Catalyst With Vanadium Trap
This invention provides a catalyst composition characterized in that the catalyst composition comprises one or more rare earth oxophosphorus components.
1 . A process for producing a catalyst composition characterized in that
A) one or more rare earth oxophosphorus salts is combined with a catalyst or a component of a catalyst, wherein the rare earth oxophosphorus salt is in an amount of about 0.5 wt % to about 20 wt %, expressed as rare earth oxophosphorus salt(s), relative to the total weight of dry ingredients that form the catalyst composition, optionally wherein the rare earth oxophosphorus salt is made in situ; or
B) one or more rare earth oxophosphorus salts is introduced during the process prior to drying, wherein the rare earth oxophosphorus salt is in an amount of about 0.5 wt % to about 20 wt % relative to the total weight of dry ingredients that form the catalyst composition, optionally wherein the drying is by spray drying, and optionally wherein the rare earth oxophosphorus salt is made in situ.
2 . (canceled)
3 . A process as in claim 1 in A) which comprises combining starting materials for one or more zeolites, one or more aluminum-containing components and/or a silica component, and one or more rare earth oxophosphorus salts in an amount of about 0.5 wt % to about 20 wt %, expressed as rare earth oxophosphorus salt(s), relative to the total weight of dry ingredients that form the catalyst composition to form a mixture, and calcining the mixture to form the catalyst composition.
4 . A process as in claim 1 in A) which comprises
I-a) combining ingredients comprising water, a catalyst and the rare earth oxophosphorus salts to form an aqueous slurry; or
I-b) combining ingredients comprising
water,
one or more zeolites in an amount of about 5 wt % to about 50 wt %,
one or more aluminum-containing components in an amount of about 0.1 to about 50 wt % and/or a silica component in an amount of about 0.1 to about 20 wt %, and
one or more rare earth oxophosphorus salts in an amount of about 0.5 wt % to about 20 wt %; or
I-c) combining ingredients comprising
water,
one or more zeolites in an amount of about 5 wt % to about 50 wt %;
a silica component in an amount of about 0.1 to about 20 wt %;
boehmite and/or pseudoboehmite in a total amount of about 0.1 to about 50 wt %, wherein the boehmite and/or pseudoboehmite are microcrystalline and/or crystalline;
optionally one or more clays in an amount of about 0.1 to about 70 wt %; and
one or more rare earth oxophosphorus salts in an amount of about 0.5 wt % to about 20 wt %,
wherein the boehmite and/or pseudoboehmite is peptized by acidification with an acid, to form an aqueous slurry, and
II) drying the aqueous slurry to form the catalyst composition, optionally wherein the drying is by spray drying.
5 . A process as in claim 1 further comprising contacting the catalyst composition with a hydrocarbon feed, a bioderived feedstock, or a mixture comprising a hydrocarbon feed and a bioderived feedstock.
6 . A process as in claim 5 which is fluid catalytic cracking.
7 . A process as in claim 1 wherein in B) an aluminum-containing component is present, and is boehmite and/or pseudoboehmite.
8 . A process as in claim 4 wherein boehmite and pseudoboehmite are present.
9 . A process as in claim 3 wherein a silica component is present, and is a sodium-stabilized colloidal silica, an ammonium-stabilized colloidal silica, an acid-stabilized colloidal silica, or a mixture of any two or all three of the foregoing.
10 . (canceled)
11 . A process as in claims 1 wherein the rare earth oxophosphorus salts is in an amount of about 2.5 wt % to about 17 wt %, expressed as rare earth oxophosphorus salt(s), relative to the total weight of dry ingredients that form the catalyst composition.
12 . (canceled)
13 . A process as in claim 1 wherein the rare earth oxophosphorus salt is a yttrium, lanthanum, cerium, or praseodymium oxophosphorus salt, and/or wherein the rare earth oxophosphorus salt is a rare earth phosphate.
14 . (canceled)
15 . A process as in claim 1 wherein the rare earth oxophosphorus salt is yttrium phosphate, cerium phosphate, lanthanum phosphate, or praseodymium phosphate.
16 . A process as in claim 1 wherein the rare earth oxophosphorus salt is cerium phosphate or lanthanum phosphate.
17 . (canceled)
18 . A catalyst composition characterized in that the catalyst composition comprises one or more rare earth oxophosphorus components in an amount of about 0.5 wt % to about 20 wt %, expressed as rare earth oxophosphorus salt(s), relative to the total weight of dry ingredients that form the catalyst composition.
19 . A catalyst composition as in claim 18 comprising one or more zeolites in an amount of about 5 wt % to about 50 wt %; one or more aluminum-containing components in an amount of about 0.1 to about 50 wt % and/or a silica component in an amount of about 0.1 to about 20 wt %, and one or more rare earth oxophosphorus components in an amount of about 0.5 wt % to about 20 wt %, where all amounts are relative to the total weight of dry ingredients that form the catalyst composition.
20 . A catalyst composition as in claim 19 wherein the aluminum-containing component is a polyaluminum chloride, polyaluminum nitrate, or a polyaluminum sulfate.
21 . A catalyst composition as in claim 19 wherein the aluminum-containing component is boehmite and/or pseudoboehmite, or wherein a silica component is present, and is a sodium-stabilized colloidal silica, an ammonium-stabilized colloidal silica, an acid-stabilized colloidal silica, or a mixture of any two or all three of the foregoing.
22 . (canceled)
23 . A catalyst composition as in claim 18 comprising
one or more zeolites in an amount of about 5 wt % to about 50 wt %;
silica in an amount of about 0.1 to about 20 wt % and/or boehmite and/or pseudoboehmite in a total amount of about 0.1 to about 50 wt %, wherein the boehmite and/or pseudoboehmite are microcrystalline and/or crystalline;
optionally one or more clays in an amount of about 0.1 to about 70 wt %; and
one or more rare earth oxophosphorus components in an amount of about 0.5 wt % to about 20 wt %,
where all amounts are relative to the total weight of dry ingredients that form the catalyst composition.
24 . A catalyst composition as in claim 23 wherein boehmite and pseudoboehmite are present.
25 . A catalyst composition as in claim 18 wherein the rare earth oxophosphorus components is in an amount of about 2.5 wt % to about 17 wt %, expressed as rare earth oxophosphorus salt(s), relative to the total weight of dry ingredients that form the catalyst composition.
26 . (canceled)
27 . A catalyst composition as in claim 18 wherein the rare earth oxophosphorus component is a yttrium, lanthanum, cerium, or praseodymium oxophosphorus component, and/or wherein the rare earth oxophosphorus component is a rare earth phosphate-based component.
28 . A catalyst composition as in claim 18 wherein the rare earth oxophosphorus component is a lanthanum or cerium oxophosphorus component.
29 . (canceled)
30 . A catalyst composition as in claim 18 wherein the rare earth oxophosphorus component is a lanthanum phosphate-based component.
31 . A process which comprises contacting a catalyst composition of 18 with a hydrocarbon feed, a bioderived feedstock, or a mixture comprising a hydrocarbon feed and a bioderived feedstock.
32 . A process as in claim 31 which is fluid catalytic cracking.