Patent EP0757503A2 successfully refreshed from Google Patents.
US4458023A
Expired / Lapsed
US
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Catalyst manufacture
Assignee: WR Grace and Co Conn
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Filing: 1982-11-02
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Granted: 1984-07-03
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Expires: 2002-11-02
Abstract
Abstract Zeolite containing catalysts and catalyst supports are prepared by forming and drying an aqueous slurry of zeolite, aluminum chlorhydrol and optimally clay to obtain particulate composites in which the zeolite component contains in excess of about 1 percent by weight alkali metal oxide. The particulate composites are calcined, and in some instances ion exchanged to obtain hard, attrition resistant catalytic particles.
Inventors
- 👤 William A. Welsh
- 👤 Mark A. Seese
- 👤 Alan W. Peters
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-03 11:43
CPC Classifications
B; B01; B01J; B01J29/00; B01J29/04; B01J29/06; B01J29/08; B01J29/085; B01J29/088; B01J29/084; C; C10; C10G; C10G11/00; C10G11/02; C10G11/04; C10G11/05; C10G49/00; C10G49/02; C10G49/08; B01J2229/00; B01J2229/30; B01J2229/40; B01J2229/42
Claims Analysis
Total Claims: 30
Claim 1
Independent Claim
95 words
In a process for preparing catalyst compositions wherein (a) a zeolite is mixed with an aluminum chlorhydrol binder, (b) the mixture is formed into particles, and (c) the particles are calcined to obtain hard, attrition resistant catalysts, the improvement comprising; combining a zeolite which contains in excess of about one percent by weight alkali metal oxide with the chlorhydrol, calcining the particles at a temperature of about 300° to 600° C., and ion exchanging and washing the formed calcined particles to obtain a catalyst containing less than about one percent by weight alkali metal oxide.
Claim 2
Dependent Claim
95 words
In a process for preparing catalyst compositions wherein (a) a zeolite is mixed with an aluminum chlorhydrol binder, (b) the mixture is formed into particles, and (c) the particles are calcined to obtain hard, attrition resistant catalysts, the improvement comprising; combining a zeolite which contains in excess of about one percent by weight alkali metal oxide with the chlorhydrol, calcining the particles at a temperature of about 300° to 600° C., and ion exchanging and washing the formed calcined particles to obtain a catalyst containing less than about one percent by weight alkali metal oxide.
Claim 3
Dependent Claim
21 words
The method of claim 1 wherein said catalyst particles have an alkali metal oxide content of below about 0.5 weight percent.
Claim 4
Dependent Claim
28 words
The method of claim 1 wherein said aluminum chlorhydrol has the formula Al 2+m (OH) 3m Cl 6 wherein m has a value of about 4 to 12.
Claim 5
Dependent Claim
25 words
The method of claim 1 wherein the zeolite is a type Y zeolite which contains about 3 to 6 percent by weight Na 2 O.
Claim 6
Dependent Claim
15 words
The method of claim 1 wherein said aqueous mixture prepared in step (a) includes clay.
Claim 7
Dependent Claim
16 words
The method of claim 1 wherein said mixture is formed at step (b) by spray drying.
Claim 8
Dependent Claim
26 words
The method of claim 1 wherein said ion exchange step includes contacting the calcined particles with a solution which includes ammonium ions and/or rare earth ions.
Claim 9
Dependent Claim
39 words
The method of claim 1 wherein said particles are calcined at a temperature of 500° to 550° C. and is ion exchanged and/or washed to lower the alkali metal oxide content thereof to below about 0.5 percent by weight.
Claim 10
Dependent Claim
20 words
The method of claim 8 wherein said alkali metal oxide content is lowered to below about 0.2 percent by weight.
Claim 11
Dependent Claim
10 words
A catalyst composition prepared by the method of claim 1.
Claim 12
Dependent Claim
12 words
A fluid cracking catalyst composition prepared by the method of claim 6.
Claim 13
Dependent Claim
52 words
The composition of claim 10 wherein said catalyst contains from about 1 to 60 parts by weight zeolite, 5 to 25 parts by weight alumina binder, and up to about 90 parts by weight of a particulate component selected from the group consisting of alumina, rare-earth impregnated alumina, clay and mixtures thereof.
Claim 14
Dependent Claim
13 words
The catalyst composition of claim 12 wherein said zeolite is type Y zeolite.
Claim 15
Dependent Claim
17 words
The catalyst composition of claim 13 wherein said zeolite is exchanged with rare earth and/or ammonium ions.
Claim 16
Dependent Claim
15 words
A hydroprocessing catalyst support prepared in accordance with the method set forth in claim 1.
Claim 17
Dependent Claim
74 words
In a method for preparing catalyst compositions wherein (a) a zeolite is mixed with an aluminum chlorhydrol binder, (b) the mixture is formed into particles, and (c) the particles are calcined to obtain hard, attrition resistant catalysts, the improvement consisting essentially of; mixing a zeolite containing about 3 to 6 percent by weight alkali metal oxide in amounts to provide active catalysts which contain less than about 0.6 percent by weight alkali metal oxide.
Claim 18
Dependent Claim
74 words
In a method for preparing catalyst compositions wherein (a) a zeolite is mixed with an aluminum chlorhydrol binder, (b) the mixture is formed into particles, and (c) the particles are calcined to obtain hard, attrition resistant catalysts, the improvement consisting essentially of; mixing a zeolite containing about 3 to 6 percent by weight alkali metal oxide in amounts to provide active catalysts which contain less than about 0.6 percent by weight alkali metal oxide.
Claim 19
Dependent Claim
18 words
The method of claim 16 wherein said particles are calcined at a temperature of 500° to 700° C.
Claim 20
Dependent Claim
18 words
The method of claim 17 wherein said particles contain below about 0.5 percent by weight alkali metal oxide.
Claim 21
Dependent Claim
28 words
The method of claim 16 wherein said aluminum chlorhydrol has the formula Al 2+m (OH) 3m Cl 6 wherein m has a value of about 4 to 12.
Claim 22
Dependent Claim
13 words
The method of claim 16 wherein the zeolite is a type Y zeolite.
Claim 23
Dependent Claim
14 words
The method of claim 16 wherein the mixture prepared in step (a) includes clay.
Claim 24
Dependent Claim
27 words
The method of claim 16 wherein said ion exchange step (d) includes contacting the calcined particles with a solution which includes ammonium ions and/or rare earth ions.
Claim 25
Dependent Claim
10 words
A catalyst composition prepared by the method of claim 16.
Claim 26
Dependent Claim
12 words
A fluid cracking catalyst composition prepared by the method of claim 22.
Claim 27
Dependent Claim
52 words
The composition of claim 25 wherein said catalyst contains from about 1 to 60 parts by weight zeolite, 5 to 25 parts by weight alumina binder, and up to about 90 parts by weight of a particulate component selected from the group consisting of alumina, rare-earth impregnated alumina, clay and mixtures thereof.
Claim 28
Dependent Claim
13 words
The catalyst composition of claim 26 wherein said zeolite is type Y zeolite.
Claim 29
Dependent Claim
17 words
The catalyst composition of claim 27 wherein said zeolite is exchanged with rare earth and/or ammonium ions.
Claim 30
Dependent Claim
15 words
A hydroprocessing catalyst support prepared in accordance with the method set forth in claim 16.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1987-07-03 | 1988-01-02 | 1988-07-03 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-07-03 | 1992-01-02 | 1992-07-03 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-07-03 | 1996-01-02 | 1996-07-03 | $7700.00 | Window Closed / Lapsed |