Metal trap for use in fluid catalytic cracking (fcc)

Abstract

A metal trap for an FCC catalyst include pre-formed microspheres impregnated with an organic acid salt of a rare earth element.

1 .- 13 . (canceled) 
     
     
         14 . A fluid catalytic cracking (FCC) catalyst composition comprising:
 a zeolite component comprising a first microsphere; and   a non-zeolitic component comprising pre-formed second microspheres, separate from the first microsphere, and impregnated with an organic acid salt of a rare earth element.   
     
     
         15 . The FCC catalyst composition of  claim 14 , wherein the pre-formed second microspheres comprise kaolinite, montmorillonite, bentonite, attapulgite, kaolin, amorphous kaolin, metakaolin, mullite, spinel, hydrous kaolin, calcined hydrous kaolin, clay, or a mixture of any two or more thereof. 
     
     
         16 . The FCC catalyst composition of  claim 14  wherein the rare earth element is lanthanum, cerium, ytterbium, gadolinium, yttrium, neodymium, or a mixture of any two or more thereof. 
     
     
         17 . (canceled) 
     
     
         18 . (canceled) 
     
     
         19 . The FCC composition of  claim 14 , wherein the organic acid salt is a formate salt. 
     
     
         20 . The FCC composition of  claim 14 , wherein the organic acid salt of the rare earth element is lanthanum formate, lanthanum acetate, cerium formate, cerium acetate, or a mixture of any two or more thereof. 
     
     
         21 . (canceled) 
     
     
         22 . A method of preparing a metal trap, the method comprising contacting pre-formed second microspheres with an organic acid salt of a rare earth element, preparing the organic salt of the rare earth element by reacting an alkaline salt of the rare earth element with the organic acid. 
     
     
         23 .- 25 . (canceled) 
     
     
         26 . The method of  claim 26 , wherein the alkaline salt of the rare earth element is a carbonate salt. 
     
     
         27 . The method of  claim 22 , wherein the rare earth element is lanthanum, cerium, ytterbium, gadolinium, yttrium, neodymium, or a mixture of any two or more thereof. 
     
     
         28 . (canceled) 
     
     
         29 . The method of  claim 22 , wherein the organic acid is formic acid, acetic acid, propionic acid, or a mixture of any two or more thereof. 
     
     
         30 . The method of  claim 29 , wherein the organic acid is formic acid. 
     
     
         31 . The method of  claim 29 , wherein the organic acid salt of the rare earth element is lanthanum formate, lanthanum acetate, cerium formate, cerium acetate, or a mixture of any two or more thereof. 
     
     
         32 .- 36 . (canceled) 
     
     
         37 . A fluid catalytic cracking (FCC) catalyst composition comprising:
 a non-cracking component comprising a first microsphere; and   a non-zeolitic component comprising pre-formed second microspheres, separate from the first microsphere, and impregnated with an organic acid salt of a rare earth element.   
     
     
         38 . The FCC catalyst composition of  claim 37 , wherein the pre-formed second microspheres comprise kaolinite, montmorillonite, bentonite, attapulgite, kaolin, amorphous kaolin, metakaolin, mullite, spinel, hydrous kaolin, calcined hydrous kaolin, clay, or a mixture of any two or more thereof. 
     
     
         39 . The FCC catalyst composition of  claim 37 , wherein the rare earth element is lanthanum, cerium, ytterbium, gadolinium, yttrium, neodymium, or a mixture of any two or more thereof. 
     
     
         40 . The FCC catalyst composition of  claim 37 , wherein the rare earth element is lanthanum, cerium, or a mixture thereof. 
     
     
         41 . The FCC composition of  claim 37 , wherein the organic acid salt is a formate, an acetate, or a propionate salt, or a mixture of any two or more thereof. 
     
     
         42 . The FCC composition of  claim 41 , wherein the organic acid salt is a formate salt. 
     
     
         43 . The FCC composition of  claim 41 , wherein the organic acid salt of the rare earth element is lanthanum formate, lanthanum acetate, cerium formate, cerium acetate, or a mixture of any two or more thereof. 
     
     
         44 . The FCC catalyst composition of  claim 37 , wherein the rare earth element is present in a range of 0.1 wt % to about 20.0 wt % on an oxide basis. 
     
     
         45 . A method of preparing a FCC catalyst composition according to  claim 37 , comprising blending the non-cracking component and the non-zeolitic component.