Zeolite catalysts and method of producing the same

Claim 2

A process of forming a catalyst containing a sodium zeolite of the faujasite type which comprises mixing in a water slurry, a zeolite of the faujasite type containing from about 12 to about 15% sodium expressed as Na 2 O, clay and sodium silicate, the weight ratio of the zeolite to the silica equivalent to the sodium silicate being in the range of about 0.8 to about 1.2 parts by weight of the zeolite to one part by weight of the SiO 2 on a volatile free basis, drying the mixture and mixing the mixture with an ammonium salt solution at a pH of about 4 to 7 to form a silica gel in situ in the mixture and drying the treated mixture.

Claim 3

A process of forming a catalyst containing a Y zeolite containing sodium equivalent to about 12% to about 15% of Na 2 O based on the zeolite on a volatile free basis, which comprises mixing in a water slurry, a Y zeolite containing sodium, equivalent to about 12% to about 15% of Na 2 O based on the weight of the zeolite on a volatile free basis clay and sodium silicate, the weight ratio of the zeolite to the silica equivalent to the sodium silicate being in the range of about 0.8 to about 1.2 parts by weight of the zeolite to one part by weight of the SiO 2 on a volatile free basis, drying the mixture, mixing the dried mixture with an ammonium salt solution at a pH of about 4 to 7 to form a silica gel in situ in the mixture and spray drying said mixture.

Claim 4

A process of forming a catalyst containing a Y zeolite containing sodium equivalent to about 12% to about 15% of Na 2 O based on the zeolite on a volatile free basis, which comprises mixing in a water slurry, a Y zeolite containing sodium, equivalent to about 12% to about 15% of Na 2 O based on the weight of the zeolite on a volatile free basis clay and sodium silicate, the weight ratio of the zeolite to the silica equivalent to the sodium silicate being in the range of about 0.8 to about 1.2 parts by weight of the zeolite to one part by weight of the SiO 2 on a volatile free basis, drying the mixture, mixing the dried mixture with an ammonium salt solution at a pH of about 4 to 7 to form a silica gel in situ in the mixture and spray drying said mixture.

Claim 5

A process of forming a catalyst containing a sodium Y, as in claim 2, zeolite which comprises exchanging the sodium Y to reduce the sodium content of the Y zeolite to less than about 3% to about 6% by weight of the exchanged Y expressed as Na 2 O on a volatile free basis, mixing in said zeolite, clay and sodium silicate in water, the weight ratio of the zeolite to the silica equivalent to the sodium silicate being in the range of about 0.8 to about 1.2 parts by weight of the zeolite to one part by weight of the SiO 2 on a volatile free basis, drying the mixture and mixing the dried mixture with an ammonium salt solution at a pH of about 4 to 7 to form a silica gel in situ in the mixture and spray drying said mixture.

Claim 6

A process of forming a catalyst containing a Y zeolite, containing sodium equivalent to about 12% to about 15% of Na 2 O based on the zeolite on a volatile free basis, which comprises comminuting Y zeolite by milling the zeolite and mixing the milled Y zeolite in a water slurry, with clay and sodium silicate, the weight ratio of the zeolite to the silica equivalent to the sodium silicate being in the range of about 0.8 to about 1.2 facts by weight of the zeolite to one part by weight of the SiO 2 on a volatile free basis, drying the mixture and mixing the dried mixture with an ammonium salt solution at a pH of about 4 to 7 to form a silica gel in situ in the mixture and spray drying said mixture.

Claim 7

A process of forming a catalyst containing a Y zeolite, containing sodium equivalent to about 12% to about 15% of Na 2 O based on the zeolite on a volatile free basis, which comprises comminuting Y zeolite by milling the zeolite and mixing the milled Y zeolite in a water slurry, with clay and sodium silicate, the weight ratio of the zeolite to the silica equivalent to the sodium silicate being in the range of about 0.8 to about 1.2 facts by weight of the zeolite to one part by weight of the SiO 2 on a volatile free basis, drying the mixture and mixing the dried mixture with an ammonium salt solution at a pH of about 4 to 7 to form a silica gel in situ in the mixture and spray drying said mixture.

