FCC catalyst

Abstract

This invention relates to a mesoporous catalytic cracking catalyst, a process for the production of such catalysts, and a process utilizing such catalysts in cracking operations. The mesoporous fluidized catalytic cracking catalyst is selective for minimizing the production of coke and light gas. The catalyst comprises an amorphous, porous matrix having pores ranging in diameter from about 1 Å to about 10 Å and ranging in diameter from about 40 Å to about 500 Å, but substantially free of pores ranging in diameter from about 10 Å to about 40 Å.

1 . A catalyst composition, comprising:
 an amorphous, porous matrix having pores ranging in diameter from about 1 Å to about 10 Å and pores ranging in diameter from about 40 Å to about 500 Å, wherein in the pore range from 50 Å to 250 Å, there is a single maximum in differential pore volume distribution over the 50 Å to 250 Å range;   wherein the amorphous, porous matrix is comprised of at least one clay, an aluminum hydroxide, and binder colloids.   
   
   
       2 . The composition of  claim 1 , wherein the aluminum hydroxide is selected from gibbsite, bayerite, nordstrandite, and doyelite. 
   
   
       3 . The composition of  claim 2 , wherein the aluminum hydroxide is gibbsite. 
   
   
       4 . The composition of  claim 1 , wherein the amorphous, porous matrix is substantially free of pores ranging in size from about 10 Å to about 40 Å. 
   
   
       5 . The composition of  claim 1 , wherein the integrated maximum pore volume for matrix pores having a diameter between about 10 Å and about 40 Å is less than about 0.03 cc/g. 
   
   
       6 . The composition of  claim 1 , further comprising at least one molecular sieve. 
   
   
       7 . The composition of  claim 6 , wherein the molecular sieve is a zeolite. 
   
   
       8 . The composition of  claim 5 , wherein the zeolite is a faujasite. 
   
   
       9 . The composition of  claim 7 , wherein the zeolite is a faujasite. 
   
   
       10 . The composition of  claim 7 , wherein the clay is selected from kaolin, bentonite, attapulgite, montmorillonite, hectorite, and pyrophyllite. 
   
   
       11 . The composition of  claim 7 , wherein the catalyst composition further comprises a shape-selective zeolite with a framework structure type selected from MFI, MFS, MEL, MTW, EUO, MTT, HEU, FER, and TON. 
   
   
       12 . The composition of  claim 7 , wherein the aluminum hydroxide is gibbsite. 
   
   
       13 . The composition of  claim 7  wherein the binder colloid comprises alkaline silicate. 
   
   
       14 . The composition of  claim 13  wherein the alkaline silicate is sodium silicate.