High zeolite content and attrition resistant catalyst, methods for preparing the same and catalyzed processes therewith

Abstract

A catalyst composition suitable for reacting hydrocarbons, e.g., conversion processes such as fluidized catalytic cracking (FCC) of hydrocarbons, comprises attrition resistant particulate having a high level (30-85%) of stabilized zeolites having a constraint index of 1 to 12. The stabilized zeolite is bound by a phosphorous compound, alumina and optional binders wherein the alumina added to make the catalyst is about 10% by weight or less and the molar ratio of phosphorous (P 2 O 5 ) to total alumina is sufficient to obtain an attrition index of about 20 or less. The composition can be used as a catalyst per se or as additive catalyst to a conventional catalyst and is especially suitable for enhancing yields of light olefins, and particularly ethylene, produced during conversion processes.

What is claimed is:  
     
         1 . A catalyst comprising 
 (a) about 30 to about 85% by weight zeolite having a constraint index of 1 to 12,    (b) about 6-24% by weight phosphorus, measured as P2O5, and    (c) alumina, wherein added alumina is present in an amount of less than about 10% and total alumina is less than about 30%, by weight of the catalyst,    said catalyst further comprising a molar ratio of phosphorous to total alumina sufficient to obtain a Davison attrition index for the catalyst equal to or less than about 20.    
     
     
         2 . A catalyst according to  claim 1  comprising greater than about 60 to about 85% ZSM-5.  
     
     
         3 . A catalyst according to  claim 2  wherein the phosphorous (P 2 O 5 ) to total alumina molar ratio is at least 0.2 to about 1.9.  
     
     
         4 . A catalyst according to 3 wherein the catalyst has an attrition index of about 10 or less.  
     
     
         5 . A catalyst according to  claim 2  wherein the added alumina (c) is present in an amount ranging from about 5 to about 10% by weight.  
     
     
         6 . A catalyst according to  claim 1  comprising about 30 to about 60% ZSM-5.  
     
     
         7 . A catalyst according to  claim 6  wherein the molar ratio of phosphorous to alumina is about 0.2 to about 1.0.  
     
     
         8 . A catalyst according to  claim 6  where the added alumina is present in an amount ranging from about 3 to about 8% by weight.  
     
     
         9 . A catalyst according to  claim 8  further comprising clay.  
     
     
         10 . A catalyst according to  claim 7  wherein the catalyst has an attrition index of about 10 or less.  
     
     
         11 . A process for preparing a catalyst comprising 
 (a) preparing a slurry comprising zeolite having a constraint index of 1 to 12, phosphorus-containing compound and alumina, where the alumina is less than about 10% by weight of the total weight of the zeolite, phosphorus-containing compound, alumina, and any optional components, and    (b) spray drying and calcining the resulting slurry to produce particulate having a DI attrition index equal to or less than 20 and having total alumina content of less than about 30% by weight.    
     
     
         12 . A process according to  claim 11  wherein the added alumina is present in the slurry of (a) in a range of 3-8% by weight.  
     
     
         13 . A process according to  claim 11  wherein the zeolite is ZSM-5 and is present in the amount of about 30 to about 85% of the total weight of ZSM-5, the phosphorus compound, alumina, and any other optional components.  
     
     
         14 . The product prepared by the process of  claim 11 .  
     
     
         15 . A process for chemically and catalytically reacting a hydrocarbon feed comprising contacting the feed at catalytic reactive conditions with a catalyst comprising 
 (a) about 30 to about 85% by weight zeolite having a constraint index of 1 to 12,    (b) about 6-24% by weight phosphorus, measured as P 2 O 5 , and    (c) alumina, wherein added alumina is present in an amount of less than about 10% and total alumina is less than about 30% by weight of the catalyst,    said catalyst further comprising a molar ratio of phosphorous to total alumina sufficient to obtain an attrition index for the catalyst equal to or less than about 20.    
     
     
         16 . A process according to  claim 15  wherein the catalyst comprises greater than about 60 to about 85% ZSM-5.  
     
     
         17 . A process according to  claim 16  wherein the catalyst consists essentially of (a), (b), and (c).  
     
     
         18 . A process according to  claim 15  wherein the catalyst comprises about 60 to about 70% by weight ZSM-5.  
     
     
         19 . A process according to  claim 15  wherein the catalyst comprises about 40-60% by weight ZSM-5.  
     
     
         20 . A process according to  claim 16  wherein the phosphorous to total alumina ratio is about 0.2 to about 1.9 and the catalyst has an attrition index of about 10 or less.  
     
     
         21 . A process according to  claim 18  wherein the phosphorous to total alumina ratio is at least 0.45 to about 1.0 and the catalyst has an attrition index of about 10 or less.  
     
     
         22 . A process according to  claim 19  wherein the phosphorus to total alumina ratio is about 0.25 to about 0.7 and the catalyst has an attrition index of about 10 or less.  
     
     
         23 . A process according to  claim 19  where the added alumina of (c) is present in an amount ranging from about 3 to about 8% by weight.  
     
     
         24 . A process according to  claim 23  wherein the additive further comprises clay.  
     
     
         25 . A process according to  claim 15  further comprising recovering ethylene and/or propylene from said process.  
     
     
         26 . A process according to  claim 15  wherein the process is fluidized.  
     
     
         27 . A process according to  claim 26  wherein the process is fluidized catalytic cracking of hydrocarbons.  
     
     
         28 . A catalyst composition comprising a large pore aluminosilicate and 0.1 to about 90 weight % additive comprising 
 (a) about 30 to about 85% by weight zeolite having a constraint index of 1 to 12,    (b) about 6-24% by weight phosphorus, measured as P 2 O 5 , and    (c) alumina, wherein added alumina is present in an amount of less than about 10% and total alumina is less than about 30% by weight of the total additive,    said additive further having a molar ratio of phosphorous to total alumina sufficient to obtain an attrition index for the additive equal to or less than about 20.    
     
     
         29 . A catalyst according to  claim 28  wherein the additive comprises greater than about 60 to about 85% ZSM-5.  
     
     
         30 . A catalyst according to  claim 29  wherein the additive consists essentially of (a), (b), and (c).  
     
     
         31 . A catalyst according to  claim 28  wherein the additive comprises about 30 to about 60% ZSM-5.  
     
     
         32 . A catalyst according to  claim 31  wherein the additive comprises about 3 to about 8% by weight added alumina.  
     
     
         33 . A catalyst according to  claim 32  wherein the additive has an attrition index of less than 10.  
     
     
         34 . A catalyst according to  claim 2  wherein the catalyst consists of essentially (a), (b) and (c).