Specification
TECHNICAL FIELD
[0001]
The present invention relates to a novel catalyst for
catalytic cracking of hydrocarbons and a method for producing the
same.
10 [0002]
More specifically, the present invention relates to a
catalyst for catalytic cracking of hydrocarbons which has an
excellent hydrothermal stability, a high capability to crack
distillation residue (bottoms), and an excellent selectivity
15 (high liquid yield, with low gas and low coke yield) , when used
in the catalytic cracking of hydrocarbons, particularly, heavy
oil hydrocarbons; and a method for producing the catalyst.
BACKGROUND ART
[0003]
20 Raw materials, which contain a high proportion of heavy
hydrocarbons, such as heavy oil and heavy residual oil were used
when gasoline is produced by catalytic cracking of hydrocarbons.
In the catalytic cracking of heavy oil and heavy residual oil,
a faujasite-type zeolite is often used as a catalyst.
SF-2667 2
Specifically, it is well known that a faujasite-type zeolite
ion-exchanged with rare earth ions or an ultra-stable
faujasite-type zeolite (sometimes written as USY zeolite) is used.
[0004]
5 Heavy oil contains heavy metals, such as nickel, vanadium
and iron, which not only complicate the catalytic cracking of heavy
oil, but also act as catalyst poisons, and also contains sulfur
and nitrogen. Heavy metals adhere to the catalyst, and cause to
increase the amount of dry gas (such as hydrogen, methane and
10 ethane) and coke generated, thereby reducing the yield of gasoline
and the like. Further, in cases where the amount of coke generated
is increased, it causes a temperature rise in the catalyst
i
regenerator, and to decrease the crystallinity of the zeolite due
to the water contained in the cokes, thereby resulting in a
15 reduction of the activity of the catalyst.
[0005]
In view of these problems, the present inventors have
disclosed that a catalyst for catalytic cracking of hydrocarbons
in which (1) alumina particles having a particle diameter of from
20 2 to 60 urn, and containing a metal component selected from one
or more of alkali earth metals and rare earth metals and a
phosphorus component; and (2) a crystalline aluminosilicate
zeolite; are uniformly dispersed in (3) a porous inorganic oxide
matrix, has a metal resistance, high activity and high selectivity,
SF-2667 3
and is capable of inhibiting the generation of hydrogen and coke
(Patent Document 1: JP 5-16908 B).
Further, the present inventors have disclosed that a
catalyst composition for fluid catalytic cracking of hydrocarbons
5 containing alumina, a crystalline aluminosilicate zeolite and an
inorganic oxide matrix other than alumina, each of the components
containing a phosphorus atom, has an excellent capability to crack
bottoms (bottom oil), generates a reduced amount of hydrogen and
coke, and increases the fractions of gasoline, kerosene and light
10 oil, when used in the catalytic cracking of heavy oil hydrocarbons
(Patent Document 2: JP 8-173816 A).
In addition, JP 2009-511245 A (Patent Document 3) discloses
t
t
that a hydrothermally stable, porous molecular sieve catalyst
obtained by evaporating moisture from a raw material mixture
15 containing (1) a molecular sieve having a -Si-OH-Al- skeleton
whose surface pores are modified by a specific phosphate; (2) a
water insoluble metal salt; and (3) a phosphoric acid compound;
has a high hydrothermal resistance and an improved gas olefin yield
and selectivity. It is also disclosed that the above mentioned
20 (2) water insoluble metal salt contains magnesia (MgO). In
Examples in Patent Document 3, HZSM-5 and ferrierite are used as
the molecular sieves, and MgO, Mg(OH)2 and the like are used as
the water insoluble metal salts.
[0006]
a
SF-2667 4
The present inventors have also disclosed a method for
producing a catalyst for catalytic cracking, in which minute
spherical particles are formed by spray drying an aqueous slurry
of a mixture comprising: air flow calcined alumina; a clay
5 comprising as major components, silica and alumina; a silica-based
inorganic oxide precursor; and a crystalline aluminosilicate; and
the obtained minute spherical particles are washed such that the
content of alkali metal oxides in terms of oxides is 1.0% by weight
or less, followed by introduction of a rare earth(s) . It is also
10 disclosed that the thus obtained catalyst exhibits a high cracking
activity and high gasoline selectivity, generates a reduced amount
of coke and gas, and has a high hydrothermal resistance, when used
in the catalytic cracking of heavy hydrocarbon oil containing a
large amount of metals (Patent Document 4: JP 60-193543 A).
15 Further, the present inventors have proposed a catalyst for
catalytic cracking of hydrocarbons in JP 11-246868 A (Patent
Document 5) and in JP 2004-130193 A (Patent Document 6).
PRIOR ART DOCUMENTS
PATENT DOCUMENTS
20 [0007]
Patent Document 1: JP 5-16908 B
Patent Document 2: JP 8-173816 A
Patent Document 3: JP 2009-511245 A
Patent Document 4: JP 60-193543 A
SF-2667 5
Patent Document 5: JP 11-246868 A
Patent Document 6: JP 2004-130193 A
SUMMARY OF THE INVENTION
PROBLEMS TO BE SOLVED BY THE INVENTION
5 [0008]
However, although the catalyst for catalytic cracking
obtained by: spray drying the aqueous slurry of the above mentioned
mixture to form minute spherical particles; washing the minute
spherical particles; and then by introducing a rare earth(s);
10 exhibits a high cracking activity and high gasoline selectivity,
there are problems that an effort to increase the amount of rare
earth (s) introduced to the catalyst in order to further improve
its activity have failed to significantly increase the introduced
amount of rare earth (s) , and that the improvement in the cracking
15 activity, gasoline selectivity and the like is small, thereby
resulting in a reduction in the utilization efficiency of valuable
rare earths and in economic efficiency.
[00093
In the catalyst disclosed in Patent Document 1, although
20 the metal resistance, activity, selectivity and the like of the
catalyst are improved, the improvement in the activity and the
selectivity is attributed to the improvement in the metal
resistance, and the improvement in the gasoline yield, selectivity
and the like is insufficient (possibly due to the rare earth (s)
•d
SF-2667 6
not being carried by the zeolite), leaving a room for further
improvement.
