Phosphorus-containing FCC catalyst

1. A method of manufacturing a fluid catalytic cracking (FCC) catalyst,

the method comprising:

pre-forming a precursor microsphere comprising a non-zeolitic material and alumina;

in situ crystallizing a Y zeolite on the pre-formed microsphere to provide a zeolite containing microsphere;

adding a first portion of a phosphorus component to the zeolite-containing microsphere to form a first phosphorus-modified microsphere;

adding a rare earth component to the first phosphorus-modified microsphere to provide a rare earth-containing microsphere; and

adding a second portion of the phosphorus component to the rare earth-containing precursor microsphere to provide a catalytic microsphere.

2. The method of claim 1 , wherein the non-zeolitic material is selected from the group consisting of kaolinite, halloysite, montmorillonite, bentonite, attapulgite, kaolin, amorphous kaolin, metakaolin, mullite, spinel, hydrous kaolin, clay, gibbsite (alumina trihydrate), boehmite, titania, alumina silica, silica-alumina, silica-magnesia, magnesia, and sepiolite.

3. The method of claim 2 , wherein the zeolite comprises a crystallized aluminosilicate material comprising about 20 to about 65 wt. % zeolite Y.

4. The method of claim 3 , wherein the method further comprises adding an ammonium component.

5. The method of claim 4 , wherein the rare-earth component is selected from one or more of ceria, lanthana, praseodymia, and neodymia.

6. The method of claim 5 , wherein the rare earth component comprises lanthana, wherein the lanthana is added by ion exchange.

7. The method of claim 6 , wherein the ion exchanging is carried out until the resulting catalyst comprises less than 0.2 wt % of Na 2 O.

8. The method of claim 7 , wherein the phosphorus component is added by contacting with phosphorus acid, phosphoric acid, salts of phosphorus acid, salts of phosphoric acid, or combinations thereof.

9. The method of claim 7 , wherein the phosphorus component is added by contacting with monoammonium phosphate, diammonium phosphate, and mixtures thereof.

10. The method of claim 9 , wherein the contacting is carried out until the phosphorus component is present in an amount of about 1% to about 5% by weight on an oxide basis.

11. The method of claim 9 , further comprising adding a phosphorus component to the zeolite-containing microsphere.

12. A method of manufacturing an FCC catalyst, the method comprising:

pre-forming a precursor microsphere comprising a non-zeolitic material and alumina;

in situ crystallizing a Y zeolite on the pre-formed microsphere to provide a zeolite containing microsphere;

adding a first portion of a phosphorus component to the rare earth-containing precursor microsphere to provide a phosphorus-modified microsphere;

adding a rare earth component to the zeolite-containing microsphere to provide a rare earth-containing microsphere; and

adding a second portion of the phosphorus component to the rare earth-containing precursor microsphere to provide a catalytic microsphere;

wherein the FCC catalyst comprises,

5% to 25% by weight of a transition alumina;

20% to 65% by weight of the Y zeolite, wherein the zeolite is intergrown with the non-zeolite component; and

1% to 5% by weight of the phosphorus component on an oxide basis;

wherein the FCC catalyst is effective in preventing at least one of nickel and vanadium from increasing coke and hydrogen yields during cracking of a hydrocarbon.

13. The method of claim 12 , wherein the rare-earth component is selected from one or more of ceria, lanthana, praseodymia, and neodymia.

14. The method of claim 13 , wherein the phosphorus component is added by contacting with monoammonium phosphate, diammonium phosphate, and mixtures thereof.

15. The method of claim 14 , wherein the amount of phosphorus component is 2.5 to 3.5wt. % on an oxide basis.