Attrition resistant zeolite containing catalyst

Claim 2

A process for forming a hydrocarbon conversion catalyst comprising comminuting crystals of a zeolite of the faujasite type and combining the comminuted zeolite with pseudoboehmite, clay and ammonium polysilicate or silica sol in a water slurry, spray drying said water slurry and forming microspheres.

Claim 3

The process for producing microspheres of hydrocarbon conversion catalyst comprising comminuting crystals of a Y type zeolite in amount in the range of about 10% to about 50% and combining said comminuted zeolite in a slurry containing about 10% to about 50% pseudoboehmite, and ammonium polysilicate or silica sol, the amount of said ammonium polysilicate or silica sol expressed as the equivalent SiO 2 being in the range of about 5% to about 30% and kaolin clay in the range of from about 10% to about 30% and spray drying said slurry to form microspheres, said percentages being by weight based on the microspheres on a volatile free basis, comminuting the said slurry and spray drying said comminuted slurry.

Claim 4

The process for producing microspheres of hydrocarbon conversion catalyst comprising comminuting crystals of a Y type zeolite in amount in the range of about 10% to about 50% and combining said comminuted zeolite in a slurry containing about 10% to about 50% pseudoboehmite, and ammonium polysilicate or silica sol, the amount of said ammonium polysilicate or silica sol expressed as the equivalent SiO 2 being in the range of about 5% to about 30% and kaolin clay in the range of from about 10% to about 30% and spray drying said slurry to form microspheres, said percentages being by weight based on the microspheres on a volatile free basis, comminuting the said slurry and spray drying said comminuted slurry.

Claim 5

A process for producing a hydrocarbon cracking catalyst comprising comminuting a Y type zeolite in a water slurry, comminuting a Type B pseudoboehmite in a water slurry and combining said comminuted zeolite, a type A pseudoboehmite and said comminuted Type B pseudoboehmite with kaolin clay and ammonium polysilicate in a water slurry, said last named water slurry containing from about 10% to about 30% of said comminuted zeolite and said pseudoboehmite each being in the range of about 10% to about 50% and said pseudoboehmite including both Type A pseudoboehmite and comminuted Type B aluminas and said catalyst also including from about 5% to about 30% of SiO 2 equivalent to the ammonium polysilicate and from about 10% to about 50% of kaolin clay, and spray drying said slurry to form microspheres, all percentages based on the weight of the microspheres.

Claim 6

A process for producing a hydrocarbon cracking catalyst comprising comminuting a Y type zeolite in a water slurry, comminuting a Type B pseudoboehmite in a water slurry and combining said comminuted zeolite, a type A pseudoboehmite and said comminuted Type B pseudoboehmite with kaolin clay and ammonium polysilicate in a water slurry, said last named water slurry containing from about 10% to about 30% of said comminuted zeolite and said pseudoboehmite each being in the range of about 10% to about 50% and said pseudoboehmite including both Type A pseudoboehmite and comminuted Type B aluminas and said catalyst also including from about 5% to about 30% of SiO 2 equivalent to the ammonium polysilicate and from about 10% to about 50% of kaolin clay, and spray drying said slurry to form microspheres, all percentages based on the weight of the microspheres.

Claim 7

A process for producing microspheres of hydrocarbon conversion catalyst comprising comminuting crystals of a Y type zeolite in amount in the range of about 10% to about 50% and combining said comminuted zeolite in a slurry containing about 10% to about 50% pseudoboehmite, and ammonium polysilicate or silica sol, the amount of said ammonium polysilicate or silica sol expressed as the equivalent SiO 2 being in the range of about 5% to about 30% and kaolin clay in the range of from about 10% to about 30% comminuting said combination of comminuted zeolite and pseudoboehmite, ammonium polysilicate or silica sol and clay and spray drying said slurry to form microspheres, said percentages being by weight based on the microspheres on a volatile free basis.

Claim 8

A process for producing microspheres of hydrocarbon conversion catalyst comprising comminuting crystals of a Y type zeolite in amount in the range of about 10% to about 50% and combining said comminuted zeolite in a slurry containing about 10% to about 50% pseudoboehmite, and ammonium polysilicate or silica sol, the amount of said ammonium polysilicate or silica sol expressed as the equivalent SiO 2 being in the range of about 5% to about 30% and kaolin clay in the range of from about 10% to about 30% comminuting said combination of comminuted zeolite and pseudoboehmite, ammonium polysilicate or silica sol and clay and spray drying said slurry to form microspheres, said percentages being by weight based on the microspheres on a volatile free basis.