[0010]
In the case of the catalyst disclosed in Patent Document
5 2, although the metal resistance, activity, selectivity and the
like are improved, the improvement in the activity, and the
selectivity is also attributed to the improvement in the metal
resistance, due to the catalyst containing phosphorus . Thus, the
improvement in the gasoline yield, selectivity and the like is
10 insufficient, leaving a room for further improvement. Further,
a catalyst carrying a rare earth(s) is disclosed in Examples in
Patent Document 2, and in this catalyst, although an improvement
in the activity and the selectivity is observed, further
improvement in the metal resistance, activity, and selectivity
15 is required. In addition, there is a problem that, an effort to
increase the amount of rare earth(s) carried by the catalyst in
order to increase its activity and selectivity results in a
decrease in the utilization efficiency of the rare earth(s), as
with the catalyst disclosed in Patent Document 4 to be described
20 later.
[0011]
The catalyst disclosed in Patent Document 3 has a problem
that, although the hydrothermal resistance of the catalyst is
improved, the yield and the selectivity of gas olefin are increased
SF-2667 7
and the yield and the selectivity of gasoline are decreased.
[0012]
Further, conditions for introducing a rare earth (s) to the
catalyst have been investigated in order to improve the
5 utilization efficiency of the rare earth (s) . However, there are
problems that, in cases where the pH of the solution introduced
the rare earth(s) to the catalyst which is disclosed in Patent
Document 4 is not within the range of from 4.5 to 5.5, for example,
4 or less, the utilization efficiency of the rare earth(s) is
10 decreased; and in cases where the pH is greater than 6, while the
utilization efficiency of the rare earth(s) is improved, the
improvement in the performance of the catalyst is insufficient,
possibly due to generation of precipitation or double salts.
[0013]
15 On the other hand, although alkali earth metals are known
to have effects similar to those provided by rare earths, the
effects of alkali earth metals to improve the cracking activity,
gasoline selectivity, hydrothermal resistance and the like are
inferior to those of rare earths.
20 In addition, in the catalyst disclosed by the present
inventors in Patent Document 5, a fibrillary pseudoboehmite
alumina-type hydrated alumina treated with phosphate ions is used,
but the gasoline yield, selectivity and the like of the catalyst
are insufficient, as with the catalyst disclosed in Patent
SF-2667 8
Document 1, and there was a room for a further improvement. In
the catalyst disclosed in Patent Document 6, a magnesium compound
or the like was used as a metal scavenger. In this catalyst, while
the metal resistance, activity, selectivity and the like are
5 improved, the improvement in the activity and selectivity is also
attributed to the improvement in the metal resistance, due to
containing the metal scavenger. Thus, the improvement in the
yield and the selectivity of gasoline are insufficient, leaving
a room for further improvement. A catalyst carrying a rare
10 earth(s) is disclosed in Examples in Patent Document 6, and in
this catalyst, although the activity and selectivity are improved,
a further improvement in the metal resistance, activity and
selectivity is needed. In addition, as with the catalyst
disclosed in Patent Document 4, this catalyst has a problem that
15 an effort to increase the amount of rare earth (s) carried by the
catalyst, in order to improve its activity and the selectivity,
results in a decrease in the utilization efficiency of the rare
earth(s).
MEANS FOR SOLVING THE PROBLEMS
20 [0014]
In view of the above problems, the present inventors have
discovered, as a result of intensive studies, that it is possible
to obtain a catalyst which has a high cracking activity and high
gasoline selectivity, which generates a reduced amount of gas and
SF-2667 9
coke, and which is excellent in hydrothermal resistance, by:
forming minute spherical particles by spray drying; thoroughly
washing the minute spherical particles; and introducing magnesium,
and then phosphorus to the minute spherical particles; thereby
5 completing the present invention.
[0015]
As a result, it is possible to provide a catalyst for
catalytic cracking which has a high cracking activity and high
gasoline selectivity, which generates a reduced amount of gas and
10 coke, and which is excellent in hydrothermal resistance and in
economic efficiency.
[1] A catalyst for catalytic cracking of hydrocarbons
t
comprising a faujasite-type zeolite, a matrix component, a
phosphorus component and a magnesium component,
15 wherein the content of the faujasite-type zeolite (Cz) in
terms of solid is within the range of from 10 to 50 % by weight;
the content of phosphorus (CP) in terms of P2O5 is within the range
of from 0.1 to 10 % by weight; and the content of magnesium (CH)
in terms of MgO is within the range of from 0.05 to 3% by weight.
20 [2] The catalyst for catalytic cracking of hydrocarbons
according to item [1] , wherein the ratio (CP) / (CM) of the content
of phosphorus (CP) to the content of magnesium (CM) is within the
range of from 0.1 to 8.
[3] The catalyst for catalytic cracking of hydrocarbons
SF-2667 10
according to item [1] or [2] , wherein the ratio (Cw) / (Cz) of the
content of magnesium (CM) to the content of the faujasite-type
zeolite 2 as a standard reference material.
[0030]
The above mentioned ultra-stable zeolite (USY) can be
SF-2667 16
produced by a conventionally known method. For example,
Procedure A and Procedure B described in ZEOLITES AND CLAY MINERALS
as Sorbents and Molecular Sieves, p 350 (1975), by R. M. Barrer,
can be suitably used.
5 [0031]
Specifically, Procedure B describes that a zeolite whose
lattice constant is decreased by 1 to 1,5% can be obtained as
follows. A NaY zeolite is ion-exchanged with ammonium chloride
to form (NH4) (0.75 to o. 90)Na{0.25 to o.io)-Y; the resultant is then washed,
10 subjected to heat treatment at a temperature of from 200 to 600°C,
and subjected to ion exchange again to eliminate residual Na+ so
that the resultant is in a metastable state; and then the resultant
is rapidly heated at a temperature of 600 to 800°C in a steam
atmosphere; to obtain the ultra-stable zeolite.
15 [0032]
In the present invention, a zeolite obtained by further
subjecting the resulting ultra-stable zeolite (USY) to acid
treatment and the like can also be suitably used.
[0033]
20 Matrix component
The matrix component to be used in the present invention
refers to a material(s) other than the above mentioned
faujasite-type zeolite. As the matrix component, a
conventionally known inorganic oxide(s) or an inorganic
SF-2667 17
compound(s) , such as silica, alumina, silica alumina and aluminum
phosphate, can be used. These also include a material referred
to as a binder or filler.
[0034]
5 Specific examples of the matrix component which can be used
include: conventionally known inorganic oxides and inorganic
compounds derived from silica gel, silica sol, silica hydrosol,
alumina gel, alumina sol, silica alumina gel, silica alumina sol,
aluminum phosphate compounds and the like. Among these, silica
10 sol, silica hydrosol, alumina sol, silica alumina sol, aluminum
phosphate compounds and the like can be suitably used, because
they are capable of serving as a carrier (base material) or a binder
of the faujasite-type zeolite, and allow for obtaining a catalyst
for catalytic cracking of hydrocarbons which is excellent in
15 activity, abrasion resistance and the like, and which is also
excellent in the cracking activity for distillation residue, metal
resistance and the like.
