Description:FIELD OF THE INVENTION:

The present invention relates to petroleum refining. Specifically, the present invention relates to petroleum refining catalyst for FCC to produce LPG, gasoline and LCO range molecules. The present invention is related to a process for synthesis of petrochemical catalyst and specifically synthesis of fluid catalytic cracking catalyst. More specifically, the present invention relates to an attrition resistant FCC catalyst and a process for preparation thereof.
BACKGROUND OF THE INVENTION:

Fluid catalytic cracking (FCC) is routinely used to convert heavy hydrocarbons to LPG, gasoline and distillate range molecules by using microspheres of FCC catalyst. The catalyst composition mainly is rare-earth exchanged Y zeolite and matrix materials such as alumina, silica and clay. In this, matrix component is known to perform a number of important functions, relating to both the catalytic and physical properties of the catalyst. Matrix materials help to improve the strength, attrition, stabilizing the zeolite and also improves the porosity properties. Reported inventions are generally talks about FCC catalyst and its preparation process; mesoporosity on microspheres; utilization of soda and ammonium stabilized silica; utilization of mesoporous Y zeolite for improving gasoline yield and reduction in bottoms yield etc. Some of the prior arts are discussed hereinbelow.

US11827855 discloses a process for converting crude oil to light olefins, aromatics, or both, includes contacting a crude oil with an FCC catalyst composition in a fluidized catalytic cracking system at a temperature of greater than or equal to 580° C., a weight ratio of the FCC catalyst to the crude oil of from 2:1 to 10:1, and a residence time of from 0.1 seconds to 60 seconds. Contacting causes at least a portion of hydrocarbons in the crude oil to undergo cracking reactions to produce a cracked effluent comprising at least olefins. The FCC catalyst composition for producing olefins and aromatics from crude oil includes ultrastable Y-type zeolite impregnated with lanthanum, ZSM-5 zeolite impregnated with phosphorous, where the nano-ZSM-5 zeolite has an average particle size of from 0.01 µm to 0.2 µm, an alumina binder, colloidal silica, and a matrix material comprising Kaolin clay.

US11814594 discloses a process for processing crude oil with an API between 25 and 29 degrees includes contacting the crude oil with one or more hydroprocessing catalysts to produce a hydroprocessed effluent. The hydroprocessed effluent is passed to an HS-FCC unit, where the hydroprocessed effluent is contacted with a cracking catalyst composition comprising nano-ZSM-5 zeolite and an ultrastable Y-type zeolite (USY zeolite) to form a cracked effluent comprising at least one product. The HS-FCC catalyst composition further comprises nano-ZSM-5 zeolite that has an average particle size of from 0.01 micrometers (µm) to 0.2 µm, USY zeolite impregnated with lanthanum, an alumina binder, colloidal silica, and a matrix material comprising Kaolin clay. The cracked effluent comprises at least olefins, aromatic compounds, or both.

US11814593 discloses a process for processing crude oil with an API between 30 and 35 degrees includes contacting the crude oil with one or more hydroprocessing catalysts to produce a hydroprocessed effluent. The hydroprocessed effluent is passed to an HS-FCC unit, where the hydroprocessed effluent is contacted with a cracking catalyst composition comprising nano-ZSM-5 zeolite and an ultrastable Y-type zeolite (USY zeolite) to form a cracked effluent comprising at least one product. The HS-FCC catalyst composition further comprises nano-ZSM-5 zeolite that has an average particle size of from 0.01 micrometers (µm) to 0.2 µm, USY zeolite impregnated with lanthanum, an alumina binder, colloidal silica, and a matrix material comprising Kaolin clay. The cracked effluent comprises at least olefins, aromatic compounds, or both.

US20200338536 discloses a process for the preparation of a catalyst and a catalyst comprising enhanced mesoporosity. Thus, in one embodiment, provided is a particulate FCC catalyst comprising 2 to 50 wt % of one or more ultra stabilized high Si02/A1203 ratio large pore faujasite zeolite or a rare earth containing USY, 0 to 50 wt % of one or more rare-earth exchanged large pore faujasite zeolite, 0 to 30 wt % of small to medium pore size zeolites, 5 to 45 wt % quasi-crystalline boehmite 0 to 35 wt % microcrystalline boehmite, 0 to 25 wt % of a first silica, 2 to 30 wt % of a second silica, 0.1 to 10 wt % one or more rare earth components showing enhanced mesoporosity in the range of 6-40 nm, the numbering of the silica corresponding to their orders of introduction in the preparation process.

