Mesoporous fcc catalysts with excellent attrition resistance

Abstract

This application discloses a mesoporous catalyst formed by combining a matrix precursor treated with a polyphosphate, and a metallic oxide treated with a cationic electrolyte. The combined treatment with the polyphosphate and cationic polyelectrolyte yields unexpected improvements in attrition resistance, while maintaining high overall pore volume, even as the ratio of meso pore volume to macro pore volume of the formed FCC catalyst increases.

1 . A mesoporous catalyst comprising: 1) a first metal oxide modified by a phosphorus structuring agent through heating; 2) a second metal oxide that is treated by a cationic polyelectrolyte; and 3) an active zeolite cracking component, wherein said first and said second metal oxide can be the same or different and said catalyst is in the form of particles having an average particle size of from 20 to 200 microns. 
     
     
         2 . The mesoporous catalyst of  claim 1 , wherein said polyelectrolyte is added to a slurry containing both the first and second metal oxides. 
     
     
         3 . The mesoporous catalyst of  claim 1 , wherein said first or second metal oxide is selected from the group consisting of spinel, mullite, calcined kaolin, metakaolin, hydrous kaolin, alumina and mixtures thereof. 
     
     
         4 . The mesoporous catalyst of  claim 1 , wherein said first metal oxide is present in the amount of 30 wt. % to 70 wt. % of said catalyst. 
     
     
         5 . The mesoporous catalyst of  claim 4 , wherein said first metal oxide is present in the amount of 40 wt. % to 52 wt. % of said catalyst. 
     
     
         6 . The mesoporous catalyst of  claim 1 , wherein said second metal oxide is present in the amount of 30 wt. % to 70 wt. % of said catalyst. 
     
     
         7 . The mesoporous catalyst of  claim 6 , wherein said second metal oxide is present in the amount of 48 wt. % to 60 wt. % of said catalyst. 
     
     
         8 . The mesoporous catalyst of  claim 1 , wherein said phosphorus structuring agent is a polyphosphate. 
     
     
         9 . The mesoporous catalyst of  claim 8 , wherein said polyphosphate is a fertilizer grade ammonium polyphosphate. 
     
     
         10 . The mesoporous catalyst of  claim 1 , wherein said cationic electrolyte is selected from the group consisting of polyamines, quaternary ammonium salts, dialkyl ammonium polymer salts, dimethyl dialkyl ammonium chloride and mixtures thereof. 
     
     
         11 . The mesoporous catalyst of  claim 10 , wherein said cationic electrolyte is a polyamine. 
     
     
         12 . The mesoporous catalyst of  claim 1 , wherein said first metal oxide is spinel or mullite. 
     
     
         13 . The mesoporous catalyst of  claim 1 , wherein said second metal oxide is hydrous kaolin. 
     
     
         14 . The mesoporous catalyst of  claim 1 , wherein said cationic polyelectrolyte-treated metal oxide further includes a dispersant. 
     
     
         15 . The mesoporous catalyst of  claim 1 , wherein said first metal oxide is structured by said phosphorus structuring agent in the amount of 0.01 to 5 wt. % of said first metal oxide. 
     
     
         16 . The mesoporous catalyst of  claim 1 , wherein said modification of said phosphorus structuring agent occurs at a temperature of at least about 350° F. 
     
     
         17 . The mesoporous catalyst of  claim 1 , wherein said second metal oxide is treated with said cationic polyelectrolyte in the amount of 0.005 to 0.25 wt. % of said second metal oxide. 
     
     
         18 . The mesoporous catalyst of  claim 1 , wherein said catalyst has a meso/macro ratio of 0.65 to 1.2 
     
     
         19 . The mesoporous catalyst of  claim 18 , wherein said catalyst has a meso-macro ratio of 0.675 to 1.1. 
     
     
         20 . The mesoporous catalyst of  claim 1 , wherein said catalyst has an air jet attrition rate of at least 0.5 and less than 2.5. 
     
     
         21 . The mesoporous catalyst of  claim 20 , wherein said catalyst has an air jet attrition rate of at least 0.5 and less than 1.5. 
     
     
         22 . A method of cracking a hydrocarbon under FCC conditions with said mesoporous catalyst of  claim 1 . 
     
     
         23 . The mesoporous catalyst of  claim 1 , wherein said cationic electrolyte treatment of said second metal oxide includes heating.