[0035]
As alumina, air flow calcined alumina powder used in the
20 catalyst disclosed in JP 60-193543 A (Patent Document 4) can also
be suitably used. Activated alumina can also be used. There are
cases where activated alumina binds to a silica component, thereby
contributing to the activity.
[0036]
SF-2667
The catalyst for catalytic cracking of hydrocarbons
according to the present invention containing phosphorus and
magnesium, preferably contains alumina. The content of alumina
in terms of solid (AI2O3) is preferably within the range of from
5 1 to 30% by weight, and more preferably, within the range of from
2 to 20% by weight.
[0037]
If the matrix component contains alumina within the above
mentioned range, it is possible to obtain a catalyst for catalytic
10 cracking of hydrocarbons whose cracking activity and selectivity
are significantly improved, and which is excellent in cracking
activity for distillation residue and in metal resistance, when
i
i
the magnesium component and phosphorus component to be described
later are incorporated to the catalyst.
15 [0038]
Further, in the present invention, a conventionally known
clay mineral, such as kaolin, metakaolin, hydrotalcite,
montmorillonite or the like can be used as a filler. These clay
minerals have no activity, and serve as an extender.
20 [0039]
The content of the matrix component in terms of solid in
the catalyst for catalytic cracking of hydrocarbons is preferably
within the range of from 50 to 90% by weight, and more preferably
form 60 to 85% by weight.
SF-2667 19
[0040]
Too low a content of the matrix component in terms of solid
results in too high a content of the faujasite-type zeolite. As
a result, there are cases where the obtained catalyst has too low
a bulk density despite a high activity, or has an insufficient
abrasion resistance, fluidity and the like. In such a case, the
catalyst is not practical to be used as a catalyst for catalytic
cracking of hydrocarbons, particularly, as a catalyst for fluid
catalytic cracking of hydrocarbons.
[0041]
On the other hand, too high a content of the matrix component
in terms of solid results in too low a content of the faujasite-type
i
zeolite, which is a main active ingredient of the catalyst, and
there are cases where the resulting catalyst has an insufficient
cracking activity.
[0042]
In the present invention, a magnesium component, a
phosphorus component, and a rare earth component are used. By
incorporating these components, a catalyst excellent in cracking
performance and gasoline selectivity can be obtained.
[0043]
Magnesium component
The catalyst for catalytic cracking of hydrocarbons
according to the present invention contains a magnesium component,
SF-2667 20
as MgO, in an amount within the range of from 0.05 to 3% by weight,
and more preferably, within the range of from 0 .1 to 2 . 5% by weight.
The magnesium component is usually contained in the catalyst in
the form of ion, oxide or hydroxide. In the present invention,
5 a catalyst excellent in cracking performance and gasoline
selectivity can be obtained, by incorporating a magnesium
component.
[0044]
If the content of the magnesium component is too low, there
10 are cases where a sufficient effect of improving the hydrothermal
resistance cannot be obtained, or where the cracking activity and
the selectivity of the resulting catalyst for catalytic cracking
of hydrocarbons are decreased, depending on the content of the
phosphorus component to be described later. If the content of
15 the magnesium component is too high, on the other hand, while it
depends on the type and the content of the faujasite-type zeolite
used, there are cases where the magnesium component cannot be
carried by the zeolite, and even if it could be carried, the
efficiency of the zeolite to carry the magnesium component may
20 be significantly reduced. In addition, there are cases where the
resulting catalyst has an insufficient cracking activity,
gasoline selectivity, hydrothermal resistance and the like,
depending on the content of the phosphorus component to be
described later.
SF-2667 21
[0045]
Phosphorus component
The catalyst for catalytic cracking of hydrocarbons
according to the present invention preferably contains a
5 phosphorus component, as P205/ within the range of from 0.1 to 10%
by weight, and more preferably, within the range of from 0.2 to
5% by weight. By containing the phosphorus component, a catalyst
excellent in cracking activity, hydrothermal resistance, and
metal resistance can be obtained.
10 [0046]
The phosphorus component is contained in the form of
phosphate ion or phosphorus oxide.
[0047] *
If the content of the phosphorus component is too low, there
15 are cases where the resulting catalyst for catalytic cracking of
hydrocarbons has an insufficient cracking activity, selectivity,
cracking activity for distillation residue, metal resistance,
hydrothermal resistance and the like, depending on the content
of the above mentioned magnesium component.
20 [0048]
If the content of the phosphorus component is too high, there
also are cases where the resulting catalyst for catalytic cracking
of hydrocarbons has a reduced cracking activity, selectivity,
cracking activity for distillation residue, metal resistance,
SF-2667 22
hydrothermal resistance and the like. The reason for this is not
known. However, a conceivable explanation may be that an
excessive amount of the phosphorus component causes to reduce the
crystallinity of the faujasite-type zeolite, or to clog the
5 micropores-of the catalyst, or the like.
[0049]
Particularly, in the present invention, since the
phosphorus component is incorporated in the catalyst in
combination with the magnesium component, it is possible to
10 improve the cracking activity, selectivity, cracking activity for
distillation residue, metal resistance, hydrothermal resistance
and the like of the resulting catalyst.
[0050] *
If the content of the phosphorus component (CP) in terms
15 of P2O5 is greater than 10% by weight, there are cases where the
cracking activity, selectivity, cracking activity for
distillation residue, metal resistance, hydrothermal resistance
and the like of the catalyst for catalytic cracking of hydrocarbons
may be reduced, depending on the content of the faujasite-type
20 zeolite, the content of alumina as the above mentioned matrix
component, and the content of the above mentioned magnesium
component.
[0051]
Further, it is preferred that phosphorus component be used
SF-2667 23
in an amount such that the ratio (CP) / (CM) (the weight ratio,
each in terms of oxide) of the content of the phosphorus component
(CP) to the content of the magnesium component (CM) is within the
range of from 0.1 to 8, and more preferably, within the range of
5 from 0.2 to 5.
[0052]
Rare earth component
The catalyst for catalytic cracking of hydrocarbons
according to the present invention may also contain a rare earth
10 component. The content of the rare earth component in terms of
RE2O3 is preferably within the range of from 0.1 to 2% by weight,
and more preferably, within the range of from 0. 2 to 1. 5% by weight.
By incorporating the rare earth component, itis possible to obtain
a catalyst excellent in cracking activity, selectivity of gasoline
15 and the like.
