Ferrierite compositions for reducing NOx emissions during fluid catalytic cracking

Abstract

Compositions for reduction of NOx generated during a catalytic cracking process, preferably, a fluid catalytic cracking process, are disclosed. The compositions comprise a fluid catalytic cracking catalyst composition, preferably containing a Y-type zeolite, and a particulate NOx reduction composition containing ferrierite zeolite particles. Preferably, the NOx reduction composition contains ferrierite zeolite particles bound with an inorganic binder. In the alternative, the ferrierite zeolite particles are incorporated into the cracking catalyst as an integral component of the catalyst. NOx reduction compositions in accordance with the invention are very effective for the reduction of NOx emissions released from the regenerator of a fluid catalytic cracking unit operating under FCC process conditions without a substantial change in conversion or yield of cracked products. Processes for the use of the compositions are also disclosed.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] The application is a continuation in part application of U.S. patent application Ser. No. 10 / 702,240, filed Nov. 6, 2003.FIELD OF THE INVENTION [0002] The present invention relates to NOx reduction compositions and the method of use thereof to reduce NOx emissions in refinery processes, and specifically in fluid catalytic cracking (FCC) processes. More particularly, the present invention relates to NOx reduction compositions and their method of use to reduce the content of NOx off gases released from a fluid catalytic cracking unit (FCCU) regenerator during the FCC process without a substantial change in hydrocarbon conversion or the yield of valuable cracked products. BACKGROUND OF THE INVENTION [0003] In recent years there has been an increased concern in the United States and elsewhere about air pollution from industrial emissions of noxious oxides of nitrogen, sulfur and carbon. In response to such concerns, government agencies have...

AI Technical Summary

Benefits of technology

[0014] It has now been discovered that the incorporation of a ferrierite zeolite component with a catalytically cracking catalyst inventory, in particular a cracking catalyst inventory containing an active Y-type zeolite, being circulated throughout a fluid catalytic cracking unit (FCCU) during a fluid catalytic cracking (FCC) process provides superior NOx control performance without substantially changing or affecting the hydrocarbon conversion or the yield of cracked petroleum products produced during the FCC process.

[0016] In one aspect of the invention, novel ferrierite zeolite-containing NOx reduction compositions are provided which are added to a circulating inventory of the catalytic cracking catalyst as a separate admixture of particles to reduce NOx emissions released from the FCCU regenerator during the FCC process.

[0018] In yet another aspect of the invention, novel NOx reduction compositions are provided which compositions reduce NOx emissions from the FCCU regenerator during the FCC process while substantially maintaining hydrocarbon conversion and the yield of cracked petroleum products and minimizing an increase in the production of coke.

[0020] Another aspect of the invention is to provide improved FCC processes for the reduction of the content of NOx in the off gases of the FCCU regenerator without substantially affecting hydrocarbon conversion or the yield of petroleum products produced during the FCC process.

Problems solved by technology

NOx, or oxides of nitrogen, in flue gas streams exiting from fluid catalytic cracking (FCC) regenerators is a pervasive problem.

Thus, all FCCUs processing nitrogen-containing feeds can have a NOx emissions problem due to catalyst regeneration.

When a NOx reduction additive increases coke production, the FCCU may have insufficient air capacity to burn the extra coke and may result in a lower feed throughput in the unit.

If the additive increases the production of low value dry gas, the production of more valuable products may decrease.

An increase in dry gas may exceed the ability of the unit to handle it, thus forcing a reduction of the amount of feed processed.

While an additive that increases light olefins production may be desirable if the refinery values these products and the unit has the equipment necessary to process the extra light hydrocarbons, the additive may, however, reduce profitability if the refinery's goal is to maximize gasoline production.

Even an additive which increases unit conversion may be undesirable if it affects product yields, causes the unit to reach an equipment limitation, and / or decreases the amount of feed that can be processed.

Consequently, any change to the FCCU that affects the product slate or changes the ability to process feed at the desired rate can be detrimental to the refinery profitability.

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