Novel cracking catalytic compositions

Abstract

Novel catalytic compositions for cracking of crude oil fractions are disclosed. The catalytic compositions comprise a basic material. When used in a cracking process, preferably a FCC process, the resulting LCO and HCO fractions have desirably low aromatics levels. Further disclosed is a one-stage FCC process using the catalytic composition of the invention. Also disclosed is a two-stage FCC process for maximizing the LCO yield.

1 . An FCC process comprising the step of contacting an FCC feedstock with a catalytic composition under FCC reaction conditions, wherein said catalytic composition comprises a basic material, and wherein said catalytic compositions are substantially free of acidic zeolite. 
     
     
         2 . The process of  claim 1  wherein the FCC feedstock is selected from the group consisting of vacuum gas oil, hydrotreated vacuum gas oil, atmospheric resid feed, crude oil, shale oil, tar sand, and mixtures thereof. 
     
     
         3 . The process of  claim 1 , which is carried out at a reaction temperature in the range of 400-600° C. 
     
     
         4 . A two-stage cracking process for cracking a feedstock selected from vacuum gasoils, hydrotreated vacuum gasoils, coker gasoils, atmospheric residues, vacuum residues and the hydrotreated products thereof, characterized in that at least one of the stages is a fluid catalytic cracking process in which the catalytic composition comprises a basic material, and wherein said catalytic composition is substantially free of acidic zeolite. 
     
     
         5 . A process according to  claim 4  in which the first stage is operated at a reaction temperature of i) 460 to 900° C., ii) between 460 to 600° C., or iii) between 460 to 500° C. 
     
     
         6 . A process according to  claim 4  in which both stages are FCC processes, and the second stage is operated at a reaction temperature of i) 480 to 900° C., ii) between 500 to 600° C., or iii) between 530 to 570° C. 
     
     
         7 . A process according to  claim 4  in which said FCC process comprises a stripper and a regenerator and the stripper temperature is adjusted between 520 to 600° C. by routing some catalyst from the regenerator to the stripper. 
     
     
         8 . A cracking process according to  claim 4  wherein:
 a. one of the stages is a hydrocracking process; 
 b. one of the stages is a hydrocracking process and the first stage is a fluid catalytic cracking process; 
 c. one of the stages is a hydrocracking process and the first stage is a hydrocracking process; or 
 d. both of the stages are fluid catalytic cracking processes. 
 
     
     
         9 . An LCD, HCO, and/or gasoline fraction obtained with the process of  claim 8 . 
     
     
         10 . The process according to  claim 1  wherein said catalytic composition is substantially free of components having a dehydrogenating activity. 
     
     
         11 . The process according to  claim 1  wherein said catalytic composition has sufficient catalytic activity to provide a conversion of FCC feedstock of at least 30% at a CTO ratio of 10 and a reaction temperature below 600° C. 
     
     
         12 . The process according to  claim 1  wherein the basic material of said catalytic composition:
 a. is selected from the group consisting of compounds of alkali metals, compounds of alkaline earth metals, compounds of trivalent metals, compounds of transition metals, and mixtures thereof; 
 b. is the oxide, the hydroxide or the phosphate of a transition metal, an alkali metal, an earth alkaline metal, or a transition metal, or a mixture thereof; 
 c. comprises an alkali metal compound; 
 d. comprises an alkaline earth metal compound; 
 e. is a mixed metal oxide; 
 f. comprises a compound of a transition metal; 
 g. is a hydrotalcite; 
 h. is an aluminum phosphate; 
 i. is doped with a metal cation; 
 j. is supported on a carrier material; 
 k. any combination of j) with a)-i); 
 l. any combination of i) with a)-h); and/or, 
 m. any combination of a)-j). 
 
     
     
         13 . The process according to  claim 1  wherein the compound of a transition metal of said catalytic composition is selected from the group consisting of ZrO2, Y2O3, Nb2O5, and mixtures thereof; and/or wherein the dopant metal cation is selected from metals of Group IIb, Group IIIb, Group IVb, the rare earth metals, and mixtures thereof; and/or wherein the carrier is a refractory oxide. 
     
     
         14 . A process according to  claim 4  in which the catalyst in one of the stages is a traditional acidic zeolite-containing cracking catalyst. 
     
     
         15 . The process according to  claim 4  wherein the catalytic composition used in one or more of the fluidized catalytic cracking stages is substantially free of components having a dehydrogenating activity, 
     
     
         16 . The process according to  claim 4  wherein the catalytic composition used in one or more of the fluidized catalytic cracking stages is substantially free has sufficient catalytic activity to provide a conversion of FCC feedstock of at least 30% at a CTO ratio of 10 and a reaction temperature below 600° C. 
     
     
         17 . The process according to  claim 4  wherein the basic material of said catalytic composition:
 a. is selected from the group consisting of compounds of alkali metals, compounds of alkaline earth metals, compounds of trivalent metals, compounds of transition metals, and mixtures thereof; 
 b. is the oxide, the hydroxide or the phosphate of a transition metal, an alkali metal, an earth alkaline metal, or a transition metal, or a mixture thereof; 
 c. comprises an alkali metal compound; 
 d. comprises an alkaline earth metal compound; 
 e. is a mixed metal oxide; 
 f. comprises a compound of a transition metal; 
 g. is a hydrotalcite; 
 h. is an aluminum phosphate; 
 i. is doped with a metal cation; 
 j. is supported on a carrier material; 
 k. any combination of j) with a)-i); 
 l. any combination of i) with a)-h); and/or, 
 m. any combination of a)-j). 
 
     
     
         18 . The process according to  claim 8  wherein the compound of a transition metal of said catalytic composition is selected from the group consisting of ZrO2, Y2O3, Nb2O5, and mixtures thereof; and/or wherein the dopant metal cation is selected from metals of Group IIb, Group IIIb, Group IVb, the rare earth metals, and mixtures thereof; and/or wherein the carrier is a refractory oxide. 
     
     
         19 . The process according to  claim 8  wherein the carrier is selected from alumina, silica, silica-alumina, titania, and mixtures thereof; and/or wherein the dopant metal is selected from the group consisting of La, Zn, Zr, and mixtures thereof. 
     
     
         20 . The process according to  claim 8  wherein said catalytic composition comprises a material having acidic sites.