[0053]
Examples of the rare earth component include rare earth
metals such as lanthanum, cerium, and neodymium; and mixtures of
these metals. Usually, mixed rare earths comprising as major
20 components lanthanum and cerium are used.
[0054]
If the content of the rare earth component in terms of RE2O3
in the catalyst for catalytic cracking of hydrocarbons is too low,
the cracking activity, selectivity, hydrothermal resistance,
SF-2667 24
metal resistance and the like of the catalyst may be insufficient,
depending on the content of the above mentioned magnesium
component.
[0055]
5 If the content of the rare earth component in terms of RE2O3
in the catalyst for catalytic cracking of hydrocarbons is too high,
on the other hand, it is difficult for the catalyst to carry the
rare earth component, when the catalyst is produced by the method
according to the present invention. Even if the rare earth
10 component could be carried by the catalyst, its content being too
high is not preferred, because the effect of carrying the rare
earth component, in other words, the effect of further improving
the cracking activity, selectivity, hydrothermal resistance,
metal resistance and the, like cannot be obtained, and the
15 efficiency of the catalyst to carry the rare earth component is
significantly reduced.
[0056]
The above described catalyst for catalytic cracking of
hydrocarbons can be suitably used as a catalyst for fluid catalytic
20 cracking of hydrocarbons, and in this case, the average particle
diameter of the catalyst is preferably within the range of from
40 to 100 pm, and more preferably within the range of from 50 to
80um.
[0057]
SF-2667 25
The catalyst for catalytic cracking of hydrocarbons
according to the present invention can be produced by a method
described below.
[0058]
5 Method for producing catalyst for catalytic cracking of
hydrocarbons
The method for producing the catalyst for catalytic cracking
of hydrocarbons according to the present invention includes the
following steps (a) to (f):
10 (a) a step of spray drying a mixed slurry of a faujasite-type
zeolite and a matrix-forming component in a hot air flow to form
minute spherical particles;
(c) a step of subjecting the resultant to ion exchange with
magnesium ions;
15 (e) a step of bringing the resultant into contact with phosphate
ions; and
(f) a step of drying the resultant.
Step (a)
A mixed slurry of a faujasite-type zeolite and a
20 matrix-forming component is spray dried in a hot air flow to form
minute spherical particles.
[0059]
As the faujasite-type zeolite, the above mentioned
faujasite-type zeolite is used. Among these, an ultra-stable
il
SF-2667 26
zeolite can be suitably used. As the matrix-forming component,
the above mentioned matrix component, or one which turns into the
matrix component after being incorporated into the catalyst, such
as silica gel, silica sol, alumina gel, alumina sol, silica alumina
5 gel, silica alumina sol, an aluminum phosphate compound or the
like can be suitably used.
[0060]
The mixed slurry may contain the above mentioned extender.
[0061]
10 The concentration of the mixed slurry is not particularly
limited, as long as a catalyst for catalytic cracking having a
desired average particle diameter, particle size distribution,
abrasion resistance and the like can be obtained. Generally, it
is preferred that the concentration of the mixed slurry be within
15 the range of from 10 to 50% by weight, and more preferably, within
the range of from 20 to 40% by weight. If the concentration is
within the above mentioned range, the spray drying can be performed
easily, and the particle size and the particle size distribution
can be adjusted to desired values.
20 [0062]
If the concentration of the mixed slurry is too low, the
economic efficiency may be reduced, because the slurry contains
large amount of water that evaporates during the spray drying,
and thus requires a large amount of thermal energy. In addition,
SF-2667 27
there are cases where a catalyst having a desired average particle
diameter and particle size distribution cannot be obtained, or
where the bulk density is decreased to result in an insufficient
fluidity. If the concentration of the slurry is too high, on the
5 other hand, the viscosity of the mixed slurry may be too high,
resulting in a difficulty to perform the spray drying, or a failure
to obtain a catalyst having a desired average particle diameter
and particle size distribution.
[0063]
10 The method of spray drying is not particularly limited as
long as a catalyst for catalytic cracking having a desired average
particle diameter, particle size distribution, abrasion
resistance and the like can be obtained, and a conventionally known
method can be used. For example, a conventionally known method
15 such as a rotating disk method, pressure nozzle method, two-fluid
nozzle method or the like can be used.
In general, the inlet temperature of the hot air used in
the spray drying is preferably within the range of from 250 to
500°C, and the outlet temperature is preferably within the range
20 of from 150 to 250°C.
[0064]
In the present invention, in general, the average particle
diameter of the minute spherical particles is preferably within
the range of from 40 to 100 um, and more preferably within the
SF-2667 28
range of from 50 to 80 urn. The particle size is evaluated based
on the measurement by the dry-type micromesh sieve method, and
the value at 50% by weight is determined as the average particle
diameter.
5 [0065]
In the present invention, it is preferred that the following
step (b) be carried out after the above mentioned step (a).
[0066]
Step (b)
10 Then, the minute spherical particles are washed.
[0067]
Washing is carried out in order to remove catalyst poisons
i
such as alkali metals, CI , SO4 and the like which may be included
in the above mentioned faujasite-type zeolite or the
15 matrix-forming component. It is preferred that these catalyst
poisons are reduced as much as possible. In general, the content
of the alkali metals in terms of alkali metal oxides is preferably
1% by weight or less, and more preferably, 0.5% by weight or less.
In general, the content of anions such as CI , S04 and the like
20 is preferably 2% by weight or less, and more preferably 1% by weight
or less.
[0068]
Usually, the minute spherical particles can be washed with
splashing water, preferably hot water. However, an aqueous
SF-2667 29
solution of ammonium salts, such as ammonium sulphate, ammonium
chloride and the like; hot aqueous ammonia; or the like can also
be used to wash the minute spherical particles.
[0069]
5 Step (c)
Then, magnesium is introduced into the minute spherical
particles by subjecting the particles to ion exchange with
magnesium ions.
[0070]
10 The ion exchange with magnesium ions can be carried out,
for example, by bringing the washed minute spherical particles
into contact with an aqueous magnesium compound solution, or
j
preferably, by dispersing the washed minute spherical particles
in the aqueous magnesium compound solution.
15 [0071]
Examples of the magnesium compound include magnesium
chloride, magnesium nitrate, magnesium sulfate and the like. The
magnesium compound is used in an amount such that the content of
magnesium (CM) in terms of MgO in the resulting catalyst for
20 catalytic cracking of hydrocarbons is within the range of from
0.05 to 3% by weight, and more preferably within the range of from
0.1 to 2.5% by weight.