Claim 9

A process for producing a hydrocarbon cracking catalyst comprising comminuting a Y type zeolite in a water slurry, comminuting a Type B pseudoboehmite in a water slurry and combining said comminuted zeolite, a type A pseudoboehmite and said comminuted Type B pseudoboehmite with kaolin clay and ammonium polysilicate in a water slurry, said last named water slurry containing from about 10% to about 30%, said comminuted zeolite and said pseudoboehmite each being in the range of about 10% to about 50% and said pseudoboehmite including both Type A pseudoboehmite and comminuted Type B aluminas and said catalyst also including from about 5% to about 30% of SiO 2 equivalent to the ammonium polysilicate from about 10% to about 50% of kaolin clay, comminuting said combination of zeolite, pseudoboehmite, clay and ammonium polysilicate and spray drying said slurry to form microspheres, all percentages based on the weight of the microspheres.

Claim 10

A process for producing a hydrocarbon cracking catalyst comprising comminuting a Y type zeolite in a water slurry, comminuting a Type B pseudoboehmite in a water slurry and combining said comminuted zeolite, a type A pseudoboehmite and said comminuted Type B pseudoboehmite with kaolin clay and ammonium polysilicate in a water slurry, said last named water slurry containing from about 10% to about 30%, said comminuted zeolite and said pseudoboehmite each being in the range of about 10% to about 50% and said pseudoboehmite including both Type A pseudoboehmite and comminuted Type B aluminas and said catalyst also including from about 5% to about 30% of SiO 2 equivalent to the ammonium polysilicate from about 10% to about 50% of kaolin clay, comminuting said combination of zeolite, pseudoboehmite, clay and ammonium polysilicate and spray drying said slurry to form microspheres, all percentages based on the weight of the microspheres.

Claim 11

The process of claims 1, 2, 3, 4 or 5, in which comminution of the zeolite increases the percentage of particles of less than three (3) microns to produce a zeolite.

Claim 12

The process of claims 1, 2, 3, 4 or 5, in which the comminution of the zeolite crystals is by milling a slurry of the zeolite to increase the percent of particles of crystals which are less than three (3) microns to 55% or greater percentage.

Claim 13

The process of claims 1, 2, 3, 4 or 5, in which the comminution of the zeolite is by milling a slurry of the zeolite containing from about 15% to about 35% solids and said milling raises the temperature of the slurry in the range of from about 10° F. to about 30° F.

Claim 14

The process of claims 1, 2, 3, 4 or 5, in which the said zeolite is comminuted by milling a slurry of the zeolite containing from about 15% to about 35% of solids, said milling increasing the fraction of particle size of the zeolite that are less than about three (3) microns from substantially less than about 55% to substantially more than 55%.

Claim 15

The process of claims 1, 2, 3, 4, or 5, in which the zeolite is comminuted by milling a slurry of the zeolite containing about 15% to about 35% of solids, said milling raising the temperature of the slurry in the range of about 10° F. to about 30° F. and increasing the percent of the zeolite crystals that are less than three microns.

Claim 16

A hydrocarbon conversion catalyst in the form of microspheres having an average particle size diameter from about 50 to 70 microns derived by spray drying a water slurry consisting of a comminuted zeolite of the Y type having an SiO 2 /Al 2 O 3 molar ratio in excess of 4 and sodium as Na 2 O of less than about 5% of the zeolite on a volatile free basis, and a matrix, said matrix including more than about 15% by weight of alumina derived from pseudoboehmite, and from about 5% to about 30% by weight of SiO 2 derived from ammonium polysilicate or silica sol and from about 0% to about 30% of clay, said weight percentage based on the weight of the zeolite and matrix on a volatile free basis.

Claim 17

A hydrocarbon conversion catalyst in the form of microspheres having an average particle size diameter from about 50 to 70 microns derived by spray drying a water slurry consisting of a comminuted zeolite of the Y type having an SiO 2 /Al 2 O 3 molar ratio in excess of 4 and sodium as Na 2 O of less than about 5% of the zeolite on a volatile free basis, and a matrix, said matrix including more than about 15% by weight of alumina derived from pseudoboehmite, and from about 5% to about 30% by weight of SiO 2 derived from ammonium polysilicate or silica sol and from about 0% to about 30% of clay, said weight percentage based on the weight of the zeolite and matrix on a volatile free basis.

