Catalytic cracking with zeolite ITQ-13

Abstract

A catalytic cracking process is disclosed for feedstock containing hydrocarbons having at least 5 carbon atoms. The feedstock is contacted, under catalytic cracking conditions, with a 9-member ring catalyst composition and, optionally, a large pore molecular sieve, such as zeolite Y.

We claim:  
     
         1 . A catalytic cracking process comprising contacting, under catalytic cracking conditions, a feedstock comprising hydrocarbons having at least 5 carbon atoms with a catalyst composition comprising a synthetic porous crystalline material having a multi-dimensional channel system, at least a first parallel set of said channels comprising 9-member rings having a pore size of at least about 3.6 Angstroms.  
     
     
         2 . The process of  claim 1 , wherein at least a second set of said channels comprises 10-member rings.  
     
     
         3 . The process of  claim 1 , wherein the catalyst channel system is 3-dimensional.  
     
     
         4 . The process of  claim 1 , wherein said at least first parallel set of channels has a pore size of at least about 4.0 Angstroms.  
     
     
         5 . The process of  claim 1 , wherein said at least first parallel set of channels has a pore size of at least about 4.2 Angstroms.  
     
     
         6 . The process of  claim 4 , wherein said at least first parallel set of channels has a pore size less than or equal to about 5.0 Angstroms.  
     
     
         7 . The process of  claim 5 , wherein said at least first parallel set of channels has a pore size less than or equal to about 5.0 Angstroms.  
     
     
         8 . The process of  claim 1 , wherein the catalyst is metal-stabilized.  
     
     
         9 . The process of  claim 8 , wherein the catalyst is metal-stabilized with at least one of at least one metal of Group 2a, 3b, 4b, 7b, 8, 1b, 2b, 3a and 5a of The Periodic Table of the Elements.  
     
     
         10 . The process of  claim 9 , wherein the catalyst is metal-stabilized with at least one of copper, phosphorus, iron, silver, magnesium, lanthanum, zinc, aluminum, zirconium, manganese, and cerium.  
     
     
         11 . The process of  claim 10 , wherein the catalyst is metal stabilized with at least one of copper and phosphorous.  
     
     
         12 . The process of  claim 1 , wherein the feedstock is naphtha.  
     
     
         13 . The process of  claim 1 , wherein the feedstock is at least one of gas oil, vacuum gas oil and residual oil vacuum resid.  
     
     
         14 . The process of  claim 1 , which is a fluid catalytic cracking process.  
     
     
         15 . The process of  claim 1 , wherein the catalyst composition is used as an additive catalyst.  
     
     
         16 . The process of  claim 1 , wherein the catalyst composition is used as a base catalyst.  
     
     
         17 . The process of  claim 1 , wherein the catalyst composition comprises a molecular sieve.  
     
     
         18 . The process of  claim 17 , wherein the catalyst comprises at least one of zeolite Y, zeolite REY, zeolite X, zeolite USY and zeolite REUSY.  
     
     
         19 . The process of  claim 1 , wherein propylene is produced.  
     
     
         20 . The process of  claim 19 , wherein the propylene selectivity is at least about 30%.  
     
     
         21 . The process of  claim 20 , wherein the propylene selectivity is at least about 50%.  
     
     
         22 . The process of  claim 21 , wherein the propylene selectivity is at least about 60%.  
     
     
         23 . The process of  claim 19 , wherein light olefins are produced and the light olefin selectivity is at least about 50%.  
     
     
         24 . The process of  claim 23 , wherein the light olefin selectivity is at least about 70%.  
     
     
         25 . The process of  claim 24 , wherein the light olefin selectivity is at least about 80%.  
     
     
         26 . The process of  claim 20 , wherein light olefins are produced and the light olefin selectivity is at least about 50%.  
     
     
         27 . The process of  claim 21 , wherein light olefins are produced and the light olefin selectivity is at least about 70%.  
     