[0072]
In addition, it is preferred that the magnesium compound
Jl
SF-2667 30
be used in an amount such that the ratio (CM) / (Cz) of the content
of magnesium (CM) to the content (Cz) of the faujasite-type zeolite
in the resulting catalyst for catalytic cracking of hydrocarbons
is within the range of from 0 . 001 to 0.1, and more preferably within
5 the range of from 0.002 to 0.08.
[0073]
If the above mentioned ratio (CM) / 2
/ AI2O3 = 5.2, lattice constant = 24.66 Angstrom; manufactured by
JGC C&C) was dispersed in 10 kg of pure water, and the temperature
5 of the resultant was elevated to 60°C. Then 2 molar equivalent
of ammonium sulphate relative to the amount of the NaY zeolite
was added to the resultant, followed by ion exchange for 1 hour.
The resultant was then filtered, thoroughly washed with hot water,
and dried at 130°C for 10 hours, to prepare ammonium ion-exchanged
10 zeolite powder (1). At this time, in the obtained ammonium
ion-exchanged zeolite powder (1) , NH4 ion-exchange ratio was 65%,
and the ratio of residual Na ions was 35% (this is referred to
i
i
as NH4(65)Na(35)Y) .
Next, the resulting ammonium ion-exchanged zeolite powder
15 was baked at 500°C for 4 hours to obtain H(65)Na(35)Y powder, which
was then dispersed again in 5 kg of aqueous ammonium sulphate
solution having a concentration of 40% by weight, and the
temperature of the obtained dispersion liquid was elevated to 60°C,
and the pH of the dispersion liquid was adjusted to 4.5, followed
20 by ion exchange for 8 hours. Then the resultant was thoroughly
washed by splashing hot water and dried at 150°C for 10 hours to
prepare ammonium ion-exchanged zeolite powder (2) . At this time,
in the obtained ammonium ion-exchanged zeolite powder (2), the
NH4 ion-exchange ratio was 90%, and the ratio of residual Na ions
SF-2667 40
was 10% (this is referred to as NH4(90)Na(io)Y) .
The resulting ammonium ion-exchanged zeolite powder (2) was
filled in a stainless container, and subjected to heat treatment
at a temperature of 700 °C for 1 hour, in a saturated water vapor
5 atmosphere, using a rotary steaming apparatus, to prepare
faujasite-type zeolite (1), as an ultra-stable zeolite.
[0100]
The molar ratio: S102 / A1203, the Na20 content, the lattice
constant, and the specific surface area of the resulting
10 faujasite-type zeolite (1) were measured, and the results are
shown in the Table.
[0101]
i
Preparation of catalyst (1) for catalytic cracking of hydrocarbons
A commercially available water glass #3 and sulfuric acid
15 were rapidly stirred and mixed, to prepare silica hydrosol having
a concentration of 12.5% by weight in terms of Si02- To 4,000 g
of the above mentioned silica hydrosol, 1,125 g (dry basis) of
kaolin, 125 g (dry basis) of activated alumina, and 750 g (dry
basis) of faujasite-type zeolite (1) were added, to prepare mixed
20 slurry (1) having a solids concentration of 30%.
[0102]
Then, mixed slurry (1) having a solids concentration of 30%
was sprayed into a hot air flow having an inlet temperature of
250°C, to prepare minute spherical particles (1) . At this time,
i
SF-2667 41
the average particle diameter of the minute spherical particles
(1) was 65 um, and the outlet temperature of the hot air flow was
150°C. (step (a))
A quantity of 2, 000 g, in dry weight, of the resulting minute
5 spherical particles (1) were suspended in 10 kg of hot water, which
amounted to 5 times the amount of the minute spherical particles
(1) , followed by addition of 203 g of ammonium sulphate, which
was an equimolar amount as alumina in faujasite-type zeolite (1)
contained in the minute spherical particles (1) . The resultant
10 was then dehydrated and washed with splashing water. (step (b) )
The washed minute spherical particles (1) were suspended
in 10 kg of hot water, and 200 g of aqueous magnesium chloride
i
solution having a concentration of 10% by weight in terms of MgO
was added to the resultant, followed by ion exchange at 60°C for
15 30 minutes. At this time, aqueous ammonia having a concentration
of 15% by weight was added to adjust the pH of the resultant to
5.5. The resultant was then dehydrated and washed with splashing
water. (step (c))
Then the thus obtained magnesium ion-exchanged minute
20 spherical particles (1) were then suspended in 10 kg of hot water,
and followed by addition of 14 ..1 g of aqueous H3PO4 solution having
a concentration of 85% by weight in terms of P2O5. The pH of the
resultant at this time was adjusted to 4. The resultant was then
dehydrated and washed with splashing water. (step (e))
SF-2667 42
The washed minute spherical particles (1) carrying the
magnesium component and the phosphorus component were dried at
150°C using a drier, such that the water content of the particles
was 10% by weight, to prepare catalyst (1) for catalytic cracking
of hydrocarbons . (step (f) ) The MgO content, the P205 content and
the average particle diameter of the resulting catalyst (1) for
catalytic cracking of hydrocarbons were measured, and the results
are shown in the Table. Further, the catalytic performance of
the catalyst (1) for catalytic cracking of hydrocarbons was
evaluated according to the following conditions, and results are
shown in the Table.
TOiXKB] "" » - • - - . - -•
i
Performance test
First, the catalyst (1) for catalytic cracking of
hydrocarbons was pseudo-equilibrated according to the following
conditions, and the cracking performance thereof was evaluated.
[0104]
Pseudo-equilibration
The catalyst (1) for catalytic cracking of hydrocarbons was
baked at 600°C for 1 hour, and then allowed to absorb a solution
of nickel naphthenate and vanadium naphthenate in benzene such
that the concentrations of the nickel and vanadium were 2,000 ppm
and 4, 000 ppm, respectively. Then the catalyst was dried at 110°C,
followed by baking at 600 °C for 1. 5 hours. The resultant was then
SF-2667 43
subjected to steam treatment at 780°C for 6 hours, and baked again
at 600°C for 1 hour to complete pseudo-equilibration.
[0105]
Cracking performance
5 A cracking reactor (ACE-MAT, . model R +; manufactured by
Kayser Technology Inc.) was used.
