The present invention relates to a heavy oil catalytic cracking catalyst and preparation method thereof. The catalyst comprises 2 to 50% by weight of an ultra-stable rare earth type Y molecular sieve, 0.5 to 30% by weight of one or more other molecular sieves, 0.5 to 70% by weight of clay, 1.0 to 65% by weight of high-temperature-resistant inorganic oxides, and 0.01 to 12.5% by weight of rare earth oxide. The ultra-stable rare earth type Y molecular sieve is obtained as follows: the raw material, NaY molecular sieve, is subjected to a rare earth exchange and a dispersing pre-exchange, and the molecular sieve slurry is filtered, washed and subjected to a first calcination to produce a “one-exchange one-calcination” rare earth sodium Y molecular sieve, wherein the order of the rare earth exchange and the dispersing pre-exchange is not limited; and the “one-exchange one-calcination” rare earth sodium Y molecular sieve is further subjected to ammonium salt exchange for sodium reduction and a second calcination. The catalyst provided in the present invention is characteristic in its high heavy-oil-conversion capacity, a high total liquid yield and a high light oil yield.

The present invention provides a magnesium-modified ultra-stable rare earth type Y molecular sieve and the preparation method thereof, which method is carried out by subjecting a NaY molecular sieve as the raw material to a rare earth exchange and a dispersing pre-exchange, then to an ultra-stabilization calcination treatment, and finally to a magnesium modification. The molecular sieve comprises 0.2 to 5% by weight of magnesium oxide, 1 to 20% by weight of rare earth oxide, and not more than 1.2% by weight of sodium oxide, and has a crystallinity of 46 to 63%, and a lattice parameter of 2.454 nm to 2.471 nm. In contrast to the prior art, in the molecular sieve prepared by this method, rare earth ions are located in sodalite cages, which is demonstrated by the fact that no rare earth ion is lost during the reverse exchange process. Moreover, the molecular sieve prepared by such a method has a molecular particle size D(v,0.5) of not more than 3.0 μm and a D(v,0.9) of not more than 20 μm. Such a molecular sieve has both high stability and high selectivity for the target product, while cracking catalysts using the molecular sieve as an active component is characterized by a high heavy-oil-conversion capacity and a high yield of valuable target products.

A catalyst is provided for production of hydrocarbons including monocyclic aromatic hydrocarbons having a carbon number of 6 to 8 and aliphatic hydrocarbons having a carbon number of 3 to 4 from feedstock in which a 10 vol % distillation temperature is 140° C. or higher and a 90 vol % distillation temperature is 380° C. or lower. The catalyst includes crystalline aluminosilicate including large-pore zeolite having a 12-membered ring structure.

Improved alkylation catalysts, alkylation methods, and methods of making alkylation catalysts are described. The alkylation method comprises reaction over a solid acid, zeolite-based catalyst and can be conducted for relatively long periods at steady state conditions. The alkylation catalyst comprises a crystalline zeolite structure, a Si/Al molar ratio of 20 or less, less than 0.5 weight percent alkali metals, and further having a characteristic catalyst life property. Some catalysts may contain rare earth elements in the range of 10 to 35 wt %. One method of making a catalyst includes a calcination step following exchange of the rare earth element(s) conducted at a temperature of at least 575° C. to stabilize the resulting structure followed by an deammoniation treatment. An improved method of deammoniation uses low temperature oxidation.

Process for the preparation of a catalyst and a catalyst comprising the use of more than one silica source is provided herein. Thus, in one embodiment, the invention provides a particulate FCC catalyst comprising about 5 to about 60 wt % one or more zeolites, about 15 to about 35 wt % quasicrystalline boehmite (QCB), about 0 to about 35 wt % microcrystalline boehmite (MCB), greater than about 0 to about 15 wt % silica from sodium stabilized basic colloidal silica, greater than about 0 to about 30 wt % silica from acidic colloidal silica or polysilicic acid, and the balance clay and the process for making the same. This process results in attrition resistant catalysts with a good accessibility.

In accordance with one or more embodiments of the present disclosure, a catalyst composition includes a catalyst support and at least one hydrogenative component disposed on the catalyst support. The catalyst support includes at least one USY zeolite having a framework substituted with titanium and/or zirconium and/or hafnium. The framework-substituted USY zeolite has an average crystallite size from 5 μm to 50 μm. Methods of making and using such a catalyst in a hydrocracking process are also disclosed.

The present disclosure relates to a process for the hydrodealkylation of aromatic rich hydrocarbon streams to produce benzene, toluene and mixed xylenes (BTX), with high selectivity towards high value xylenes. The process uses catalysts containing a framework-substituted zirconium and/or titanium and/or hafnium-modified ultra-stable Y (USY) type zeolite.

Described are fluid catalytic cracking (FCC) compositions, methods of manufacture and use. FCC catalyst compositions comprise particles first particle type comprising one or more boron oxide components and a first matrix component and a second particle type having a composition different from the first particle type, the second particle type comprising a second matrix component, a phosphorus component and 20% to 95% by weight of a zeolite component. The FCC catalyst compositions can be used to crack hydrocarbon feeds, particularly resid feeds containing high V and Ni, resulting in lower hydrogen and coke yields.

The present invention provides an ultra-stable rare earth type Y molecular sieve and the preparation method thereof, which method is carried out by subjecting a NaY molecular sieve as the raw material to a rare earth exchange and a dispersing pre-exchange, then to an ultra-stabilization calcination treatment. The molecular sieve comprises 1 to 20% by weight of rare earth oxide, not more than 1.2% by weight of sodium oxide, has a crystallinity of 51 to 69%, and a lattice parameter of 2.451 nm to 2.469 nm. In contrast to the prior art, in the molecular sieve prepared by this method, rare earth ions are located in sodalite cages, which is demonstrated by the fact that no rare earth ion is lost during the reverse exchange process. Moreover, the molecular sieve prepared by such a method has a molecular particle size D(v,0.5) of not more than 3.0 μm and a D(v,0.9) of not more than 20 μm. Cracking catalysts using the molecular sieve as an active component is characterized by a high heavy-oil-conversion capacity and a high yield of valuable target products.

The present invention relates to a catalyst composition for Fluid Catalytic Cracking (FCC) which contains a combination of a FCC catalyst component and an additive component with certain physical properties attributed therein. The present invention is also directed to provide methods for the preparation of the catalyst composition for FCC. The admixture of the FCC catalyst component and additive component is used in cracking of hydrocarbon feedstock containing hydrocarbons of higher molecular weight and higher boiling point and/or olefin gasoline naphtha feedstock for producing lower yield of fuel gas without affecting the conversion and yield of general cracking products such as gasoline, propylene and C.sub.4 olefins.