Ammonia-stable Y zeolite compositions

Claim 2

CALCINING AN AMMONIUM-SODIUM Y ZEOLITE CONTAINING ABOUT 0.6-5 WEIGHT-PERCENT OF SADIUM Y ZEOLITE CONTAINING CALCINING BEING CARRIED OUT AT A TEMPERATURE BETWEEN ABOUT 600*F IN CONTACT WITH AT LEAST ABOUT 0.2 PSI. OF WATER VAPOR FOR A SUFFICIENT TIME TO SUBSTANTIALLY REDUCE THE UNIT CELL SIZE OF SAID ZEOLITE AND BRING IT TO A VALUE BETWEEN ABOUT 24.40 AND 24.64 A; AND S 2. SUBJECTING THE CALCINED ZEOLITE TO FURTHER AMMONIUM ION EXCHANGE UNDER CONDITIONS ADJUSTED TO REPLACE AT LEAST ABOUT 25 PERCENT OF ITS RESIDUCAL ZEOLITIC SODIUM IONS WITH AMMONIUM IONS AND PRODUCE A FINAL PRODUCT CONTAINING LESS THAN ABOUT 1 WEIGHT-PERCENT NA2O.

Claim 3

A CATALYST COMPOSITION COMPRISING A MINOR PROPORTION OF IF HYDROGENATION COMPONENT SELECTED FROM THE CLASS CONSISTING OF THE GROUP VIB AND GROUP VIII METALS AND THEIR OXIDES AND SULFIDES INTIMATELY COMPOSITED WITH A HYDROTHERMALLY STABLE, AMMONIA-STABLE Y ZEOLITE BASE, AND Y ZEOLITE BASE HAVING BEEN PREPARED BY THE STEPS OF*

Claim 4

A CATALYST COMPOSITION COMPRISING A MINOR PROPORTION OF IF HYDROGENATION COMPONENT SELECTED FROM THE CLASS CONSISTING OF THE GROUP VIB AND GROUP VIII METALS AND THEIR OXIDES AND SULFIDES INTIMATELY COMPOSITED WITH A HYDROTHERMALLY STABLE, AMMONIA-STABLE Y ZEOLITE BASE, AND Y ZEOLITE BASE HAVING BEEN PREPARED BY THE STEPS OF*

Claim 5

CALCINING AN AMMONIUM SODIUM Y ZEOLITE CONTAINING ABOUT 0.6-5 WEIGHT-PERCENT OF SODIUM AS NA2O, SAID CALCINING BEING CARRIED OUT AT A TEMPERATURE BETWEEN ABOUT 600* AND 1650*F IN CONTACT WITH AT LEAST ABOUT 0.2 PSI OF WATER VAPOR FOR A SUFFICIENT TIME TO SUBSTANTIALLY REDUCE THE UNIT CELL SIZE OF SAID ZEOLITE AND BRING IT TO A VALUE BETWEEN ABOUT 24.40 AND 24.64 A;

Claim 6

CALCINING AN AMMONIUM SODIUM Y ZEOLITE CONTAINING ABOUT 0.6-5 WEIGHT-PERCENT OF SODIUM AS NA2O, SAID CALCINING BEING CARRIED OUT AT A TEMPERATURE BETWEEN ABOUT 600* AND 1650*F IN CONTACT WITH AT LEAST ABOUT 0.2 PSI OF WATER VAPOR FOR A SUFFICIENT TIME TO SUBSTANTIALLY REDUCE THE UNIT CELL SIZE OF SAID ZEOLITE AND BRING IT TO A VALUE BETWEEN ABOUT 24.40 AND 24.64 A;

Claim 7

SUBJECTING THE CALCINED ZEOLITE TO FURTHER AMMONIUM ION EXCHANGE UNDER CONDITIONS ADJUSTED TO REPLACED AT LEAST ABOUT 25 PERCENT OF ITS RESIDUAL ZEOLITIC SODIUM IONS WITH AMMONIUM IONS AND PRODUCE A PRODUCT CONTAINING LESS THAN ABOUT 1 WEIGHT-PERCENT NA2O

Claim 8

SUBJECTING THE CALCINED ZEOLITE TO FURTHER AMMONIUM ION EXCHANGE UNDER CONDITIONS ADJUSTED TO REPLACED AT LEAST ABOUT 25 PERCENT OF ITS RESIDUAL ZEOLITIC SODIUM IONS WITH AMMONIUM IONS AND PRODUCE A PRODUCT CONTAINING LESS THAN ABOUT 1 WEIGHT-PERCENT NA2O

Claim 9

A catalyst composition as defined in claim 1 wherein step (4) is carried out under substantially dry conditions.

Claim 10

A catalyst composition as defined in claim 1 wherein said hydrogenation component is palladium.