[0106]
Raw material oil: desulfurized atmospheric residue (DSAR)
Ratio of the catalyst / raw material (C/O): 5
10 Reaction temperature: 520°C
Space velocity: 8 hr"1
Boiling range of gasoline: C5 to 216°C
<
Boiling range of light cycle oil (LCO): 216°C to 343°C *
Boiling range of heavy cycle oil (HCO): 343°C or more
15 Conversion ratio {% by weight) = 100 - (LCO + HCO % by weight)
(% by weight)
Hydrothermal resistance
The same procedure as described above was repeated to carry
out the pseudo-equilibration and the evaluation of the cracking
20 performance, except that the pseudo-equilibration was performed
at a temperature of 800°C. The conversion ratio (2) at this time
is shown in the Table. Further, the ratio: conversion ratio (2)
/ conversion ratio (1) of the conversion ratio (2) at this time
to the conversion ratio (1) as measured above, is shown in the
SF-2667 44
Table, as the hydrothermal resistance. The higher the ratio is,
the higher the hydrothermal resistance is.
[0107]
[Example 2]
5 Preparation of catalyst (2) for catalytic cracking of hydrocarbons
The same procedure as in Example 1 was carried out except
that, in step (c), 24 g of aqueous magnesium chloride solution
having a concentration of 10% by weight in terms of MgO was added,
to prepare catalyst (2) for catalytic cracking of hydrocarbons.
10 [0108]
The MgO content, the P2O5 content, and the average particle
diameter of the resulting catalyst (2) for catalytic cracking of
hydrocarbons were measured, and the results are shown in the Table.
Further, the catalytic performance and the hydrothermal
15 resistance of the catalyst (2) for catalytic cracking of
hydrocarbons were evaluated, and the results are shown in the
Table.
[0109]
[Example 3]
20 Preparation of catalyst (3) for catalytic cracking of hydrocarbons
The same procedure as in Example 1 was carried out except
that, in step (c) , 400 g of aqueous magnesium chloride solution
having a concentration of 10% by weight in terms of MgO was added,
to prepare catalyst (3) for catalytic cracking of hydrocarbons.
SF-2667 45
[0110]
The MgO content, the P2O5 content, and the average particle
diameter of the resulting catalyst (3) for catalytic cracking of
hydrocarbons were measured, and the results are shown in the Table.
5 Further, the catalytic performance and the hydrothermal
resistance of the catalyst (3) for catalytic cracking of
hydrocarbons were evaluated, and the results are shown in the
Table.
[0111]
10 [Example 4]
Preparation of catalyst (4) for catalytic cracking of hydrocarbons
The same procedure as in Example 1 was carried out except
that, in step (e) , 6.8 g of aqueous H3PO4 solution having a
concentration of 85% by weight in terms of P2O5 was added, to prepare
15 catalyst (4) for catalytic cracking of hydrocarbons.
[0112]
The MgO content, the P2O5 content, and the average particle
diameter of the resulting catalyst (4) for catalytic cracking of
hydrocarbons were measured, and the results are shown in the Table.
20 Further, the catalytic performance and the hydrothermal
resistance of the catalyst (4) for catalytic cracking of
hydrocarbons were evaluated, and the results are shown in the
Table.
[0113]
SF-2667 46
[Example 5]
Preparation of catalyst (5) for catalytic cracking of hydrocarbons
The same procedure as in Example 1 was carried out except
that, in step (e), 162.4 g of aqueous H3PO4 solution having a
5 concentration of 85% by weight in terms of P205 was added, to prepare
catalyst (5) for catalytic cracking of hydrocarbons.
[0114]
The MgO content, the P2O5 content, and the average particle
diameter of the resulting catalyst (5) for catalytic cracking of
10 hydrocarbons were measured, and the results are shown in the Table.
Further, the catalytic performance and the hydrothermal
resistance of the catalyst (5) for catalytic cracking of
hydrocarbons were evaluated, and the results are shown in the
Table.
15 [0115]
[Example 6]
Preparation of catalyst (6) for catalytic cracking of hydrocarbons
A commercially available water glass #3 and sulfuric acid
were rapidly stirred and mixed, to prepare silica hydrosol having
20 a concentration of 12.5% by weight in terms of Si02. To 4,000 g
of the above mentioned silica hydrosol, 1,375 g {dry basis) of
kaolin, 125 g (dry basis) of activated alumina, and 500 g (dry
basis) of faujasite-type zeolite (1) were added, to prepare mixed
slurry (2) having a solids concentration of 30%.
il
' SF-2667 47
[0116]
Then, mixed slurry (2) having a solids concentration of 30%
was sprayed into a hot air flow having an inlet temperature of
250°C, to prepare minute spherical particles (2) . At this time,
5 the average particle diameter of the minute spherical particles
(2) was 65 urn, and the outlet temperature of the hot air flow was
150°C. {step (a))
A quantity of 2, 000 g, in dry weight, of the resulting minute
spherical particles (2) were suspended in 10 kg of hot water, which
10 amounted to 5 times the amount of the minute spherical particles
(2), followed by addition of 135 g of ammonium sulphate, which
was an equimolar amount as alumina in faujasite-type zeolite (1)
contained in the minute spherical particles (1). The resultant
was then dehydrated and washed with splashing water. (step (b) )
15 The washed minute spherical particles (2) were suspended
in 10 kg of hot water, and 200 g of aqueous magnesium chloride
solution having a concentration of 10% by weight in terms of MgO
was added to the resultant, followed by ion exchange at 60°C for
30 minutes. At this time, aqueous ammonia having a concentration
20 of 15% by weight was added to adjust the pH of the resultant to
5.5. The resultant was then dehydrated and washed with splashing
water. (step (c))
Then- the thus obtained magnesium ion-exchanged minute
spherical particles (2) were then suspended in 10 kg of hot water,
1
-1 SF-2667 48
and followed by addition of 14.1 g of aqueous H3PO4 solution having
a concentration of 85% by weight in terms of P2O5. The pH of the
resultant at this time was adjusted to 4. The resultant was then
dehydrated and washed with splashing water. (step (e) )
5 The washed minute spherical particles (2) carrying the
magnesium component and the phosphorus component were dried at
150°C using a drier, such that the water content of the particles
was 10% by weight, to prepare catalyst (6) for catalytic cracking
of hydrocarbons. (step (f) ) The MgO content, the P2O5 content,
10 and the average particle diameter of the resulting catalyst (6)
for catalytic cracking of hydrocarbons were measured, and the
results are shown in the Table. Further, the catalytic
performance and the hydrothermal resistance of the catalyst (6)
for catalytic cracking of hydrocarbons were evaluated, and the
15 results are shown in the Table.
[0117]
[Example 7]
Preparation of catalyst (7) for catalytic cracking of hydrocarbons
A commercially available water glass #3 and sulfuric acid
20 were rapidly stirred and mixed, to prepare silica hydrosol having
a concentration of 12.5% by weight in terms of SiC>2. To 4,000 g
of the above mentioned silica hydrosol, 875 g {dry basis) of kaolin,
125 g (dry basis) of activated alumina, and 1,000 g (dry basis)
of faujasite-type zeolite (1) were added, to prepare mixed slurry
SF-2667 49
(3) having a solids concentration of 30%.
