Additives for metal contaminant removal

Abstract

The present invention is directed to catalytic cracking additives comprising a metals trapping material; and a high activity catalyst. The present invention is directed to processes for the catalytic cracking of feedstock comprising contacting said feedstock under catalytic cracking conditions with a composition comprising a bulk catalyst and a catalytic cracking additive, wherein the catalytic cracking additive comprises a metals trapping material; and a high activity catalyst. The invention is also directed to processes for increasing the performance of a bulk catalyst in the presence of at least one metal comprising contacting a feedstock with a catalytic cracking additive comprising a metals trapping material; and a high activity catalyst.

1 . A catalytic cracking additive comprising: 
 a) a metals trapping material; and    b) a high activity catalyst.    
   
   
       2 . The catalytic cracking additive of  claim 1 , wherein the metals trapping material comprises from about 2% to about 98% of the additive by weight.  
   
   
       3 . The catalytic cracking additive of  claim 1 , wherein the metals trapping material comprises from about 30% to about 95% of the additive by weight.  
   
   
       4 . The catalytic cracking additive of  claim 1 , wherein the metals trapping material comprises from about 70% to about 90% of the additive by weight.  
   
   
       5 . The catalytic cracking additive of  claim 1 , wherein the high activity catalyst comprises from about 5% to about 60% of the additive by weight.  
   
   
       6 . The catalytic cracking additive of  claim 1 , wherein the metals trapping material and the high activity catalyst comprise separate particles.  
   
   
       7 . The catalytic cracking additive of  claim 1 , wherein the metals trapping material and the high activity catalyst are within the same particle.  
   
   
       8 . The catalytic cracking additive of  claim 1 , wherein the metals trapping material comprises a calcium-containing compound, a magnesium-containing compound, or a combination thereof.  
   
   
       9 . The catalytic cracking additive of  claim 1 , wherein the metals trapping material comprises a hydrotalcite-like compound, a silica- and alumina-containing compound, a mixed metal oxide, or a combination thereof.  
   
   
       10 . The catalytic cracking additive of  claim 1 , wherein the high activity catalyst comprises a zeolite.  
   
   
       11 . The catalytic cracking additive of  claim 1 , wherein the high activity catalyst comprises an in situ-synthesized zeolite.  
   
   
       12 . The catalytic cracking additive of  claim 10 , wherein the zeolite is zeolite X, Y zeolite, zeolite A, zeolite L, zeolite ZK-4, beta zeolite, faujasite, or a combination thereof.  
   
   
       13 . The catalytic cracking additive of  claim 10 , wherein the zeolite is Y zeolite, beta zeolite, faujasite, or a combination thereof.  
   
   
       14 . The catalytic cracking additive of  claim 1 , wherein the metals trapping material is a vanadium trapping material.  
   
   
       15 . A circulating inventory of catalyst particles in a fluid catalytic cracking process, wherein from about 2 to about 80% by weight of said inventory comprises the catalytic cracking additive of  claim 1 .  
   
   
       16 . A process for the catalytic cracking of feedstock comprising contacting said feedstock under catalytic cracking conditions with a composition comprising a bulk catalyst and a catalytic cracking additive, wherein the catalytic cracking additive comprises: 
 a) a metals trapping material; and    b) a high activity catalyst.    
   
   
       17 . The process of  claim 16 , wherein the catalytic cracking additive comprises from about 2% to about 80% of the composition by weight.  
   
   
       18 . The process of  claim 16 , wherein the catalytic cracking additive comprises from about 20% to about 60% of the composition by weight.  
   
   
       19 . The process of  claim 16 , wherein the catalytic cracking additive comprises from about 5% to about 20% of the composition by weight.  
   
   
       20 . The process of  claim 16 , wherein the metals trapping material comprises from about 2% to about 98% of the additive by weight.  
   
   
       21 . The process of  claim 16 , wherein the metals trapping material comprises from about 60% to about 95% of the additive by weight.  
   
   
       22 . The process of  claim 16 , wherein the metals trapping material comprises from about 70% to about 90% of the additive by weight.  
   
   
       23 . The process of  claim 16 , wherein the high activity catalyst comprises from about 5% to about 40% of the additive by weight.  
   
   
       24 . The process of  claim 16 , wherein the metals trapping material and the high activity catalyst comprise separate particles.  
   
   
       25 . The process of  claim 16 , wherein the metals trapping material and the high activity catalyst are within the same particle.  
   
   
       26 . The process of  claim 16 , wherein the metals trapping material comprises a calcium-containing compound, a magnesium-containing compound, or a combination thereof.  
   
   
       27 . The process of  claim 16 , wherein the metals trapping material comprises a non-anionic magnesium- and aluminum-containing compound that has not been derived from a hydrotalcite-like compound, a hydrotalcite-like compound, a silica- and alumina-containing compound, or a combination thereof.  
   
   
       28 . The process of  claim 16 , wherein the high activity catalyst comprises a zeolite.  
   
   
       29 . The process of  claim 16 , wherein the high activity catalyst comprises an in situ-synthesized zeolite.  
   
   
       30 . The process of  claim 28 , wherein the zeolite is zeolite X, Y zeolite, zeolite A, zeolite L, zeolite ZK-4, beta zeolite, ZSM-5 zeolite, faujasite, or a combination thereof.  
   
   
       31 . The process of  claim 28 , wherein the zeolite is Y zeolite, beta zeolite, or a combination thereof.  
   
   
       32 . The process of  claim 16 , wherein the metals trapping material is a vanadium trapping material.  
   
   
       33 . The process of  claim 16 , wherein the bulk catalyst is about 5% to about 40% zeolite.  
   
   
       34 . A process for increasing the performance of a bulk catalyst in the presence of at least one metal comprising contacting a feedstock with a catalytic cracking additive comprising: 
 a) a metals trapping material; and    b) a high activity catalyst.    
   
   
       35 . The process of  claim 34 , wherein the catalytic cracking additive increases a catalytic conversion of a feedstock.  
   
   
       36 . The process of  claim 34 , wherein the catalytic cracking additive increases a gasoline production from a feedstock.  
   
   
       37 . The process of  claim 34 , wherein the catalytic cracking additive increases an LPG production from a feedstock.  
   
   
       38 . The process of  claim 34 , wherein the catalytic cracking additive decreases an LCO production from a feedstock.  
   
   
       39 . The process of  claim 34 , wherein the catalytic cracking additive decreases a bottoms production from a feedstock.  
   
   
       40 . The process of  claim 34 , wherein the catalytic cracking additive decreases coke production from a feedstock.  
   
   
       41 . The process of  claim 34 , wherein the catalytic cracking additive decreases hydrogen gas production from a feedstock.  
   
   
       42 . The process of  claim 34 , wherein the catalytic cracking mitigates a decrease in crystallinity of a bulk catalyst.  
   
   
       43 . The process of  claim 34 , wherein the catalytic cracking additive mitigates a reduction in the peak area of the 2-theta peak at 6.3 degrees of a bulk catalyst.  
   
   
       44 . The process of  claim 34 , wherein the catalytic cracking additive mitigates a reduction in the surface area of a bulk catalyst.