Claim 11

CONSOLIDATING THE PRODUCT FROM STEP (2) INTO GRANULES HAVING INTIMATELTY ADMIXED THEREIN A FINELY DIVIDED HYDROUS OXIDE SELECTED FROM THE CLASS CONSISTING OF ALUMINA, SILICA, MAGNESIA, TITANIA, ZIRCONIA, THORIA, BERYLLIA, CHROMIA, CLAYS AND MIXTURES THEREOF; AND

Claim 12

CONSOLIDATING THE PRODUCT FROM STEP (2) INTO GRANULES HAVING INTIMATELTY ADMIXED THEREIN A FINELY DIVIDED HYDROUS OXIDE SELECTED FROM THE CLASS CONSISTING OF ALUMINA, SILICA, MAGNESIA, TITANIA, ZIRCONIA, THORIA, BERYLLIA, CHROMIA, CLAYS AND MIXTURES THEREOF; AND

Claim 13

CLACINING THE GRANULES AT A TEMPERATURE BETWEEN ABOUT 600*F FOR A TIME SUFFICIENT TO EFFECT SUBSTANTIAL DEAMMONIATION, BUT INSUFFICIENT TO REDUCE THE UNIT CELL SIZE OF THE ZEOLITE TO BELOW ABOUT 24.40 A.

Claim 14

CLACINING THE GRANULES AT A TEMPERATURE BETWEEN ABOUT 600*F FOR A TIME SUFFICIENT TO EFFECT SUBSTANTIAL DEAMMONIATION, BUT INSUFFICIENT TO REDUCE THE UNIT CELL SIZE OF THE ZEOLITE TO BELOW ABOUT 24.40 A.

Claim 15

A catalyst composition as defined in claim 1 wherein said hydrogenation component comprises nickel and molybdenum as free metals, oxides or sulfides.

Claim 16

A catalyst composition as defined in claim 1 wherein said hydrous oxide is essentially alumina.

Claim 17

A catalyst composition as defined in claim 5 wherein said hydrogenation component is palladium.

Claim 18

A catalyst composition as defined in claim 5 wherein said hydrogenation component comprises nickel and molybdenum as free metals, oxides or sulfides.

Claim 19

A catalyst composition comprising a minor proportion of a hydrogenation component selected from the class consisting of the Group VIB and Group VIII metals and their oxides and sulfides intimately composited with a hydrothermally stable, ammonia-stable Y zeolite base, said Y zeolite base having been prepared by the steps of: 1 calcining an ammonium-sodium Y zeolite containing about 1 - 4 weight-percent of sodium as Na2O, said calcining being carried out at a temperature between about 800* and 1650*F in contact with between about 2-15 psi of water vapor for a sufficienT time to substantially reduce the unit cell size of said zeolite and bring it to a value between about 24.42 and 24.62 A; 2 subjecting the calcined zeolite to further ammonium ion exchange under conditions adjusted to replace at least about 70 percent of its residual zeolitic sodium ions with ammonium ions and produce a product containing less than about 0.6 weight-percent Na2O; 3 consolidating the product from step (2) into granules having intimately admixed therein a finely divided hydrous oxide selected from the class consisting of alumina, silica, magnesia, titania, zirconia, thoria, beryllia, chromia, clays and mixtures thereof; and 4 calcining the granules at a temperature between about 800* and 1500*F for a time sufficient to effect substantial deammoniation, but insufficient to reduce the unit cell size of the zeolite to below about 24.40 A.

Claim 20

A catalyst composition comprising a minor proportion of a hydrogenation component selected from the class consisting of the Group VIB and Group VIII metals and their oxides and sulfides intimately composited with a hydrothermally stable, ammonia-stable Y zeolite base, said Y zeolite base having been prepared by the steps of: 1 calcining an ammonium-sodium Y zeolite containing about 1 - 4 weight-percent of sodium as Na2O, said calcining being carried out at a temperature between about 800* and 1650*F in contact with between about 2-15 psi of water vapor for a sufficienT time to substantially reduce the unit cell size of said zeolite and bring it to a value between about 24.42 and 24.62 A; 2 subjecting the calcined zeolite to further ammonium ion exchange under conditions adjusted to replace at least about 70 percent of its residual zeolitic sodium ions with ammonium ions and produce a product containing less than about 0.6 weight-percent Na2O; 3 consolidating the product from step (2) into granules having intimately admixed therein a finely divided hydrous oxide selected from the class consisting of alumina, silica, magnesia, titania, zirconia, thoria, beryllia, chromia, clays and mixtures thereof; and 4 calcining the granules at a temperature between about 800* and 1500*F for a time sufficient to effect substantial deammoniation, but insufficient to reduce the unit cell size of the zeolite to below about 24.40 A.

Claim 21

A catalyst composition as defined in claim 8 wherein step (4) is carried out under substantially dry conditions.

Claim 22

A catalyst composition as defined in claim 8 wherein said hydrogenation component is palladium.

Claim 23

A catalyst composition as defined in claim 8 wherein said hydrogenation component comprises nickel and molybdenum as free metals, oxides or sulfides.

Claim 24

A catalyst composition as defined in claim 8 wherein said hydrous oxide is essentially alumina.