CN1312255C discloses a preparation method of a molecular sieve containing cracking catalyst for hydrocarbons, which comprises firstly, aluminum sol, hydrated alumina, clay, acid, a molecular sieve and water are pulped and uniformly mixed to obtain slurry, and the solid content of the slurry is made as 25 to 40 wt%; secondly, the obtained slurry is dried. Silica sol comprising granules with the average granule diameter of 5 to 100 nanometers is also added during pulping, and the granule diameters of more than 80% of the granules are 0.5 to 1.5 times larger than the average granule diameter. The average pore diameter of the catalyst prepared with the method is large, and in addition, the pore volume of each mesopore with the pore diameter of 5 to 100 nanometers and the pore volume of each macropore with the pore diameter of 5 to 100 nanometers are larger. The catalyst prepared with the method has the advantages of high selectivity of light oil, and low coke selectivity.

WO2023172744 discloses a process for fluid catalytic cracking of a feedstock, which process comprises contacting a fluid catalytic cracking catalyst composition with a feedstock comprising an oxygenated feed and optionally a hydrocarbon feed, wherein the oxygenated feed comprises at least one oxygenated compound containing at least carbon, hydrogen, and oxygen.

The reported prior arts are silent about slurry viscosity FCC catalyst and its solid content in presence of higher amount of alumina as matrix. Accordingly, there is a requirement of a catalyst which has improved strength, reduced viscosity of slurry, and reduced attrition of microspheres.

OBJECTIVES OF THE PRESENT INVENTION:

It is the primary objective of the present invention to provide an attrition resistant fluid catalytic cracking catalyst and a process for preparation thereof.

It is further objective of the present invention to provide a cost-effective process for preparing an attrition resistant fluid catalytic cracking catalyst.

It is further objective of the present invention is to provide an attrition resistant FCC catalyst which has higher LPG yields and higher gasoline yield and the use of said catalyst reduces formation of undesirable coke and dry gas in FCCU.

SUMMARY OF THE INVENTION

The present invention discloses an attrition resistant fluid catalytic cracking catalyst and a process for preparation thereof. The process for preparation of an attrition resistant fluid catalytic cracking catalyst comprises steps of milling of 15% w/w to 30% w/w of clay, 10% w/w to 30% w/w of boehmite alumina, and water to obtain a slurry. The clay is a mixture of low dense clay and high dense clay, wherein, the high dense clay has a density in a range of 0.5-0.6 g/cc and the low dense clay has density in a range of 0.35-0.45 g/cc. The milling step reduces particle size from 10-15 microns to 1-2 microns.

Thereafter acidifying the slurry with protic acid to obtain an acidified slurry. Thereafter adding 5% w/w to 20% w/w of nanocrystals of colloidal silica to the acidified slurry to obtain an acidified clay-alumina-silica slurry. Then adding 20% w/w to 40% w/w of a rare-earth modified ultra stable Y zeolite on the acidified clay-alumina-silica slurry to obtain a final slurry. The rare-earth modified ultra stable Y zeolite is lanthanum modified ultra-stable Y zeolite.

Then spray-drying the final slurry to obtain spherical particles, the spray-drying of the final slurry is done with a spray dryer having an inlet temperature of 360? and outlet temperature of 130?. Finally, calcinating the spherical particles to obtain the attrition resistant fluid catalytic cracking catalyst. The calcination of the spherical particles is done at a temperature of 550? for 2 hours.

