Process for preparing a petroleum cracking catalyst

Claim 2

A PROCESS FOR PREPARING A PETROLEUN CRACKING CATALYST HAVING HIGH ACTIVITY AND HIGH DENSITY WHICH COMPRISES: A . PREPARING A SILICA SOL BY RAPIDLY DECREASING THE PH OF A SODIUM SILICATE SOLUTION TO PH 1.8 3.0, B. ADDING CLAY BEFORE, DURING OR AFTER SOL FORMATION, C. PREPARING A WATER SLURRY OF A CRYSTALLINE ZEOLITE ALUMINOSILICATE AND ADJUSTING THE PH TO ABOUT 3 TO 4.5, D, MIXING SAID SLURRY WITH THE SILICA SOL-CLAY SLURRY PREPARED IN STEP (B), TO PREPARE A SPRAY DRIED FEED SLURRY HAVING A PH OF 2.8 TO 4.0. E. SPRAY DRYING BEFORE GELLATION OCCURS, I. WASHING WITH WATER, DRYING AND RECOVERING THE PRODUCT.

Claim 3

The process according to claim 1 wherein the clay is added in an amount equal to about 10-65 percent of the finished catalyst.

Claim 4

The process according to claim 1 wherein the zeolitic aluminosilicate is added in an amount equal to about 5-60 percent of final catalyst.

Claim 5

The process according to claim 1 wherein the sol is prepared by rapidly adding a strong mineral acid to a sodium silicate solution.

Claim 6

The process according to claim 4 wherein the strong mineral acid is sulfuric acid.

Claim 7

The process according to claim 1 wherein the zeolitic alumino silicate has a silica to alumina ratio of about 3.5 to 7.

Claim 8

A process for preparing a petroleum cracking catalyst which comprises: a. preparing a silica sol by rapidly adjusting the pH of a sodium silicate solution to a pH of 2.0 to 3.0 with a 20-65 percent solution of sulfuric acid, b. adding a quantity of a kaolin clay in an amount sufficient to provide about 50-65 weight percent of the final catalyst to said silica sol. c. preparing an aqueous slurry of a faujasite having a silica to alumina ratio of about 4.5-5.2 and adjusting the pH of said slurry to about 3.0 to 4.5 by adding a mineral acid, d. adding said slurry to the silica sol-clay slurry prepaRed in step (b), in an amount sufficient to provide about 15 to 25 percent of the final catalyst, e. spray drying before gellation occurs the resultant slurry and washing with water to decrease the SO4 content to less than 1 percent, f. exchanging the dryer product with a rare earth solution to provide a rare earth content of about 2.5 to 5 weight percent in the final product, g. washing, drying and recovering the catalyst.

Claim 9

A process for preparing a petroleum cracking catalyst which comprises: a. preparing a silica sol by rapidly adjusting the pH of a sodium silicate solution to a pH of 2.0 to 3.0 with a 20-65 percent solution of sulfuric acid, b. adding a quantity of a kaolin clay in an amount sufficient to provide about 50-65 weight percent of the final catalyst to said silica sol. c. preparing an aqueous slurry of a faujasite having a silica to alumina ratio of about 4.5-5.2 and adjusting the pH of said slurry to about 3.0 to 4.5 by adding a mineral acid, d. adding said slurry to the silica sol-clay slurry prepaRed in step (b), in an amount sufficient to provide about 15 to 25 percent of the final catalyst, e. spray drying before gellation occurs the resultant slurry and washing with water to decrease the SO4 content to less than 1 percent, f. exchanging the dryer product with a rare earth solution to provide a rare earth content of about 2.5 to 5 weight percent in the final product, g. washing, drying and recovering the catalyst.