Crystalline alumino silicate-silica-alumina gel catalysts and processes for producing same

Claim 2

A process for producing an active cracking catalyst which comprises exchanging an ammoniated silica-alumina gel containing NH 4 ions associated with the gel in an ammount substantially in excess of about 0.3 equivalents per mole of alumina (Al 2 O 3 ), and having an SiO 2 /Al 2 O 3 molar ratio in the range of less than 3 with a solution of a salt of a monovalent cation other than alkali metal cation, or a polyvalent cation or both said cations and reducing the NH 4 associated with the gel to substantially less than 0.3 equivalents per mole of Al 2 O 3 in the gel and combining said treated gel with a crystalline alumino-silicate zeolite.

Claim 3

A process for producing an active cracking catalyst which comprises exchanging an ammoniated silica-alumina gel containing NH 4 ions associated with the gel substantially in excess of 0.3 equivalents per mole of Al 2 O 3 in the gel and sodium expressed as Na 2 O of less than 1% of the ammoniated gel on a volatile free basis, and having an SiO 2 /Al 2 O 3 molar ratio in the range of about less than about 3 with solution of a salt of a monovalent cation, other than alkali metal cation, or a polyvalent cation or with both said monovalent cation and polyvalent cation, and combining said treated gel with a crystalline alumino silicate zeolite.

Claim 4

A process for producing an active cracking catalyst which comprises exchanging an ammoniated silica-alumina gel containing NH 4 ions associated with the gel substantially in excess of 0.3 equivalents per mole of Al 2 O 3 in the gel and sodium expressed as Na 2 O of less than 1% of the ammoniated gel on a volatile free basis, and having an SiO 2 /Al 2 O 3 molar ratio in the range of about less than about 3 with solution of a salt of a monovalent cation, other than alkali metal cation, or a polyvalent cation or with both said monovalent cation and polyvalent cation, and combining said treated gel with a crystalline alumino silicate zeolite.

Claim 5

The process of producing a cracking catalyst which comprises forming a silica-alumina gel having an SiO 2 /Al 2 O 3 molar ratio of more than about one and less than about 2.5 and associated with sodium ions expressed as Na 2 O of substantially less than about 1% based on the gel on a volatile free basis and treating said ammoniated gel by heating said gel in a solution containing monovalent cations other than alkali metal cations, or polyvalent cations, or both said cations to reduce the NH 4 per mole of Al 2 O 3 in the gel and separating said exchanged gel and combining said treated gel with a crystalline alumino silicate zeolite.

Claim 6

The process of producing a cracking catalyst which comprises forming a silica-alumina gel having an SiO 2 /Al 2 O 3 molar ratio of more than about one and less than about 2.5 and associated with sodium ions expressed as Na 2 O of substantially less than about 1% based on the gel on a volatile free basis and treating said ammoniated gel by heating said gel in a solution containing monovalent cations other than alkali metal cations, or polyvalent cations, or both said cations to reduce the NH 4 per mole of Al 2 O 3 in the gel and separating said exchanged gel and combining said treated gel with a crystalline alumino silicate zeolite.

Claim 7

The process of claim 1, 2, or 3, including heating said ammoniated gel during said exchange at a temperature of about 150° F. to about 450° F.

Claim 8

The process of claim 1, 2, or 3 in which the solution is acidified.

Claim 9

The process of claim 1, 2, or 3, in which the cation in the solution is a rare earth cation and said zeolite is a faujasite type zeolite having a sodium content, expressed as Na 2 O, of less than 5% by weight of the zeolite on a volatile free basis.

Claim 10

A catalyst comprising a crystalline alumino silicate zeolite and an ammoniated silica-alumina gel having an SiO 2 /Al 2 O 3 molar ratio more than 1 and less than 3 and containing less than 0.3 equivalents of NH 4 cations per mole of Al 2 O 3 in the gel and rare earth cations.

Claim 11

A catalyst comprising a crystalline alumino silicate zeolite and an ammoniated silica-alumina gel having an SiO 2 /Al 2 O 3 molar ratio more than 1 and less than 3 and containing less than 0.3 equivalents of NH 4 cations per mole of Al 2 O 3 in the gel and rare earth cations.

Claim 12

A catalyst comprising a crystalline alumino silicate zeolite and an ammoniated silica-alumina gel formed by combining a crystalline alumino silicate zeolite and a SiO 2 -Al 2 O 3 gel having a SiO 2 /Al 2 O 3 molar ratio in the range of in excess of 1 and less than about 2.5 and containing ammonium cation in amount substantially less than 0.3 equivalents per mole of Al 2 O 3 and sodium expressed as Na 2 O of less than about 1% by weight of the exchanged gel on a volatile free basis.

Claim 13

A catalyst comprising a crystalline alumino silicate zeolite and an ammoniated silica-alumina gel formed by combining a crystalline alumino silicate zeolite and a SiO 2 -Al 2 O 3 gel having a SiO 2 /Al 2 O 3 molar ratio in the range of in excess of 1 and less than about 2.5 and containing ammonium cation in amount substantially less than 0.3 equivalents per mole of Al 2 O 3 and sodium expressed as Na 2 O of less than about 1% by weight of the exchanged gel on a volatile free basis.

Claim 14

A catalyst comprising a crystalline alumino silicate zeolite and an ammoniated silica-alumina gel of SiO 2 /Al 2 O 3 ratio of more than 1 and less than 3 and containing less than 0.3 equivalents of NH 4 cations and from about 0.1 to more than 0.4 equivalents of rare earth cations expressed as ReO cations per mole of Al 2 O 3 in the gel.

Claim 15

A catalyst comprising a crystalline alumino silicate zeolite and an ammoniated silica-alumina gel of SiO 2 /Al 2 O 3 ratio of more than 1 and less than 3 and containing less than 0.3 equivalents of NH 4 cations and from about 0.1 to more than 0.4 equivalents of rare earth cations expressed as ReO cations per mole of Al 2 O 3 in the gel.

Claim 16

A catalyst comprising a crystalline alumino silicate zeolite and an ammoniated silica-alumina gel formed by combining a crystalline alumino silicate zeolite and a silica-alumino gel having an SiO 2 /Al 2 O 3 molar ratio in the range of more than 1 and up to about 2 and containing less than about 1.5 equivalents of ammonium cation per mole of Al 2 O 3 and from about 0.1 to more than 0.4 equivalents of rare earth cations expressed as ReO per mole of Al 2 O 3 in the gel, and sodium expressed as Na 2 O of less than about 0.5% by weight of the gel on a volatile free basis.

Claim 17

A catalyst comprising a crystalline alumino silicate zeolite and an ammoniated silica-alumina gel formed by combining a crystalline alumino silicate zeolite and a silica-alumino gel having an SiO 2 /Al 2 O 3 molar ratio in the range of more than 1 and up to about 2 and containing less than about 1.5 equivalents of ammonium cation per mole of Al 2 O 3 and from about 0.1 to more than 0.4 equivalents of rare earth cations expressed as ReO per mole of Al 2 O 3 in the gel, and sodium expressed as Na 2 O of less than about 0.5% by weight of the gel on a volatile free basis.

Claim 18

The catalyst of claims 7, 8, 9, or 10, in which the zeolite is a sodium containing faujasite type zeolite, the sodium content of the zeolite being less than 5% by weight of the zeolite, expressed as Na 2 O on a volatile free basis.

Claim 19

The catalyst of claims 7, 8, 9, or 10, in which the zeolite is a Y zeolite with sodium content of less than about 5% by weight of the zeolite, expressed as Na 2 O on a volatile free basis.