The attrition resistant catalyst for fluid catalytic cracking is made of 15% w/w to 30% w/w of clay comprising low dense clay and high dense clay, 10% w/w to 30% w/w of boehmite alumina, 5% w/w to 20% w/w of nanocrystals of colloidal silica, and 20% w/w to 40% w/w of lanthanum modified ultra-stable Y zeolite. The catalyst has 1-2 percent attrition, an Apparent Bulk Density of 0.8-0.85 g/cc, an average particle size of 74 micron and total acidity of 783 µmol/g. The catalyst has a BET Surface Area of 302 m2g, an external surface area of 195 m2/g, a micropore surface area of 106 m2/g, a micropore volume of 0.31 cc/g. The catalyst has slurry viscosity in a range of 38-39 Pa.s and attrition of catalyst is in range of 1.7-2.1%. The catalyst has conversion percent in range of 75-76% and bottoms reduction in range of 9-9.7.

DESCRIPTION OF THE INVENTION:

According to the main embodiment, the present invention discloses an attrition resistant FCC catalyst and a process for preparation thereof. Specifically, the present invention discloses a process for preparation of microspheres of attrition resistant FCC catalyst for improving the attrition and viscosity properties and cracking performance.

The attrition resistant FCC catalyst as disclosed herein includes 15% w/w to 30% w/w of clay wherein the clay includes low dense clay and high dense clay, 10% w/w to 30% w/w of boehmite alumina; 5% w/w to 20% w/w of nanocrystals of colloidal silica; and 20% w/w to 40% w/w of lanthanum modified ultra-stable Y zeolite.

Specifically, the attrition resistant FCC catalyst as disclosed in the present invention has two types of clay such as high dense clay and low dense clay. The high dense clay and low dense clay are utilized to reduce the boehmite alumina in the matrix. Also, the high dense clay and low dense clay helps in improving the strength, reducing the viscosity of slurry and reduces the attrition of microspheres. Further, addition of silica at post milling stage helps to improve the acidity of alumina and also reduces the slurry viscosity of milled slurry. Overall, the attrition resistant FCC catalyst and the process for preparing the same as disclosed in the present invention improves the attrition properties of microspheres, reduces the slurry viscosity and maintains the solid content. Further, the attrition resistant FCC catalyst as disclosed in the present invention has good cracking performance.

In an embodiment, the attrition resistant FCC catalyst as disclosed in the present invention is made of rare-earth zeolite, colloidal silica, clay and boehmite alumina.
In an embodiment, the attrition resistant FCC catalyst as disclosed in the present invention is made of lanthanum modified zeolite, nano sized particles of colloidal silica, low dense and high dense clay and boehmite alumina.
In another embodiment, the attrition resistant FCC catalyst as disclosed in the present invention is made of lanthanum modified zeolite having large pore size, nano sized particles of colloidal silica, low dense and high dense clay and boehmite alumina.
In another embodiment, the attrition resistant FCC catalyst as disclosed in the present invention is made of 2-3 wt.% of lanthanum modified zeolite having large pore size, nano sized particles of colloidal silica, 0.3-0.5 g/cc of low dense and 0.5-0.6 g/cc high dense clay and boehmite alumina.
In another embodiment, the attrition resistant FCC catalyst as disclosed in the present invention is made of 2-3 wt.% of lanthanum modified zeolite having large pore size, nano sized particles of colloidal silica, 0.3-0.4 g/cc of low dense and 0.45-0.55 g/cc high dense clay and boehmite alumina.
The process for preparation of attrition resistant FCC catalyst as disclosed in the present invention includes steps of milling of clay (15-30 wt.%) and binder alumina (10-30 wt.%) with appropriate amount of water to obtain a slurry. Wherein, the milling reduces the particle size from 10-15 microns to 1-2 micron. Thereafter acidifying the slurry with protic acid to obtain an acidified slurry, wherein the acidified slurry has a pH 2-3. Then adding 5% w/w to 20% w/w of small sized colloidal silica in the acidified slurry to obtain an acidified clay-alumina-silica slurry, wherein the acidified clay-alumina-silica slurry has a pH of is 3-4. Then adding of rare-earth modified zeolite (20-40 wt.%) in acidified clay-alumina-silica slurry to prepare a final slurry having a pH of 3.8, a temperature of 25-35oC, and a viscosity 10-50 Ps. Then spray-drying the final slurry to obtain spherical particles and calcinating the spherical particles to obtain the attrition resistant fluid catalytic cracking catalyst. Wherein, the spray-drying is done with a spray dryer having an inlet temperature of 360oC and outlet temperature of 130oC.

