Patent ID: 7122495

Claim:
A process comprising contacting at least one hydrocarbon feedstream with a cracking/selective hydrogen combustion catalyst system under effective catalytic reaction conditions to produce cracked products and uncracked feed comprising liquid and gaseous hydrocarbons, wherein the yield of hydrogen is less than the yield of hydrogen when contacting said hydrocarbon feedstream(s) with said cracking catalyst alone under said catalytic reaction conditions, said process comprising the steps of: (a) charging at least one hydrocarbon feedstream to a fluid catalytic cracking reactor; (b) charging a hot fluidized cracking/selective hydrogen combustion catalyst system from a catalyst regenerator to said fluid catalytic cracking reactor, said catalyst system comprising (a) at least one molecular sieve and (b) at least one metal-based component, said metal-based component consisting essentially of a combination of metals selected from the group consisting of: i) at least one metal from Group 3 and at least one metal from Groups 4–15 of the Periodic Table of the Elements; ii) at least one metal from Groups 5–15 of the Periodic Table of the Elements, and at least one metal from at least one of Groups 1, 2, and 4 of the Periodic Table of the Elements; iii) at least one metal from Groups 1–2, at least one metal from Group 3, and at least one metal from Groups 4–15 of the Periodic Table of the Elements; and iv) two or more metals from Groups 4–15 of the Periodic Table of the Elements; and at least one of oxygen and sulfur, wherein the at least one of oxygen and sulfur is chemically bound both within and between the metals; (c) catalytically cracking said feedstream(s) and simultaneously combusting resultant hydrogen in said fluid catalytic cracking reactor at a temperature of from about 300 to about 800° C. and a pressure of from about 0.1 to 10 atmospheres in the presence of said catalyst system to produce a stream comprising cracked products and a spent catalyst system which are discharged from said reactor; (d) separating a phase rich in said cracked products and uncracked feed from a phase rich in said spent catalyst system; (e) stripping said spent catalyst system at stripping conditions to produce a stripped catalyst phase; (f) decoking and oxidizing said stripped catalyst phase in a catalyst regenerator at catalyst regeneration conditions to produce said hot fluidized cracking/selective hydrogen combustion catalyst system, which is recycled to the said reactor; and (g) separating and recovering said cracked products and uncracked feed.