     
         28 . The process of  claim 23 , wherein light olefins are produced and the light olefin selectivity is at least about 80%.  
     
     
         29 . The process of  claim 1 , wherein the catalyst composition comprises a synthetic porous crystalline material comprising a framework of tetrahedral atoms bridged by oxygen atoms, the tetrahedral atom framework being defined by a unit cell with atomic coordinates in nanometers shown in Table 1, wherein each coordinate position may vary within ±0.05 nanometer.  
     
     
         30 . The process of  claim 1 , wherein the synthetic porous crystalline material has an X-ray diffraction pattern including d-spacing and relative intensity values substantially as set forth in Table 2.  
     
     
         31 . The process of  claim 29 , wherein the synthetic porous crystalline material has an X-ray diffraction pattern including d-spacing and relative intensity values substantially as set forth in Table 2.  
     
     
         32 . The process of  claim 1 , wherein the synthetic porous crystalline material has a composition comprising the molar relationship  
       X 2 O 3 :(n)YO 2 ,  
       wherein n is at least about 5, X is a trivalent element, and Y is a tetravalent element.  
     
     
         33 . The process of  claim 29 , wherein the synthetic porous crystalline material has a composition comprising the molar relationship  
       X 2 O 3 :(n)YO 2 ,  
       wherein n is at least about 5, X is a trivalent element, and Y is a tetravalent element.  
     
     
         34 . The process of  claim 30 , wherein the synthetic porous crystalline material has a composition comprising the molar relationship  
       X 2 O 3 :(n)YO 2 ,  
       wherein n is at least about 5, X is a trivalent element, and Y is a tetravalent element.  
     
     
         35 . The process of  claim 31 , wherein the synthetic porous crystalline material has a composition comprising the molar relationship  
       X 2 O 3 :(n)YO 2 ,  
       wherein n is at least about 5, X is a trivalent element, and Y is a tetravalent element.  
     
     
         36 . The process recited in  claim 35 , wherein X is a trivalent element selected from the group consisting of boron, iron, indium, gallium, aluminum, and a combination thereof; and Y is a tetravalent element selected from the group consisting of silicon, tin, titanium, germanium, and a combination thereof.  
     
     
         37 . The process recited in  claim 36 , wherein X comprises boron or aluminum and Y comprises silicon.  
     
     
         38 . The process of  claim 37 , wherein X is aluminum.  
     
     
         39 . The process of  claim 1 , wherein the catalyst composition also comprises a large pore molecular sieve having a pore size greater than 6 Angstrom.  
     
     
         40 . The process of  claim 39 , wherein the large pore molecular sieve has a pore size greater than 7 Angstrom.  
     
     
         41 . The process of  claim 39 , wherein the weight ratio of said synthetic porous crystalline material to the large pore molecular sieve is about 0.005 to about 50.  
     
     
         42 . The process of  claim 40 , wherein the weight ratio of said synthetic porous crystalline material to the large pore molecular sieve is about 0.005 to about 50.  
     
     
         43 . The process of  claim 41 , wherein the weight ratio of said synthetic porous crystalline material to the large pore molecular sieve is about 0.1 to about 1.0.  
     
     
         44 . The process of  claim 42 , wherein the weight ratio of said synthetic porous crystalline material to the large pore molecular sieve is about 0.1 to about 1.0.  
     
     
         45 . The process of  claim 11 , wherein the catalyst is metal-stabilized with copper.  
     
     
         46 . The process of  claim 1 , wherein the catalyst composition comprises at least one of a zeolite and SAPO.  
     
     
         47 . The process of  claim 1 , wherein at least part of the reaction zone is at a temperature of about 500°-600° C.  
     
     
         48 . The process of  claim 1 , wherein the process total pressure is about 0.5 to about 10 atmospheres.  
     
     
         49 . The process of  claim 48 , wherein the process total pressure is about 1 to about 3 atmospheres.