Wherein, the clay is a mixture of 0.3-0.5 g/cc of low dense clay and 0.5-0.6 g/cc of high dense clay.

Addition of 20-40 % rare-earth modified zeolite in FCC catalyst microspheres helps to get higher conversion (>75 %) in VGO cracking. The remaining 60-80 % of matrix helps to stabilize and homogenize the zeolite in FCC catalyst microspheres.
The prepared attrition resistant FCC catalyst showed ABD of 0.8-0.85 g/cc and attrition is 1-2 %. Further, the particle size of the attrition resistant FCC catalyst is in the range of 70-80 microns.

In an embodiment, the process for preparation of attrition resistant FCC catalyst as disclosed in the present invention includes steps of milling of 15% w/w to 30% w/w of a clay, 10% w/w to 30% w/w of boehmite alumina, and water to obtain a slurry. Thereafter acidifying the slurry with protic acid to obtain an acidified slurry. Then adding 5% w/w to 20% w/w of nanocrystals of colloidal silica to the acidified slurry to obtain an acidified clay-alumina-silica slurry. Then adding 20% w/w to 40% w/w of lanthanum modified ultra stable Y zeolite on the acidified clay-alumina-silica slurry to obtain a final slurry. Then spray-drying the final slurry to obtain spherical particles and calcinating the spherical particles to obtain the attrition resistant fluid catalytic cracking catalyst. The clay is a mixture of low dense clay and high dense clay.

The attrition resistant catalyst for fluid catalytic cracking is made of 15% w/w to 30% w/w of clay comprising low dense clay and high dense clay, 10% w/w to 30% w/w of boehmite alumina, 5% w/w to 20% w/w of nanocrystals of colloidal silica, and 20% w/w to 40% w/w of lanthanum modified ultra-stable Y zeolite. The catalyst has 1-2 percent attrition, an Apparent Bulk Density of 0.8-0.85 g/cc, an average particle size of 74 micron and total acidity of 783 µmol/g. The catalyst has a BET Surface Area of 302 m2g, an external surface area of 195 m2/g, a micropore surface area of 106 m2/g, a micropore volume of 0.31 cc/g. The catalyst has slurry viscosity in a range of 38-39 Pa.s, and attrition of catalyst is in range of 1.7-2.1%. The catalyst has conversion percent in range of 75-76% and bottoms reduction in range of 9-9.7.

Examples:
Example 1: Preparation of FCC catalyst – Small sized colloidal silica and two clays (low dense clay and high dense treated bentonite clay)
Example 1 of FCC catalyst is prepared by milling of low dense clay (117 grams), high dense treated bentonite clay (24 grams) and boehmite alumina (91 grams) with water (650 grams) for 3 hours. After milling the slurry was peptized by using 85 % formic acid (30 grams). To that, small sized colloidal silica (10-20 nm in size) slurry (200 grams) was added and continued stirring for another 1 hour. To that, zeolite slurry (mixing of 124 grams of lanthanum modified ultra-stable Y zeolite in 214 grams of water) was added and the final slurry is prepared, wherein the final slurry was homogeneous slurry. Total solid content in the finalized slurry was 27-28 %. Finally, the slurry was spray dried at 360 degree C as inlet temperature and 120 degree C as outlet temperature. The prepared catalyst was calcined at 550 degree C for 2 hours.

Example 2: Preparation of FCC catalyst – large sized colloidal silica and two clays
Example 2 of FCC catalyst is prepared by milling of low dense clay (117 grams), high dense treated bentonite clay (24 grams) and boehmite alumina (91 grams) with water (650 grams) for 3 hours. After milling the slurry was peptized by using 85 % formic acid (30 grams). To that, large sized colloidal silica (500 nm – 1 micron in size) slurry (200 grams) was added and continued stirring for another 1 hour. To that, zeolite slurry (mixing of 124 grams of lanthanum modified ultra-stable Y zeolite in 214 grams of water) was added and the final slurry is prepared, wherein the final slurry was homogeneous slurry. Total solid content in the finalized slurry was 27-28 %. Finally, the slurry was spray dried at 360 degree C as inlet temperature and 120 degree C as outlet temperature. The prepared catalyst was calcined at 550 degree C for 2 hours.

