EP0130734A2
Expired / Lapsed
EP
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Porous mullite production
Assignee: BASF Catalysts LLC
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Filing: 1984-06-19
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Granted: —
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Expires: 2004-06-19
Abstract
Abstract Clay convertible by thermal treatment into crystalline mullite and silica is formed into green coherent bodies of desired size and shape such as for example, microspheres, pellets or honeycombs. The bodies are then calcined to convert the clay into a mixture of crystalline mullite and silica, thereby also hardening the bodies. Without destroying the form of the bodies, e.g., without grinding and without causing the bodies to decrepitate, pores in the size range of about 150 to 350A are formed by selectively leaching silica from the bodies. The porous mullite bodies retain porosity at elevated temperatures and are useful, for example, as catalyst supports and contact materials. Pore structure in the meso- (100-600A diameter) and macro- (600-20,000A diameter) size ranges may be controlled.
Inventors
- 👤 Barry K. Speronello
Bibliographic Details
Application Number
—
Jurisdiction
EP
Data Source
google_patents
Last Synchronized
2026-10-27 10:35
CPC Classifications
C; C10; C10G; C10G25/00; C10G25/06; C10G25/09; B; B01; B01J; B01J21/00; B01J21/16; C04; C04B; C04B35/00; C04B35/01; C04B35/16; C04B35/18; C04B38/00; C04B38/04; C10G11/00; C10G11/02; C10G11/04; C10G45/00; C10G45/02; C10G45/04
Claims Analysis
Total Claims: 17
Claim 1
Independent Claim
34 words
Porous shaped bodies consisting essentially of mullite crystals and, optionally free silica, said bodies having a molar ratio of A1 2 0 3 /Si0 2 in excess of 0.50 and up to about 1.65.
Claim 2
Dependent Claim
34 words
Porous shaped bodies consisting essentially of mullite crystals and, optionally free silica, said bodies having a molar ratio of A1 2 0 3 /Si0 2 in excess of 0.50 and up to about 1.65.
Claim 3
Dependent Claim
26 words
Porous shaped bodies of claim 1 wherein the molar ratio of Al 2 O 3 /SiO 2 is in the range of about 1.58 to 1.64.
Claim 4
Dependent Claim
26 words
Porous shaped bodies of any of the foregoing claims further characterized by having a BET surface area in the range of about 20 to 60 m2/g.
Claim 5
Dependent Claim
91 words
Porous shaped bodies of any of the foregoing claims further characterized by having an alkali metal oxide content below about 1%, a BET surface area in the range of about 20 to 60 m 2 /g, a total pore volume in excess of 0.15 cc/g and a pore structure in the range of 100 to 600A characterized by a pore volume in that range of in excess of 0.1 cc/g and the greatest volume of porosity in that range centered around a pore diameter in the range of 150A to 350A.
Claim 6
Dependent Claim
22 words
Porous shaped bodies of any of the foregoing claims which are in the form of fluidizable'microspheres, monolithic honeycombs, pellets or round spheres.
Claim 7
Dependent Claim
22 words
Porous shaped bodies of any of the foregoing claims which additionally contain a catalytically active material or a precursor thereof deposited thereon.
Claim 8
Independent Claim
98 words
The method for producing the porous shaped bodies of any of the aforementioned claims which comprises: (a) providing a composition comprising clay convertible to mullite and free silica in step (b), mixing said composition with a fugitive binder such as water and forming said composition into self-supporting green bodies; (b) calcining said bodies at a temperature and . for a time controlled to substantially convert the bodies into crystalline mullite and free silica; (c) leaching free silica from said bodies without destroying said mullite crystals and without destroying the form of said bodies; and (d) recovering said bodies.
Claim 9
Independent Claim
21 words
The method of claims 7 wherein free silica is leached with an aqueous solution of soda, soda ash or sodium hydroxide.
Claim 10
Independent Claim
28 words
The method of any of the foregoing claims wherein the composition provided in step (a) consists of kaolin clay or a mixture of hydrous and calcined kaolin clay.
Claim 11
Independent Claim
107 words
The method of any of the foregoing claims further characterized in that the bodies recovered in step (d) have a molar ratio of A1 2 0 3 /Si0 2 in the range of about 1.58 to 1.64, a BET surface area in the range of about 20 to 60 m 2 /g, a total pore volume in excess of 0.15 cc/g and a pore structure in the range of 100 to 600A characterized by a pore volume in that range of an excess of 0.1 cc/g and the greatest volume of porosity in that range centered around a pore diameter in the range of 150A to 350A.
Claim 12
Independent Claim
77 words
The method of any of the foregoing claims further characterized in that the clay in the composition in step (a) comprises particles of hydrated kaolin clay or particles of a mixture thereof with particles of calcined kaolin clay and the particles of said hydrated kaolin clay or mixture thereof with calcined clay have a size distribution and a composition preselected to produce bodies which, after being leached, have a predetermined pore structure in the macropore size range.
Claim 13
Independent Claim
45 words
The method of.any of' the foregoing claims further characterized in that the temperature and time employed to substantially decompose the clay into mullite and free silica is preselected to result in a predetermined pore structure in the mesopore range after free silica has been leached.
Claim 14
Independent Claim
27 words
The method of any of the foregoing claims comprising the further step of impregnating the bodies from step (e) with a catalytically active material or precursor thereof.
Claim 15
Dependent Claim
110 words
In a process for preparing premium products from petroleum crude or residual stock which contain high boiling portions contaminated by metals, high carbon content or both, which process comprises selective vaporization by contacting said stock with a finely divided substantially inert solid contact material at low cracking severity conditions of high temperature and short hydrocarbon residence time in a rising confined column, and separating vaporous products of said contacting from said contact material bearing a combustible deposit of unvaporized high Conradson Carbon or high metal content constituents of said stock, the improvement which comprises using as said inert contact material the porous shaped bodies of any of the foregoing claims.
Claim 16
Dependent Claim
76 words
In a process for treating heavy hydrocarbon oil which contains heavy metals and/or sulfur comprising contacting said oil with hydrogen in the presence of a catalyst and recovering a hydrocarbon product having a reduced content of heavy metals and/or sulfur, the improvement which comprises using as the catalyst one or more known catalytic metals of the group consisting of cobalt, nickel, molybdenum and tungsten supported on the porous shaped bodies of any of the foregoing claims.
Claim 17
Dependent Claim
136 words
In a process for the continuous cyclic fluid catalytic cracking hydrocarbons with a zeolitic cracking catalyst in the absence of added hydrogen in a reaction zone to produce lower boiling hydrocarbons wherein cracking results in the deposition on the fluid cracking catalyst particles of a solid deposit of combustible hydrocarbons, the catalyst particles containing said deposit are regenerated in a regeneration zone by oxidation in the presence of air at elevated temperature to burn off said deposit, and the catalyst is recycled to said reaction zone where it is used to.crack hydrocarbons in the absence of added hydrogen, the improvement which comprises cycling said particles of cracking catalyst through said reduction and regeneration zones in physical admixture with fluidizable particles comprising a precious metal impregnated on the porous shaped bodies of any of the foregoing claims.
References Cited (Backward Citations)
No citation records indexed.
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