CLIAMS:1. A catalyst composition comprising:
70-98% of a non-zeolitic material; and 2-30% of at least one zeolite material, the percentage being based on weight of the catalyst composition.
2. The catalyst composition as claimed in claim 1, wherein the non-zeolitic material is a combination of active and inactive material.
3. The catalyst composition as claimed in claim 1, wherein the at least one zeolite material is selected from zeolite-1, zeolite-2, and combinations thereof.
4. The catalyst composition as claimed in claim 3, wherein the zeolite-1 has a pore size in the range of 7-8°A and selected from a group consisting of ultra-stable Y (USY), rare earth exchanged USY (REUSY), Beta, and combinations thereof.
5. The catalyst composition as claimed in claim 3, wherein the zeolite-2 has a pore size in the range of 5-6°A and selected from a group consisting of ZSM-5, ZSM-11, ZSM-22, SAPO-11, and combinations thereof and is modified with phosphorous, alkaline earth, transition elements.
6. The catalyst composition as claimed in claim 3, wherein the zeolite-2 has a Si/Al ratio in the range of 25 to 100.
7. The catalyst composition as claimed in claim 6, wherein the zeolite-2 has a Si/Al ratio in the range of 30 to 80.
8. A catalyst composition comprising:
70-95% of a non-zeolitic material;
3-18% of zeolite-1; and
2-12% of zeolite-2, the percentage being based on weight of the catalyst composition.
9. The catalyst composition as claimed in claim 8, wherein the composition comprising: 70-95% of a non-zeolitic material having a combination of active and inactive material; 3-18% of zeolite-1 having a pore size in the range of 7-8°A and selected from a group consisting of ultra-stable Y (USY), rare earth exchanged USY (REUSY), Beta, and combinations thereof; and 2-12% of zeolite-2 having a pore size in the range of 5-6°A and is selected from a group consisting of ZSM-5, ZSM-11, ZSM-22, SAPO-11, and combinations thereof and is modified with phosphorous, alkaline earth, transition elements, the percentage being based on weight of the catalyst composition.
10. A method of preparing the catalyst composition, the method comprising the steps of:
(a) mixing 70-98 wt% of a non-zeolitic material, and 2-30 wt% of at least one zeolite material to obtain a slurry;
(b) spray drying the slurry to micro-spheres; and
(b) calcining the micro-spheres at 500-600°C for 1-2 hours to obtain the catalyst composition.
11. The method as claimed in claim 10, wherein the non-zeolitic material is a combination of active and inactive material.
12. The method as claimed in claim 10, wherein the at least one zeolite material is selected from zeolite-1, zeolite-2, and combinations thereof.
13. The method as claimed in claim 12, wherein the zeolite-1 has a pore size in the range of 7-8°A and is selected from a group consisting of ultra-stable Y (USY), rare earth exchanged USY (REUSY), Beta, and combinations thereof.
14. The method as claimed in claim 12, wherein the zeolite-2 has a pore size in the range of 5-6°A and is selected from a group consisting of ZSM-5, ZSM-11, ZSM-22, SAPO-11, and combinations thereof and is modified with phosphorous, alkaline earth, transition metals.
15. A process for the fluid catalytic cracking of a hydrocarbon feedstock, which comprises
(a) contacting the hydrocarbon feedstock with a catalyst composition as claimed in claim 1 in a fluid catalytic cracking (FCC) apparatus, in the presence of steam at a temperature in the range of from 550 to 600°C , pressure in the range of from 0.5 to 2.0 kg/cm2 , a catalyst composition-to-hydrocarbon feedstock in the range of 10 to 20% by weight, riser residence time of 2 to 5 sec, and steam-to-hydrocarbon feedstock ratio in the range of 5 to 40% by weight, thereby cracking the hydrocarbon feedstock in the first reactor (1) to obtain a crackable recycle stream; and
(b) cracking the crackable recycle stream in the second reactor (2) with WHSV of 0-40 hr-1 to obtain light olefins.
16. The process as claimed in claim 15, wherein the light olefins are selected from ethylene, propylene, and butylenes.
17. The process as claimed in claim 16, wherein the ethylene yield is in the range of 3-6wt%, propylene yield is in the range of 15-21%wt %, and the butylenes yield is 11-14%wt%, each of the yields is based on the feedstock.
18. The process as claimed in claim 15, wherein the crackable recycle stream are selected from C4 stream, light naphtha, and CLO streams.
19. The process as claimed in claim 15, wherein the hydrocarbon feedstock is selected from the group consisting of hydrotreated vacuum gas oil (VGO), coker gasoline, coker fuel oil (CFO), hydro cracker bottom, vacuum gas oil (VGO), vacuum residue, residue coker oil (RCO), heavy vacuum gas oil (HVGO), and combinations thereof.
20. The process as claimed in claim 15, wherein crackable stream is step (b) is cracked at a temperature in the range of from 590 to 625°C , a pressure in the range of from 0.5 to 2.0 kg/cm2, and WHSV of 2-20 hr-1.
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