Example 3: Preparation of FCC catalyst – small sized colloidal silica and one clay (low dense clay)
Example 3 of FCC catalyst is prepared by milling of low dense clay (146 grams), and boehmite alumina (91 grams) with water (650 grams) for 3 hours. After milling the slurry was peptized by using 85 % formic acid (30 grams). To that, small sized colloidal silica slurry (200 grams) was added and continued stirring for another 1 hour. To that, zeolite slurry (mixing of 124 grams of lanthanum modified ultra-stable Y zeolite in 214 grams of water) was added and the final slurry is prepared, wherein the final slurry was homogeneous slurry. Total solid content in the finalized slurry was 27-28 %. Finally, the slurry was spray dried at 360 degree C as inlet temperature and 120 degree C as outlet temperature. The prepared catalyst was calcined at 550 degree C for 2 hours.
Example 4: Preparation of FCC catalyst – large sized colloidal silica and one clay (low dense clay)
Example 4 of FCC catalyst is prepared by milling of low dense clay (146 grams), and boehmite alumina (91 grams) with water (650 grams) for 3 hours. After milling the slurry was peptized by using 85 % formic acid (30 grams). To that, large sized colloidal silica slurry (200 grams) was added and continued stirring for another 1 hour. To that, zeolite slurry (mixing of 124 grams of lanthanum modified ultra-stable Y zeolite in 214 grams of water) was added and the final slurry is prepared, wherein the final slurry was homogeneous slurry. Total solid content in the finalized slurry was 27-28 %. Finally, the slurry was spray dried at 360 degree C as inlet temperature and 120 degree C as outlet temperature. The prepared catalyst was calcined at 550 degree C for 2 hours.

Example 5: Preparation of FCC catalyst – Small sized colloidal silica and two clay (Adding of silica for milling along with clay and alumina)
Example 5 of FCC catalyst is prepared by milling of low dense clay (117 grams), high dense treated bentonite clay (24 grams), boehmite alumina (91 grams) and small sized colloidal silica slurry (200 grams) with water (650 grams) for 3 hours. After milling the slurry was peptized by using 85 % formic acid (30 grams). To that, zeolite slurry (mixing of 124 grams of lanthanum modified ultra-stable Y zeolite in 214 grams of water) was added and the final slurry is prepared, wherein the final slurry was homogeneous slurry. Total solid content in the finalized slurry was 27-28 %. Finally, the slurry was spray dried at 360 degree C as inlet temperature and 120 degree C as outlet temperature. The prepared catalyst was calcined at 550 degree C for 2 hours.

Example 6: Preparation of FCC catalyst – Small sized colloidal silica and two clay (Adding of silica after milling of clay and alumina)
Example 6 of FCC catalyst is prepared by milling of low dense clay (117 grams), high dense treated bentonite clay (24 grams) and boehmite alumina (91 grams) with water (650 grams) for 3 hours. After milling small sized colloidal silica slurry (200 grams) was added and continued the stirring for another 1 hour. This slurry was peptized by using 85 % formic acid (30 grams). To that, zeolite slurry (mixing of 124 grams of lanthanum modified ultra-stable Y zeolite in 214 grams of water) was added and the final slurry is prepared, wherein the final slurry was homogeneous slurry. Total solid content in the finalized slurry was 27-28 %. Finally, the slurry was spray dried at 360 degree C as inlet temperature and 120 degree C as outlet temperature. The prepared catalyst was calcined at 550 degree C for 2 hours.

Example 7: Preparation of FCC catalyst – Small sized colloidal silica and two clays (low dense clay and high dense treated attapulgite clay)
Example 7 of FCC catalyst is prepared by milling of low dense clay (117 grams), high dense treated attapulgite clay (24 grams) and boehmite alumina (91 grams) with water (650 grams) for 3 hours. After milling the slurry was peptized by using 85 % formic acid (30 grams). To that, small sized colloidal silica slurry (200 grams) was added and continued stirring for another 1 hour. To that, zeolite slurry (mixing of 124 grams of lanthanum modified ultra-stable Y zeolite in 214 grams of water) was added and the final slurry is prepared, wherein the final slurry was homogeneous slurry. Total solid content in the finalized slurry was 27-28 %. Finally, the slurry was spray dried at 360 degree C as inlet temperature and 120 degree C as outlet temperature. The prepared catalyst was calcined at 550 degree C for 2 hours.