Claim 8

A process of forming a catalyst containing a sodium Y zeolite which comprises comminuting Y zeolite containing sodium equivalent to about 12% to about 15% of Na 2 O on a volatile free basis, by milling said zeolite, mixing in said communited Y zeolite, clay and sodium silicate in water, the weight ratio of the zeolite to the silica, equivalent to the sodium silicate being in the range of about 0.8 to about 1.2 parts by weight of the zeolite to one part by weight of the SiO 2 on a volatile free basis, milling said mixture, drying the mixture and mixing the dried mixture with an ammonium salt solution at a pH of about 4 to 7 to form a silica gel in situ in the mixture and spray drying said mixture.

Claim 9

A process of forming a catalyst containing a sodium Y zeolite which comprises comminuting Y zeolite containing sodium equivalent to about 12% to about 15% of Na 2 O on a volatile free basis, by milling said zeolite, mixing in said communited Y zeolite, clay and sodium silicate in water, the weight ratio of the zeolite to the silica, equivalent to the sodium silicate being in the range of about 0.8 to about 1.2 parts by weight of the zeolite to one part by weight of the SiO 2 on a volatile free basis, milling said mixture, drying the mixture and mixing the dried mixture with an ammonium salt solution at a pH of about 4 to 7 to form a silica gel in situ in the mixture and spray drying said mixture.

Claim 10

A process of forming a catalyst containing a Y zeolite which comprises, exchanging a sodium Y zeolite to reduce the sodium content of the zeolite to or equivalent to about 3% to about 6% of the exchanged zeolite, expressed as Na 2 O on a volatile free basis, comminuting said Y zeolite, mixing in said communited Y zeolite, clay and sodium silicate in water, the weight ratio of the zeolite to the silica equivalent to the sodium silicate being in the range of about 0.8 to about 1.2 parts by weight of the zeolite to one part by weight of the SiO 2 on a volatile free basis, milling said mixture drying the mixture and mixing the dried mixture with an ammonium salt solution at a pH of about 4 to 7 to form a silica gel in situ in the mixture and spray drying said mixture.

Claim 11

A process of forming a catalyst containing a Y zeolite which comprises, exchanging a sodium Y zeolite to reduce the sodium content of the zeolite to or equivalent to about 3% to about 6% of the exchanged zeolite, expressed as Na 2 O on a volatile free basis, comminuting said Y zeolite, mixing in said communited Y zeolite, clay and sodium silicate in water, the weight ratio of the zeolite to the silica equivalent to the sodium silicate being in the range of about 0.8 to about 1.2 parts by weight of the zeolite to one part by weight of the SiO 2 on a volatile free basis, milling said mixture drying the mixture and mixing the dried mixture with an ammonium salt solution at a pH of about 4 to 7 to form a silica gel in situ in the mixture and spray drying said mixture.

Claim 12

A process of forming a catalyst containing a Y zeolite which comprises comminuting said Y zeolite containing sodium equivalent to about 12% to about 15% of Na 2 O on a volatile free basis by milling said zeolite, mixing said milled zeolite with clay and sodium silicate in water, the weight ratio of the zeolite to the silica equivalent to the sodium silicate being in the range of about 0.8 to about 1.2 parts by weight of the zeolite to one part by weight of the SiO 2 on a volatile free basis, drying the mixture, mixing said dried mixture with an ammonium salt solution at a pH of about 4 to 7 to form a silica gel in situ in the mixture and spray drying said mixture.

Claim 13

A process of forming a catalyst containing a Y zeolite which comprises comminuting said Y zeolite containing sodium equivalent to about 12% to about 15% of Na 2 O on a volatile free basis by milling said zeolite, mixing said milled zeolite with clay and sodium silicate in water, the weight ratio of the zeolite to the silica equivalent to the sodium silicate being in the range of about 0.8 to about 1.2 parts by weight of the zeolite to one part by weight of the SiO 2 on a volatile free basis, drying the mixture, mixing said dried mixture with an ammonium salt solution at a pH of about 4 to 7 to form a silica gel in situ in the mixture and spray drying said mixture.

Claim 14

A process of forming a catalyst containing a sodium Y zeolite which comprises exchanging the sodium Y to reduce the sodium content of the Y zeolite to an amount equivalent about 3% to about 6% by weight of the zeolite expressed as Na 2 O on a volatile free basis, comminuting said zeolite by milling said zeolite, mixing in a water slurry, the comminuted zeolite, clay and sodium silicate, the weight ratio of the zeolite to the silica equivalent to the sodium silicate being in the range of about 0.9 to about 1.2 facts by weight by the zeolite to one part by weight of the SiO 2 on a volatile free basis, drying the mixture and mixing the dried mixture with an ammonium salt solution at a pH of about 4 to 7 to form a silica gel in situ in the mixture and spray drying said mixture.

