Vanadium traps for catalytic cracking processes

Abstract

A metal trap for an FCC catalyst include pre-formed microspheres impregnated with a salt of calcium and/or magnesium and 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 microscope; 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 and a salt of calcium and/or magnesium. 
   
     
     
         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, or a mixture thereof. 
     
     
         17 . The FCC catalyst composition of  claim 14 , wherein the organic acid salt is a formate, an acetate, or a propionate salt, or a mixture of any two or more thereof. 
     
     
         18 . The FCC catalyst composition of  claim 17 , wherein the organic acid salt is a formate salt. 
     
     
         19 . The FCC catalyst composition of  claim 17 , wherein the organic acid salt is an acetate salt. 
     
     
         20 . A method of preparing the FCC catalyst composition of  claim 14 , the method comprising blending the zeolite component and the non-zeolitic component. 
     
     
         21 . The method of  claim 20 , wherein the zeolite component is prepared by a method comprising:
 pre-forming a precursor first microsphere comprising a non-zeolitic material and alumina; and   in situ crystallizing a zeolite on the pre-formed first microsphere to provide the zeolite component.   
     
     
         22 . A method of cracking a hydrocarbon feed under fluid catalytic cracking conditions, the method comprising contacting the hydrocarbon feed with the FCC catalyst composition of  claim 14 . 
     
     
         23 . A method of passivating and/or trapping at least one metal contaminant from a hydrocarbon oil feed in an FCC unit bed, the method comprising contacting the hydrocarbon oil feed with the FCC catalyst composition of  claim 14 . 
     
     
         24 . The method of  claim 23 , wherein at least one metal contaminant is vanadium. 
     
     
         25 . 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 and a salt of calcium and/or magnesium. 
   
     
     
         26 . The FCC catalyst composition of  claim 25 , 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. 
     
     
         27 . The FCC catalyst composition of  claim 25 , wherein the rare earth element is lanthanum, cerium, ytterbium, gadolinium, yttrium, neodymium, or a mixture of any two or more thereof. 
     
     
         28 . The FCC catalyst composition of  claim 25 , wherein the salt of calcium and/or magnesium is a carbonate salt. 
     
     
         29 . The FCC catalyst composition of  claim 25 , wherein the organic acid salt is a formate, an acetate, or a propionate salt, or a mixture of any two or more thereof. 
     
     
         30 . The FCC catalyst composition of  claim 29 , wherein the organic acid salt is a formate salt.