Claim 25

A catalyst composition as defined in claim 12 wherein said hydrogenation component is palladium.

Claim 26

A catalyst composition as defined in claim 12 wherein said hydrogenation component comprises nickel and molybdenum as free metals, oxides or sulfides.

Claim 27

A HYDROTHERMALLY STABLE, AMMONIA-STABLE Y ZEOLITE COMPOSITION PREPARED BY THE STEPS OF:

Claim 28

A HYDROTHERMALLY STABLE, AMMONIA-STABLE Y ZEOLITE COMPOSITION PREPARED BY THE STEPS OF:

Claim 29

A catalyst composition prepared by the steps of: (a) consolidating the product from claim 15 into granules having intimately admixed therein a finely divided hydrous oxide selected from the class consisting of alumina, silica, magnesia, titania, zirconia, thoria, beryllia, chromia, clays and mixtures thereof; and (b) calcining the granules at a temperature between about 600* and 1500*F for a time sufficient to effect substantial deammoniation, but insufficient to reduce the unit cell size of the zeolite to below about 24.40 A.

Claim 30

A catalyst composition as defined in claim 16 wherein said hydrous oxide is essentially alumina.

Claim 31

A catalyst composition as defined in claim 16 wherein step (b) is carried out under substantially dry conditions.

Claim 32

A hydrothermally stable, ammonia-stable Y zeolite composition prepared by the steps of: 1 calcining an ammonium-sodium Y zeolite containing about 1 - 4 weight-percent of sodium as Na2O, said calcining being carried out at a temperature between about 800* and 1650*F in contact with between about 2-15 psi of water vapor for a sufficient time to substantially reduce the unit cell size of said zeolite and bring it to a value between about 24.42 and 24.62 A; and 2 subjecting the calcined zeolite to further ammonium ion exchange under conditions adjusted to replace at least abouT 70 percent of its residual zeolitic sodium ions with ammonium ions and produce a final product containing less than about 0.6 weight-percent Na2O.

Claim 33

A hydrothermally stable, ammonia-stable Y zeolite composition prepared by the steps of: 1 calcining an ammonium-sodium Y zeolite containing about 1 - 4 weight-percent of sodium as Na2O, said calcining being carried out at a temperature between about 800* and 1650*F in contact with between about 2-15 psi of water vapor for a sufficient time to substantially reduce the unit cell size of said zeolite and bring it to a value between about 24.42 and 24.62 A; and 2 subjecting the calcined zeolite to further ammonium ion exchange under conditions adjusted to replace at least abouT 70 percent of its residual zeolitic sodium ions with ammonium ions and produce a final product containing less than about 0.6 weight-percent Na2O.

Claim 34

A catalyst composition prepared by the steps of: a consolidating the product from claim 19 into granules having intimately admixed therein a finely divided hydrous oxide selected from the class consisting of alumina, silica, magnesia, titania, zirconia, thoria, beryllia, chromia, clays and mixtures thereof; and b calcining the granules at a temperature between about 800* and 1500*F for a time sufficient to effect substantial deammoniation, but insufficient to reduce the unit cell size of the zeolite to below about 24.40 A.

Claim 35

A catalyst composition as defined in claim 20 wherein step (b) is carried out under substantially dry conditions.

Claim 36

A catalyst composition as defined in claim 20 wherein said hydrous oxide is essentially alumina.

Claim 39

A method as defined in claim 23 including the further steps of: 3 consolidating the product from step (2) into granules having intimately admixed therein a finely divided hydrous oxide selected from the class consisting of alumina, silica, magnesia, titania, zirconia, thoria, beryllia, chromia, clays and mixtures thereof; and 4 calcining the granules at a temperature between about 600* and 1500*F for a time sufficient to effect substantial deammoniation, but insufficient to reduce the unit cell size of the zeolite to below about 24.40 A.

Claim 40

A method as defined in claim 24 wherein said hydrous oxide is essentially alumina.

Claim 41

A method as defined in claim 24 wherein step (4) is carried out under substantially dry conditions.

Claim 42

A method as defined in claim 23 wherein step (1) is carried out with the zeolite in contact with flowing steam.

Claim 45

A method as defined in claim 28 including the further steps of: 3 consolidating the product from step (2) into granules having intimately admixed therein a finely divided hydrous oxide selected from the class consisting of alumina, silica, magnesia, titania, zirconia, thoria, beryllia, chromia, clays and mixtures thereof; and 4 calcining the granules at a temperature betwEen about 800* and 1500*F for a time sufficient to effect substantial deammoniation, but insufficient to reduce the unit cell size of the zeolite to below about 24.40 A.

Claim 46

A method as defined in claim 29 wherein said hydrous oxide is essentially alumina.

Claim 47

A method as defined in claim 29 wherein step (4) is carried out under substantially dry conditions.

Claim 48

A method as defined in claim 28 wherein step (1) is carried out with the zeolite in contact with flowing steam.