Claim 15

A process of forming a catalyst containing a sodium Y zeolite which comprises exchanging the sodium Y to reduce the sodium content of the Y zeolite to an amount equivalent about 3% to about 6% by weight of the zeolite expressed as Na 2 O on a volatile free basis, comminuting said zeolite by milling said zeolite, mixing in a water slurry, the comminuted zeolite, clay and sodium silicate, the weight ratio of the zeolite to the silica equivalent to the sodium silicate being in the range of about 0.9 to about 1.2 facts by weight by the zeolite to one part by weight of the SiO 2 on a volatile free basis, drying the mixture and mixing the dried mixture with an ammonium salt solution at a pH of about 4 to 7 to form a silica gel in situ in the mixture and spray drying said mixture.

Claim 16

A process of forming a catalyst containing a Y zeolite which comprises mixing in a water slurry, a Y zeolite containing sodium, equivalent to about 12% to about 15% of Na 2 O on a volatile free basis, clay and sodium silicate, the weight ratio of the zeolite to the silica equivalent to the sodium silicate being in the range of about 0.8 to about 1.2 parts by weight by the zeolite to one part by weight of the SiO 2 on a volatile free basis milling said mixture, drying the milled mixture to form mixing the dried mixture with an ammonium salt solution at a pH of about 4 to 7 to form a silica gel in situ in the mixture and spray drying said mixture.

Claim 17

A process of forming a catalyst containing a Y zeolite which comprises mixing in a water slurry, a Y zeolite containing sodium, equivalent to about 12% to about 15% of Na 2 O on a volatile free basis, clay and sodium silicate, the weight ratio of the zeolite to the silica equivalent to the sodium silicate being in the range of about 0.8 to about 1.2 parts by weight by the zeolite to one part by weight of the SiO 2 on a volatile free basis milling said mixture, drying the milled mixture to form mixing the dried mixture with an ammonium salt solution at a pH of about 4 to 7 to form a silica gel in situ in the mixture and spray drying said mixture.

Claim 18

A process of forming a catalyst containing a sodium Y zeolite which comprises exchanging the sodium Y to reduce the sodium content of the Y zeolite to less than about 5% by weight expressed as Na 2 O on a volatile free basis, mixing in a water slurry, said zeolite, clay and sodium silicate, the weight ratio of the zeolite to the silica equivalent to the sodium silicate, being in the range of about 0.8 to about 1.2 parts by weight of the zeolite to one part by weight of the SiO 2 on a volatile free basis, comminuting said mixture by milling the mixture and drying the milled mixture and mixing the dried mixture with an ammonium salt solution at a pH of about 4 to 7 to form a silica gel in situ in the mixture and spray drying said mixture.

Claim 19

A process of forming a catalyst containing a sodium Y zeolite which comprises exchanging the sodium Y to reduce the sodium content of the Y zeolite to less than about 5% by weight expressed as Na 2 O on a volatile free basis, mixing in a water slurry, said zeolite, clay and sodium silicate, the weight ratio of the zeolite to the silica equivalent to the sodium silicate, being in the range of about 0.8 to about 1.2 parts by weight of the zeolite to one part by weight of the SiO 2 on a volatile free basis, comminuting said mixture by milling the mixture and drying the milled mixture and mixing the dried mixture with an ammonium salt solution at a pH of about 4 to 7 to form a silica gel in situ in the mixture and spray drying said mixture.

Claim 20

The process of claims 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 in which the drying of the mixture is by spray drying in to form microspheres and exchanging the microspheres with cations chosen from the group consisting of mono-valent and poly-valent cations to reduce the sodium content of the composite catalyst to less than about 1% expressed as Na 2 O on a volatile free basis.

Claim 21

The process of claim 4, 5, 8, 9, or 10 in which the milling raises the temperature of the milled produced in the range of 10° to 20° F.

Claim 22

The process of claims 4, 5, 6, 7, 8, 9, or 10 in which the milling raises the temperature of the milled product in a range of about 10° F. to about 20° F. and in which the drying of the mixture is by spray drying in to form microspheres and after gelling the SiO 2 , exchanging the microspheres containing the SiO 2 gel with cations chosen from the group consisting of mono-valent and poly-valent cations to reduce the sodium content of the composite catalyst to less than about 1% expressed as Na 2 O on a volatile free basis.