Systems and methods for cracking hydrocarbon streams such as crude oils utilizing catalysts which include zeolite mixtures
A hydrocarbon feed stream may be cracked by a method including contacting the hydrocarbon feed stream with a cracking catalyst in a reactor unit. The hydrocarbon feed stream has an API gravity of at least 40 degrees. The cracking catalyst may include one or more binder materials, one or more matrix materials, *BEA framework type zeolite, FAU framework type zeolite, and MFI framework type zeolite.
1. A method for cracking a hydrocarbon feed stream, the method comprising:
contacting the hydrocarbon feed stream with a cracking catalyst in a reactor unit, where the hydrocarbon feed stream has an API gravity of at least 40 degrees, and where the cracking catalyst comprises:
one or more binder materials in an amount of from 5 wt. % to 30 wt. % of the cracking catalyst;
one or more matrix materials in an amount of from 30 wt. % to 60 wt. % of the cracking catalyst;
*BEA framework zeolite in an amount of from 5 wt. % to 30 wt. % of the cracking catalyst;
FAU framework zeolite in an amount of from 5 wt. % to 45 wt. % of the cracking catalyst;
MFI framework zeolite in an amount of from 5 wt. % to 45 wt. % of the cracking catalyst; and
where the *BEA framework zeolite comprises less than 0.5 wt. % of transition metal.
2. The method of claim 1 , where the hydrocarbon feed stream has an API gravity of from 45 degrees to 60 degrees.
3. The method of claim 1 , where the amount of the FAU framework zeolite is from 10 wt. % to 20 wt. % of the total cracking catalyst.
4. The method of claim 1 , where the amount of the MFI framework zeolite is from 10 wt. % to 20 wt. % of the total cracking catalyst.
5. The method of claim 1 , where one or more of the MFI framework zeolite, *BEA framework zeolite, and FAU framework zeolite comprise phosphorus pentoxide.
6. The method of claim 1 , where at least one of the one or more binder materials is pseudoboehmite.
7. The method of claim 1 , where the amount of the one or more binder materials is from 10 wt. % to 20 wt. % of the cracking catalyst.
8. The method of claim 1 , where one or more of the matrix materials is kaolin.
9. The method of claim 1 , where cracking catalyst comprises the one or more matrix materials in an amount of from 30 wt. % to 50 wt. % of the cracking catalyst.
10. The method of claim 1 , where the catalyst to oil weight ratio is from 7 to 10.
11. The method of claim 1 , where the MFI framework zeolite comprises ZSM-5.
12. The method of claim 1 , where the FAU framework zeolite comprise zeolite Y.
13. The method of claim 1 , where the *BEA framework zeolite comprises zeolite Beta.
14. The method of claim 1 , where the contacting of the hydrocarbon feed stream with the cracking catalyst produces a product stream comprising at least 20 wt. % of light olefins selected from ethylene, propylene, and butene.
15. The method of claim 1 , where the hydrocarbon feed stream is gas condensate.
16. The method of claim 1 , where the hydrocarbon feed stream has a 5 wt. % boiling temperature of from 0° C. to 100° C., a 25 wt. % boiling temperature of from 75° C. to 175° C., a 50 wt. % boiling temperature of from 150° C. to 250° C., a 75 wt. % boiling temperature of from 250° C. to 350° C., and a 95 wt. % boiling temperature of from 450° C. to 550° C.
17. The method of claim 1 , where the FAU framework zeolite comprises less than 1 wt. % of transition metal.
18. The method of claim 1 , where the MFI framework zeolite comprises less than 1 wt. % of transition metal.
19. The method of claim 1 , where the *BEA framework zeolite comprises less than or equal to 0.1 wt. % of transition metal.