[0118]
Then, mixed slurry (3) having a solids concentration of 30%
was sprayed into a hot air flow having an inlet temperature of
5 250°C/ to prepare minute spherical particles (3) . At this time,
the average particle diameter of the minute spherical particles
(3) was 65 urn, and the outlet temperature of the hot air flow was
150°C. (step (a))
A quantity of 2, 000 g, in dry weight, of the resulting minute
10 spherical particles (3) were suspended in 10 kg of hot water, which
amounted to 5 times the amount of the minute spherical particles
(3) , followed by addition of 271 g of ammonium sulphate, which
was an equimolar amount as alumina in faujasite-type zeolite (1)
contained in the minute spherical particles (1). The resultant
15 was then dehydrated and washed with splashing water. (step (b) )
The washed minute spherical particles (3) were suspended
in 10 kg of hot water, and 200 g of aqueous magnesium chloride
solution having a concentration of 10% by weight in terms of MgO
was added to the resultant, followed by ion exchange at 60°C for
20 30 minutes. At this time, aqueous ammonia having a concentration
of 15% by weight was added to adjust the pH of the resultant to
5.5. The resultant was then dehydrated and washed with splashing
water. (step (c))
Then the thus obtained magnesium ion-exchanged minute
SF-2667 50
spherical particles (3) were then suspended in 10 kg of hot water,
and followed by addition of 14.1 g of aqueous H3PO4 solution having
a concentration of 85% by weight in terms of P2O5. The pH of the
resultant at this time was adjusted to 4. The resultant was then
5 dehydrated and washed with splashing water. (step (e))
The washed minute spherical particles (3) carrying the
magnesium component and the phosphorus component were dried at
150°C using a drier, such that the water content of the particles
was 10% by weight, to prepare catalyst (7) for catalytic cracking
10 of hydrocarbons. (step (f))
The MgO content, the P2O5 content, and the average particle
diameter of the resulting catalyst (7) for catalytic cracking of
hydrocarbons were measured, and the results are shown in the Table.
Further, the catalytic performance and the hydrothermal
15 resistance of the catalyst (7) for catalytic cracking of
hydrocarbons were evaluated, and the results are shown in the
Table.
[0119]
[Example 8]
20 Preparation of catalyst (8) for catalytic cracking of hydrocarbons
The same procedure as in Example 1 was carried out to prepare
magnesium ion-exchanged minute spherical particles (1). {step
(c))
The magnesium ion-exchanged minute spherical particles (1)
SF-2667 51
were suspended in 10 kg of hot water, and 100 g of aqueous rare
earth chloride solution having a concentration of 20% by weight
in terms of RE2O3 was added, followed by ion exchange at 60°C for
30 minutes. At this time, aqueous ammonia having a concentration
5 of 15% by weight was added to adjust the pH of the resultant to
5.5. The resultant was then dehydrated and washed with splashing
water. {step (d) )
Then the thus obtained rare earth ion-exchanged minute
spherical particles (1) were suspended in 10 kg of hot water,
10 followed by addition of 14.1 g of aqueous H3PO4 solution having
a concentration of 85% by weight in terms of P2O5. The pH of the
resultant at this time was adjusted to 4. The resultant was then
4
dehydrated and washed with splashing water (step (e)).
The washed minute spherical particles (1) carrying the
15 magnesium component, the rare earth component and the phosphorus
component were dried at 150°C using a drier, such that the water
content of the particles was 10% by weight, to prepare catalyst
(8) for catalytic cracking of hydrocarbons. (step (f))
The content of MgO, RE2O3 and P2O5, and the average particle
20 diameter of the resulting catalyst (8) for catalytic cracking of
hydrocarbons were measured, and the results are shown in the Table.
Further, the catalytic performance and the hydrothermal
resistance of the catalyst (8) for catalytic cracking of
hydrocarbons were evaluated, and the results are shown in the
SF-2667 52
Table.
[0120]
[Example 9]
Preparation faujasite-type zeolite (2)
5 The ammonium ion-exchanged zeolite powder (2), which were
prepared in the same manner as in Example 1, was filled in a
stainless container, and subjected to heat treatment at a
temperature of 760°C for 1 hour, in a saturated water vapor
atmosphere, using a rotary steaming apparatus, to prepare
10 faujasite-type zeolite (2), as an ultra-stable zeolite.
[0121]
The molar ratio: Si02 / AI2O3, the Na20 content, the lattice
t
1
constant, and the specific surface area of the resulting
faujasite-type zeolite (2) were measured, and the results are
15 shown in the Table.
[0122]
Preparation of catalyst (9) for catalytic cracking of hydrocarbons
The same procedure as in Example 1 was carried out, except
that faujasite-type zeolite (2) was used instead of faujasite-type
20 zeolite (1), to prepare catalyst (9) for catalytic cracking of
hydrocarbons.
[0123]
The MgO content, the P2O5 content, and the average particle
diameter of the resulting catalyst (9) for catalytic cracking of
SF-2667 53
hydrocarbons were measured, and the results are shown in the Table.
In addition, the catalytic performance and the hydrothermal
resistance of the catalyst (9) for catalytic cracking of
hydrocarbons were evaluated and the results are shown in the Table.
5 [0124]
[Comparative Example 1]
Preparation of catalyst (Rl) for catalytic cracking of
hydrocarbons
The same procedure as in Example 1 was carried out, up to
10 step (c), to prepare magnesium ion-exchanged minute spherical
particles (Rl) . Then the washed minute spherical particles (Rl)
carrying the magnesium component were dried at 150 °C using a drier,
i
such that the water content of the particles was 10% by weight,
to prepare catalyst (Rl) for catalytic cracking of hydrocarbons.
15 [0125]
The MgO content, and the average particle diameter of the
resulting catalyst (Rl) for catalytic cracking of hydrocarbons
were measured and the results are shown in the Table. In addition,
the catalytic performance and the hydrothermal resistance of the
20 catalyst (Rl) for catalytic cracking of hydrocarbons were
evaluated and the results are shown in the Table.
[0126]
[Comparative Example 2]
Preparation of catalyst (R2) for catalytic cracking of
SF-2667 54
hydrocarbons
The same procedure as in Example 1 was carried out, up to
step (b) , to prepare washed minute spherical particles (R2) . Then
the washed minute spherical particles (R2) were suspended in 10
5 kg of hot water, followed by addition of 14.1 g of aqueous H3PO4
solution having a concentration of 85% by weight in terms of P2O5.
