Claims:1. A catalyst composition comprising:
a) a non-zeolitic material having a weight percentage in the range of 76-86 % with respect to the catalyst composition;
b) a zeolite-1 having a weight percentage in the range of 3-18 % with respect to the catalyst composition; and
c) a zeolite-2 having a weight percentage in the range of 2-12 % with respect to the catalyst composition,
wherein the zeolite-2 is modified with at least one metal having a weight percentage in the range of 0.1-2.5 % with respect to the zeolite-2.
2. The catalyst composition as claimed in claim 1, wherein the zeolite-1 is selected from the group consisting of ultra-stable Y (USY), rare earth exchanged ultra-stable Y (REUSY), beta, and combinations thereof.
3. The catalyst composition as claimed in claim 1, wherein the zeolite-2 is selected from the group consisting of ZSM-5, ZSM-11, ZSM-22, SAPO-11, and combinations thereof.
4. The catalyst composition as claimed in any of the claims 1 to 2, wherein the zeolite-1 has a pore size in the range of 7-8 Å.
5. The catalyst composition as claimed in any of the claims 1 and 3, wherein the zeolite-2 has a pore size in the range of 5-6 Å.
6. The catalyst composition as claimed in any of the claims 1-5, wherein the zeolite-2 has a Si/Al ratio in the range of 30-500.
7. The catalyst composition as claimed in any of the claims 1-6, wherein the zeolite-2 has a Si/Al ratio in the range of 30-100.
8. The catalyst composition as claimed in any of the claims 1-7, wherein the zeolite-2 has a Si/Al ratio of 80.
9. The catalyst composition as claimed in claim 1, wherein the non-zeolitic material is a combination of a) active material selected from the group consisting of silica, alumina, and combinations thereof; and b) inactive material selected from the group consisting of silica-alumina, kaolin clay, montmorillonite clay, bentonites clay, halloysite clay, and combinations thereof.
10. The catalyst composition as claimed in claim 9, wherein the active to inactive material weight ratio is in the range of 1:2-1:2.5.
11. The catalyst composition as claimed in claim 1, wherein the zeolite-2 is modified with at least one metal selected from the group consisting of Ti, Mn, Fe, Zn, and combinations thereof.
12. The catalyst composition as claimed in claim 11, wherein the zeolite-2 is modified with 0.5 wt% each of Ti, Mn, Fe, and Zn, with respect to the zeolite-2.
13. The catalyst composition as claimed in any of the claims 1-12, for use in cracking a hydrocarbon feedstock to obtain light olefins.
14. The catalyst composition as claimed in any of the claims 1-12, for use in oligomerization of C1-4 hydrocarbon to obtain light olefins.
15. Use of catalyst as claimed in any of the claims 1-12, for cracking a hydrocarbon feedstock to obtain light olefins.
16. Use of catalyst as claimed in any of the claims 1-12, for oligomerization of C1-4 hydrocarbon to obtain light olefins.
17. A method for preparation of catalyst composition, the method comprising the steps of: (a) contacting at least one metal, a zeolite-2 and at least one solvent to obtain a first mixture; (b) vaporization of the solvent of the first mixture is followed by drying and calcining to obtain a second mixture; (c) mixing the second mixture with a zeolite-1 and a non-zeolitic material to obtain a third mixture; (d) spray drying the third mixture to obtain a fourth mixture; and (e) calcining the fourth mixture to obtain the catalyst composition, wherein the zeolite-2 is modified with at least one metal having a weight percentage in the range of 0.1-2.5 % with respect to the zeolite-2.
18. The method for preparation of catalyst composition as claimed in claim 17, wherein the method comprising the steps of: (a) contacting at least one metal, a zeolite-2 and at least one solvent to obtain a first mixture is carried out by stirring at a temperature in the range of 20-35 °C for a period in the range of 0.5 – 2.0 hours, at a stirring speed in the range of 200-700 rpm; (b) vaporization of the solvent of the first mixture is carried out at a temperature in the range of 60-70 °C under reduced pressure followed by drying at a temperature in the range of 100-120 ? for a period in the range of 10-14 hours and calcining at a temperature in the range of 500-600 °C for a period in the range of 1.0-2.0 hours to obtain the second mixture; (c) mixing the second mixture with a zeolite-1 and a non-zeolitic material to obtain a third mixture; (d) spray drying the third mixture to obtain a fourth mixture in form of micro-spheres is carried out at an inlet temperature in the range of 300-400 °C and an outlet temperature in the range of 100-200 °C; and (e) calcining the fourth mixture is carried out at a temperature in the range of 500-600 °C for a period in the range of 1.0-2.0 hours to obtain the catalyst composition, wherein the zeolite-2 is modified with at least one metal having a weight percentage in the range of 0.1-2.5 % with respect to the zeolite-2.
