US4126579A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Hydrocarbon conversion catalyst manufacture
Assignee: WR Grace and Co
•
Filing: 1977-07-12
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Granted: 1978-11-21
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Expires: 1997-07-12
Abstract
Abstract A process for preparing a silica gel bound zeolite containing catalyst by preparing an acidic silica sol and alkaline zeolite slurry feed streams, rapidly and homogeneously mixing the streams to form a rapidly gelling mixture, and spraying the mixture to produce gelled particles of catalyst.
Inventors
- 👤 Theodore V. Flaherty, Jr.
- 👤 Richard J. Nozemack
- 👤 Hanson L. Guidry
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 05:02
CPC Classifications
B; B01; B01J; B01J29/00; B01J29/04; B01J29/06; B01J29/08; B01J29/084; B01J29/082; B01J2229/00; B01J2229/30; B01J2229/42
Claims Analysis
Total Claims: 9
Claim 1
Independent Claim
143 words
A process for manufacturing hydrocarbon conversion catalysts which comprises: (a) preparing a silica sol by mixing a sodium silicate solution with a sufficient quantity of an acidic component selected from the group consisting of acids, acid salts, and mixtures thereof to adjust the pH to about 0.5 to 3.3; (b) preparing a slurry of a crystalline alumino-silicate zeolite in water and adding a sufficient quantity of sodium silicate to bring the pH to above 10.0; (c) rapidly mixing the sol and the slurry to obtain a rapidly gelling reactant mixture; (d) spraying the reactant mixture into a gaseous atmosphere, said atmosphere being at ambient temperature and substantially 100% relative humidity, to obtain formed gelled particles of silica gel bound zeolite containing catalyst, whereby said formed particles are substantially completely gelled without removal of moisture therefrom; and (e) washing, drying and recovering the catalyst.
Claim 2
Dependent Claim
143 words
A process for manufacturing hydrocarbon conversion catalysts which comprises: (a) preparing a silica sol by mixing a sodium silicate solution with a sufficient quantity of an acidic component selected from the group consisting of acids, acid salts, and mixtures thereof to adjust the pH to about 0.5 to 3.3; (b) preparing a slurry of a crystalline alumino-silicate zeolite in water and adding a sufficient quantity of sodium silicate to bring the pH to above 10.0; (c) rapidly mixing the sol and the slurry to obtain a rapidly gelling reactant mixture; (d) spraying the reactant mixture into a gaseous atmosphere, said atmosphere being at ambient temperature and substantially 100% relative humidity, to obtain formed gelled particles of silica gel bound zeolite containing catalyst, whereby said formed particles are substantially completely gelled without removal of moisture therefrom; and (e) washing, drying and recovering the catalyst.
Claim 3
Dependent Claim
21 words
The process according to claim 1 wherein clay is added to the silica sol and slurry prior to mixing and spraying.
Claim 4
Dependent Claim
22 words
The process according to claim 2 wherein the clay is added to the silicate solution prior to addition of the acidic component.
Claim 5
Dependent Claim
19 words
The process according to claim 2 wherein clay is added to the zeolite slurry prior to mixing and spraying.
Claim 6
Dependent Claim
28 words
The process according to claim 1 wherein the pH of the silica sol is adjusted to a pH of 1.0 to 3.0 by the addition of sulfuric acid.
Claim 7
Dependent Claim
21 words
The process of claim 1 wherein said zeolite is selected from the group consisting of Type X and Type Y zeolites.
Claim 8
Dependent Claim
17 words
The process of claim 1 wherein said silica sol contains up to about 30% by weight alumina.
Claim 9
Dependent Claim
19 words
The process of claim 1 wherein said catalyst contains from about 10 to 30% by weight silica gel binder.
References Cited (Backward Citations)
US3867308A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1981-11-20 | 1982-05-22 | 1982-11-21 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1985-11-20 | 1986-05-22 | 1986-11-21 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1989-11-20 | 1990-05-22 | 1990-11-21 | $7700.00 | Window Closed / Lapsed |