Claim 18

A hydrocarbon conversion catalyst in the form of microspheres having an average particle size diameter from about 50 to 70 microns derived by spray drying a water slurry comprising a comminuted zeolite of the Y type and a matrix, said matrix including alumina derived from pseudoboehmite, said pseudoboehmite composed of Type A and comminuted Type B alumina, and SiO 2 derived from ammonium polysilicate and clay.

Claim 19

A hydrocarbon conversion catalyst in the form of microspheres having an average particle size diameter from about 50 to 70 microns derived by spray drying a water slurry comprising a comminuted zeolite of the Y type and a matrix, said matrix including alumina derived from pseudoboehmite, said pseudoboehmite composed of Type A and comminuted Type B alumina, and SiO 2 derived from ammonium polysilicate and clay.

Claim 20

A hydrocarbon conversion catalyst in the form of microspheres having an average particle size diameter from 50 to 70 microns derived by spray drying a water slurry comprising comminuted zeolite of the Y type having an SiO 2 /Al 2 O 3 molar ratio in excess of 4 and sodium as Na 2 O of less than about 5% of the zeolite on a volatile free basis, and a matrix, said matrix including more than about 15% by weight of alumina derived from pseudoboehmite, and from about 5% to about 30% by weight of SiO 2 derived from ammonium polysilicate or silica sol and from about 0% to about 30% of clay, said weight percentage based on the weight of the zeolite and matrix on a volatile free basis.

Claim 21

A hydrocarbon conversion catalyst in the form of microspheres having an average particle size diameter from 50 to 70 microns derived by spray drying a water slurry comprising comminuted zeolite of the Y type having an SiO 2 /Al 2 O 3 molar ratio in excess of 4 and sodium as Na 2 O of less than about 5% of the zeolite on a volatile free basis, and a matrix, said matrix including more than about 15% by weight of alumina derived from pseudoboehmite, and from about 5% to about 30% by weight of SiO 2 derived from ammonium polysilicate or silica sol and from about 0% to about 30% of clay, said weight percentage based on the weight of the zeolite and matrix on a volatile free basis.

Claim 22

The catalyst of claims 11, 12, or 13, in which the comminuted zeolite is composed of particles more than about 55% of which are of three (3) microns or less diameter.

Claim 23

A hydrocarbon conversion catalyst in the form of microspheres derived from spray drying a water slurry comprising zeolite of the faujasite type, more than about 55% of the zeolite crystals being less than about three (3) microns, and a matrix, said matrix including alumina derived from pseudoboehmite, said microspheres containing SiO 2 derived from ammonium polysilicate or silica sol having particles of average particle size of less than 5 millimicrons and clay, said catalyst having an Attrition Index of less than about 20.

Claim 24

A hydrocarbon conversion catalyst in the form of microspheres derived from spray drying a water slurry comprising zeolite of the faujasite type, more than about 55% of the zeolite crystals being less than about three (3) microns, and a matrix, said matrix including alumina derived from pseudoboehmite, said microspheres containing SiO 2 derived from ammonium polysilicate or silica sol having particles of average particle size of less than 5 millimicrons and clay, said catalyst having an Attrition Index of less than about 20.

Claim 25

A hydrocarbon conversion catalyst in the form of microspheres, derived from spray drying a water slurry, comprising zeolite of the faujasite type, more than about 55% of the crystals of the zeolite being less than about three (3) microns, and a matrix, said matrix including more than about 15% by weight of alumina derived, from acidified pseudoboehmite, and from about 5% to about 30% by weight of SiO 2 derived from ammonium polysilicate or silica sol having particles of average size less than 5 millimicrons and from about 10% to about 30% of clay, all weight based on the weight of the zeolite and matrix on a volatile free basis, said catalyst having an Attrition Index less than about 20.

Claim 26

A hydrocarbon conversion catalyst in the form of microspheres, derived from spray drying a water slurry, comprising zeolite of the faujasite type, more than about 55% of the crystals of the zeolite being less than about three (3) microns, and a matrix, said matrix including more than about 15% by weight of alumina derived, from acidified pseudoboehmite, and from about 5% to about 30% by weight of SiO 2 derived from ammonium polysilicate or silica sol having particles of average size less than 5 millimicrons and from about 10% to about 30% of clay, all weight based on the weight of the zeolite and matrix on a volatile free basis, said catalyst having an Attrition Index less than about 20.

Claim 27

The catalyst of claim 16, in which the zeolite is a Y zeolite.