19. The method as claimed in any of the claims 17 and 18, wherein a) the zeolite-1 has a pore size in the range of 7-8 Å and is selected from the group consisting of ultra-stable Y (USY), rare earth exchanged ultra-stable Y (REUSY), beta, combinations thereof; and b) the zeolite-2 has a pore size in the range of 5-6 Å and is selected from the group consisting of ZSM-5, ZSM-11, ZSM-22, SAPO-11, and combinations thereof, wherein the zeolite-2 has a Si/Al ratio in the range of 30-500.
20. The method as claimed in any of the claims 17 and 18, wherein the non-zeolitic material is a combination of a) active material selected from the group consisting of silica, alumina, and combinations thereof; and b) inactive material selected from the group consisting of silica-alumina, kaolin clay, montmorillonite clay, bentonites clay, halloysite clay, and combinations thereof, wherein the active to inactive material weight ratio is in the range of 1:2-1:2.5.
21. The method as claimed in any of the claims 17-20, wherein the zeolite-2 is modified with 0.5 wt% each of Ti, Mn, Fe, and Zn, with respect to the zeolite-2.
22. A fluid catalytic cracking apparatus (100) for cracking a hydrocarbon feedstock to obtain light olefins, the fluid catalytic cracking apparatus (100) comprising:
a) a first reactor unit comprising a first riser (1) for cracking the hydrocarbon feedstock;
b) a second reactor unit comprising:
i) a second riser (33) for cracking C4 hydrocarbon and crackable recycle streams, and for converting methanol streams, wherein the second riser comprises a lower dense riser (2) and an upper dilute riser (3) connected in series, wherein diameter of the lower dense riser (2) is in the range of 1.1 to 2 times the diameter of the upper dilute riser (3) and length of the lower dense riser (2) is in the range of 10 to 60 % of the total length of the second riser (33);
ii) at least one C4 hydrocarbon feed nozzle (22A) and methanol feed nozzle (22B) connected to a bottom of the lower dense riser (2) for feeding C4 hydrocarbon and methanol streams;
iii) at least one crackable recycle stream feed nozzle (23) for feeding the crackable recycle feed stream; wherein the crackable recycle stream feed nozzle (23) is connected to the lower dense riser (2) at a predetermined height in the range of 15 to 50 % above the C4 hydrocarbon feed nozzle (22A) or methanol feed nozzle (22B); and
iv) at least one quenching stream feed nozzle (24) for feeding a quenching stream; wherein the quenching stream feed nozzle (24) is connected to the upper dilute riser (3) at a predetermined height in the range of 0 to 40% above the dense riser (2); and
c) a catalyst regenerator (4) in fluid connection with the first and second reactor units for regenerating spent catalyst received from the first and second reactor units.
23. The fluid catalytic cracking apparatus as claimed in claim 22, comprising:
a) a first regenerated catalyst standpipe (14) and a first regenerated catalyst slide valve (15) for feeding a first regenerated catalyst stream to the first riser (1), a first steam feed nozzle (11) connected to a bottom of the first riser (1) for feeding a first stream of steam to the first riser (1), a hydrocarbon feedstock feed nozzle (5) connected to the first riser (1) above the first steam feed nozzle (11) for feeding hydrocarbon feedstock; and
b) a second regenerated catalyst standpipe (31) and a second regenerated catalyst slide valve (32) for feeding a second regenerated catalyst stream to the second riser, a second steam feed nozzle (21) connected to the bottom of the second riser (33) for feeding a second stream of steam to the second riser (33).
24. The fluid catalytic cracking apparatus (100) as claimed in claim 22, wherein: (a) the first reactor unit includes a first stripper (6) for receiving a first spent catalyst stream for stripping the first spent catalyst of crackable recycle stream; and (b) the second reactor unit includes a second stripper (25) for receiving a second spent catalyst stream for stripping the second spent catalyst of the light olefins stream.
25. The fluid catalytic cracking apparatus (100) as claimed in claim 22, comprising:
a) a first riser termination device (7) connected to a top end of the first riser (1) for separating a first spent catalyst stream from the crackable recycle stream, at least one first reactor cyclone (9) for separating the first spent catalyst stream from the crackable recycle stream; and
b) a second riser termination device (26) connected to a top end of the second riser (33) for separating a second spent catalyst stream from the olefin stream, at least one second reactor cyclone (27) for separating the second spent catalyst stream from the light olefins stream.
26. The fluid catalytic cracking apparatus (100) as claimed in claim25, wherein the first termination device terminates (7) in the first riser (1) or above the first riser (1).
27. A process for the fluid catalytic cracking in the presence of the catalyst composition as claimed in claim 1, the process comprising the steps of: a) cracking the hydrocarbon feedstock at a predetermined temperature in the range of 550-600 ? to obtain a crackable recycle stream; and b) cracking the crackable recycle stream with a predetermined WHSV of 0-50 hr-1 and/or C4 hydrocarbon stream with a predetermined WHSV of 0-20 hr-1, at a predetermined temperature in the range of 600-650 ? to obtain light olefins.