Table 1. Physicochemical properties of FCC catalyst
Properties Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Example 7
BET surface area (m2/g) 302 289 285 275 259 273 299
External surface area (m2/g) 195 177 168 168 151 158 187
Micropore surface area (m2/g) 106 111 117 107 107 116 111
Micropore volume (cc/g) 0.31 0.29 0.28 0.28 0.27 0.28 0.30
ABD (g/cc) 0.81 0.79 0.80 0.78 0.78 0.76 0.80
Attrition index (%) 1.7 10 6.5 9 7 10 2.1
Average particle size (microns) 74 83 78 80 84 77 75
Viscosity of slurry (Pa.s) (after milling) 28 29 34 35 48 34 28
Bulk density of milled slurry (g/cc) 1.11 1.11 1.05 1.06 1.28 1.04 1.11
Viscosity of final slurry (Pa.s) 38 39 48 49 58 57 39
Bulk density of final slurry (g/cc) 1.05 1.05 1.11 1.12 1.21 1.22 1.06
Solid content in slurry (%) 27-28 27-28 27-28 27-28 27-28 27-28 27-28

From the listed examples, the presence of two clays and small sized nanocrystals of colloidal silica helps in reducing the viscosity of slurry with similar solid content and also reduced attrition of FCC catalyst microspheres.
Pre-treatment of FCC catalyst by Hydrothermal Deactivation Method
In order to maintain the desired level of conversion (feed to useful products such as dry gas (DG), liquefied petroleum gas (LPG), light cracked naphtha, heavy cracked naphtha, light cycle oil, resid and coke) in the FCC unit. In FCC unit, catalyst gets hydrothermally deactivated due to high temperature and steam, so for simulating similar catalyst deactivation, FCC and reference catalysts are hydrothermally deactivated at 815 0C for 5 hours with 80 % steaming recipe in Metal Cyclic Deactivation unit before performance evaluation.

Feedstock Characterization
The feed used in the present study is hydrotreated vacuum gas oil (VGO) and its properties are listed in below table 2.
Table 2: Feed Properties
Density at 15°C, gm/cc 0.90
Sulphur, wt% 105 ppm
CCR, wt% 0.08
Pour point, °C 39
Kinematic viscosity @100°C, cSt 6.93
ASTM-7169 Distillation, wt%
IBP 250.1
5 300
10 362.3
30 410
50 442.7
70 480.9
90 536.6
95 561.3
SARA, wt%
Saturates 51.6
Aromatics 42.1
Resin 6.3
Asphaltenes 0

Performance evaluation results
Advanced Cracking Evaluation (ACE) – R+MM unit (with micro-GC) was used to measure the micro activity of steam deactivated high propylene FCC catalyst and reference catalyst. Evaluation results shows that higher conversion (>75 wt.%) for example 1 and example 7 (examples are prepared by using two types of clay and small sized nanocrystals of colloidal silica). Also, the reduction of bottoms yields of examples 1 and 7 are higher as compared to other examples in table 3.
Table 3. Product yields
Catalyst Name Example 1
Example 2
Example 3 Example 4
Example 5
Example 6
Example 7

Feed VGO VGO VGO VGO VGO VGO VGO
Reaction temp, (OC) 527 527 527 527 527 527 527
Cat/oil 6 6 6 6 6 6 6
Conversion (%) 75.9 74.49 75 73.7 74.12 74.18 76
Yields (wt. %)
Coke 3.8 4.06 3.6 3.91 3.29 3.29 3.91
Dry Gas 2.7 2.74 2.7 2.71 2.77 2.77 2.75
LPG 21.5 21.87 21.8 21.16 18.24 18.24 20.78
Naphtha 47.9 45.47 46.9 45.91 49.88 49.88 48.55
LCO 15.1 15.91 15.3 16.01 15.6 15.6 14.78
Bottoms 9 9.95 9.7 10.29 10.22 10.22 9.23

The process for preparation of an attrition resistant FCC catalyst as disclosed herein is industrially feasible and cost-effective. The process also utilizes small sized nanocrystals of ammonium stabilized colloidal SiO2 (10 nm-20 nm in size) as a matrix. The utilization of low-cost matrix materials such as clay and silica reduce the overall cost of the final attrition resistant FCC catalyst.

