the solids content of the slurry of step (a) to be between about 5 wt % and about 30 wt % Al 2 O 3 .
6. The process of claim 1 wherein the solids content of the slurry of step (a) to be between about 9 wt % and about 30 wt % Al 2 O 3 .
7. The process of claim 1 wherein the source of the amount of P 2 O 5 is H 3 PO 4 and the P 2 O 5 is added in an amount between about 7 wt % and 15 wt %, by dry weight basis.
8. The process of claim 1 wherein the source of the amount of P 2 O 5 is H 3 PO 4 and the P 2 O 5 is added in an amount between about 8 wt % and 12 wt %, by dry weight basis.
9. The process of claim 1 wherein the P/Al molar ratio at step (b) is between 1 and 3.
10. The process of claim 1 wherein the P/Al molar ratio at step (b) is between 1.5 and 2.5.
11. The process of claim 1 wherein the silica binder is added in the range of greater than about 0 wt % to about 10 wt %.
12. The process of claim 1 wherein the silica binder is added in the range of about 3 wt % to about 8 wt %.