28. A process for oligomerization of methanol in the presence of the catalyst composition as claimed in claim 1, the process comprising the step of: a) converting the methanol stream with a predetermined WHSV of 0-20 hr-1 at a predetermined temperature in the range of 600-650 ? to obtain light olefins.
29. A fluid catalytic cracking (FCC) process (200) comprising:
a) feeding a hydrocarbon feedstock stream and a first regenerated catalyst stream into a first riser (1);
b) cracking the hydrocarbon feedstock stream with the first regenerated catalyst stream in the first riser (1) to obtain crackable recycle and first spent catalyst streams;
c) feeding C4 hydrocarbon, methanol and second regenerated catalyst streams into a lower dense riser (2) of a second riser (33);
d) cracking the C4 hydrocarbon stream and converting the methanol stream, in the presence of second regenerated catalyst stream in the lower dense riser (2) to obtain light olefins and coked catalyst;
e) feeding a crackable recycle stream into the lower dense riser (2) of the second riser (33) above the C4 hydrocarbon and methanol streams;
f) cracking the crackable recycle stream with the coked catalyst to obtain light olefins and second spent catalyst streams;
g) feeding a quenching stream into an upper dilute riser (3) of the second riser (33);
h) quenching the second spent catalyst stream by the quenching stream in the upper dilute riser (3); and
i) conveying the second spent catalyst and light olefins streams through the upper dilute riser (3), wherein gas superficial velocity of the light olefins streams in the upper dilute riser (3) is higher than the gas superficial velocity of the light olefins streams in the lower dense riser (2).
30. The fluid catalytic cracking (FCC) process (200) as claimed in claim 29, wherein the catalyst used in the FCC process (200) comprises:
a) a non-zeolitic material having a weight percentage in the range of 76-86 % with respect to the catalyst composition;
b) a zeolite-1 having a weight percentage in the range of 3-18 % with respect to the catalyst composition; and
c) a zeolite-2 having a weight percentage in the range of 2-12 % with respect to the catalyst composition,
wherein the zeolite-2 is modified with at least one metal having a weight percentage in the range of 0.1-2.5 % with respect to the zeolite-2.
31. The process (200) as claimed in claim 29, wherein the process (200) comprises operating the first riser (1) at:
a) a predetermined temperature in the range of 550 to 600°C, a predetermined pressure in the range of 0.5 to 2.0 kg/cm2;
b) a predetermined catalyst to hydrocarbon feedstock ratio in the range of 10 to 20 weight by weight;
c) a predetermined riser residence time in the range of 1 to 4 seconds; and
d) a predetermined steam to hydrocarbon feedstock ratio of 5 to 40 % by weight.
32. The process (200) as claimed in claim 29, wherein the process (200) comprises:
a) cracking the C4 hydrocarbon stream and converting the methanol stream in the lower dense riser (2) at a predetermined WHSV in the range of 0-20 hr-1, and
b) cracking the crackable recycle stream in the lower dense riser (2) at a predetermined WHSV in the range of 0-50 hr-1;
wherein the process (200) comprises operating the second riser (33) at:
- a predetermined temperature in the range of 600–700°C, a predetermined pressure in the range of 0.5 to 2.0 kg/cm2;
- a predetermined steam to hydrocarbon feedstock ratio of 0 to 5 % by weight; and
- total residence time is in the range of 3 – 6 seconds.
33. The process (200) as claimed in claim 29, wherein the coked catalyst comprises of a coke in a predetermined range of 0 – 0.1 % by weight, providing improved selectivity of light olefins during cracking in the lower dense riser (2).
34. The process (200) as claimed in claim 23, wherein riser flux and riser density in the lower dense riser (2) is 1.8 to 2 times the riser flux and riser density in the first riser (1).
35. The process (200) as claimed in claim 29, wherein:
a) the hydrocarbon feedstock comprises vacuum gas oil (VGO), reduced crude oil (RCO), crude oil, light naphtha, clarified oil (CLO) and combinations thereof;
b) the C4 hydrocarbon comprises butanes, butylenes, and combinations thereof;
c) the crackable recycle stream comprises light cracked naphtha (LCN), light cycle oil (LCO), CLO and combinations thereof;
d) the quenching stream comprises aromatic rich stream comprising CLO, LCO and combinations thereof, and
e) the light olefins comprises ethylene, propylene, butylene, and combinations thereof.
36. The process as claimed in claim 29, wherein the quenching stream blocks pores of the second spent catalyst by depositing a plurality of aromatic molecules on

the pores and thereby suppressing a secondary cracking reaction in the upper dilute riser (3).
, Description:AS ATTACHED