At this time, the pH of the resultant was adjusted to 4. The
resultant was then dehydrated and washed with splashing water.
[0127]
10 The washed minute spherical particles (R2) carrying the
phosphorus component were dried at 150°C using a drier, such that
the water content of the particles was 10% by weight, to prepare
catalyst (R2) for catalytic cracking of hydrocarbons.
[0128]
15 The P2O5 content and the average particle diameter of the
resulting catalyst (R2) for catalytic cracking of hydrocarbons
were measured, and the results are shown in the Table. In addition,
the catalytic performance and the hydrothermal resistance of the
catalyst (R2) for catalytic cracking of hydrocarbons were
20 evaluated and the results are shown in the Table.
[0129]
[Comparative Example 3]
Preparation of catalyst (R3) for catalytic cracking of
hydrocarbons
SF-2667 55
The same procedure as in Example 1 was carried out, up to
step (b) , to prepare washed minute spherical particles (R3) . Then
the washed minute spherical particles (R3) were suspended in 10
kg of hot water, and 100 g of aqueous rare earth chloride solution
5 having a concentration of 20% by weight in terms of RE2O3 was added
to the resultant, followed by ion exchange at 60°C for 30 minute.
At this time, aqueous ammonia having a concentration of 15% by
weight was added to adjust the pH of the resultant to 5.5. The
resultant was then dehydrated and washed with splashing water.
10 [0130]
The washed minute spherical particles (R3) carrying the rare
earth component were dried at 150°C using a drier, such that the
water content of the particles was 10% by weight, to prepare
catalyst (R3) for catalytic cracking of hydrocarbons.
15 [0131]
The RE203 content and the average particle diameter of the
resulting catalyst (R3) for catalytic cracking of hydrocarbons
were measured, and the results are shown in the Table. In addition,
the catalytic performance and the hydrothermal resistance of the
20 resulting catalyst (R3) for catalytic cracking of hydrocarbons
were evaluated and the results are shown in the Table.
[0132]
[Comparative Example 4]
Preparation of catalyst (R4) for catalytic cracking of
0
SF-2667 56
hydrocarbons
The same procedure as in Comparative Example 3 was carried
out, except that 400 g of aqueous rare earth chloride solution
having a concentration of 20% by weight in terms of RE2O3 was added,
5 followed by ion exchange at 60°C for 30 minute. At this time,
aqueous ammonia having a concentration of 15% by weight was added
to adjust the pH of the resultant to 5.5. The resultant was then
dehydrated and washed with splashing water.
[0133]
10 The washed minute spherical particles (R4) carrying the rare
earth component were dried at 150°C for 2 hours, using a drier,
such that the water content of the particles was 10% by weight,
to prepare catalyst (R4) for catalytic cracking of hydrocarbons.
[0134]
15 The RE2O3 content and the average particle diameter of the
resulting catalyst (R4) for catalytic cracking of hydrocarbons
were measured, and the results are shown in the Table. The
utilization efficiency of the rare earth (s) at this time was as
low as 60%.
20 [0135]
In addition, the catalytic performance and the hydrothermal
resistance of the catalyst (R4) for catalytic cracking of
hydrocarbons were evaluated and the results are shown in the Table.
[0136]
SF-2667 57
[Comparative Example 5]
Preparation of catalyst (R5) for catalytic cracking of
hydrocarbons
The same procedure as in Example 1 was carried out, up to
5 step {b) , to prepare washed minute spherical particles (R5) . Then
the washed minute spherical particles (R5) were dried at 150°C
for 2 hours, using a drier, to prepare catalyst (R5) for catalytic
cracking of hydrocarbons.
[0137]
10 The average particle diameter of the resulting catalyst (R5)
for catalytic cracking of hydrocarbons was measured, and the
results are shown in the Table. In addition, the catalytic
performance and the hydrothermal resistance of the catalyst (R5)
for catalytic cracking of hydrocarbons were evaluated and the
15 results are shown in the Table.
[0138]
[Table 1-1]
SF-2667 62
[0142]
In can be seen from the Tables shown above that, when the
catalysts obtained in Examples are compared with those obtained
in Comparative Examples, those obtained in Examples have a higher
5 conversion ratio, and a better hydrothermal resistance and metal
resistance, in general.
CLAIMS
1. A catalyst for catalytic cracking of hydrocarbons
comprising a faujasite-type zeolite, a matrix component, a
phosphorus component and a magnesium component,
5 wherein the content of the faujasite-type zeolite (Cz) in
terms of solid is within the range of from 10 to 50 % by weight;
the content of phosphorus (CP) in terms of P2O5 is within the range
of from 0.1 to 10 % by weight; and the content of magnesium (CM)
in terms of MgO is within the range of from 0.05 to 3% by weight.
10
2. The catalyst for catalytic cracking of hydrocarbons
according to claim 1, wherein the ratio (CP) / 3 is within the range of from 1 to 30% by weight.
6. The catalyst for catalytic cracking of hydrocarbons
according to any one of claims 1 to 5, wherein said faujasite-type
zeolite is an ultra-stable zeolite (USY).
10
7. A method for producing a catalyst for catalytic cracking
of hydrocarbons, comprising the following steps (a) to (f):
(a) a step of spray drying a mixed slurry of a faujasite-type
zeolite and a matrix-forming component in a hot air flow to form
15 minute spherical particles;
(c) a step of subjecting the resultant to ion exchange with
magnesium ions;
{e) a step of bringing the resultant into contact with
phosphate io.ns; and
20 (f) a step of drying the resultant.
8 . The method for producing a catalyst for catalytic cracking
of hydrocarbons according to claim 1, wherein the pH at the step
(c) of ion exchange with magnesium ions is within the range of
SF-2667 65
from 3 to 8.
9. The method for producing a catalyst for catalytic cracking
of hydrocarbons according to claim 7 or 8, wherein the pH at the
5 step (e) of contact with phosphate ions is within the range of
from 2 to 6.
10. The method for producing a catalyst for catalytic cracking
of hydrocarbons according to any one of claims 7 to 9, wherein
10 the following step {d} is carried out before or after carrying
out said step (c):
(d) the step of performing ion exchange with rare earth ions.
11. The method for producing a catalyst for catalytic cracking
15 of hydrocarbons according to claim 10, wherein the pH at the step
(d) of ion exchange with rare earth (RE) ions is within the range
of from 4 to 6.
12. The method for producing a catalyst for catalytic cracking
20 of hydrocarbons according to any one of claims 7 to 11, wherein
the following step (b) is carried out after said step (a):
(b) the step of performing washing.