Performance evaluation of the attrition resistant FCC catalyst shows higher conversion (>75 wt.%), and gasoline yield (> 45 wt. %). Also reduced bottoms yield. The use of said catalyst reduces formation of undesirable coke & dry gas in FCCU.

Utilization of high dense clay materials (0.45-0.55 g/cc) and more than one clay materials: High dense clay (treated bentonite and treated attapulgite clays) helps in improving the binding of zeolites, clay and silica materials in the slurry); it reduces the utilization of binder alumina content; Cost of catalyst will reduce due to minimization of binder alumina in slurry.

Higher rare-earth loaded ultra-stable zeolites: It improves the hydrothermal stability of zeolite and also higher rare earth helps in trapping contaminated metals which is present in the crude oil/VGO etc.

Preparation of lower viscous FCC catalyst slurry: Processing of lower viscous slurry is easy and fast at industrial scale and also it reduces the processing cost. , Claims:1. A process for preparation of an attrition resistant fluid catalytic cracking catalyst, wherein the process comprises steps of:
milling of 15% w/w to 30% w/w of clay, 10% w/w to 30% w/w of boehmite alumina, and water to obtain a slurry;
acidifying the slurry with protic acid to obtain an acidified slurry;
adding 5% w/w to 20% w/w of nanocrystals of colloidal silica to the acidified slurry to obtain an acidified clay-alumina-silica slurry;
adding 20% w/w to 40% w/w of a rare-earth modified ultra stable Y zeolite on the acidified clay-alumina-silica slurry to obtain a final slurry;
spray-drying the final slurry to obtain spherical particles; and
calcinating the spherical particles to obtain the attrition resistant fluid catalytic cracking catalyst.

2. The process as claimed in claim 1, wherein, the clay is a mixture of low dense clay and high dense clay.

3. The process as claimed in claim 1, wherein, the high dense clay has a density in a range of 0.5-0.6 g/cc.

4. The process as claimed in claim 1, wherein, the low dense clay has density in a range of 0.35-0.45 g/cc.

5. The process as claimed in claim 1, wherein, the milling step reduces particle size from 10-15 microns to 1-2 microns.

6. The process as claimed in claim 1, wherein, the rare-earth modified ultra stable Y zeolite is lanthanum modified ultra-stable Y zeolite.

7. The process as claimed in claim 1, wherein, the spray-drying of the final slurry is done with a spray dryer having an inlet temperature of 360? and outlet temperature of 130?.

8. The process as claimed in claim 1, wherein, the calcinating the spherical particles is done at a temperature of 550? for 2 hours.

9. The process as claimed in claim 1, wherein, the acidified slurry and the final slurry have pH below 4.

10. An attrition resistant catalyst for fluid catalytic cracking, wherein the catalyst comprises:
15% w/w to 30% w/w of clay comprising low dense clay and high dense clay;
10% w/w to 30% w/w of boehmite alumina;
5% w/w to 20% w/w of nanocrystals of colloidal silica; and
20% w/w to 40% w/w of lanthanum modified ultra-stable Y zeolite.

11. The catalyst as claimed in claim 10, wherein the catalyst has 1-2 percent attrition, an Apparent Bulk Density of 0.8-0.85 g/cc, an average particle size of 74 micron and total acidity of 783 µmol/g.

12. The catalyst as claimed in claim 10, wherein the catalyst has a BET Surface Area of 302 m2g, an external surface area of 195 m2/g, a micropore surface area of 106 m2/g, a micropore volume of 0.31 cc/g,

13. The catalyst as claimed in claim 10, wherein the catalyst has slurry viscosity in a range of 38-39 Pa.s.

14. The catalyst as claimed in claim 10, wherein the catalyst has attrition in range of 1.7-2.1%.

15. The catalyst as claimed in claim 10, wherein the catalyst has conversion percent in range of 75-76% and bottoms reduction in range of 9-9.7.