Phosphorus-containing catalyst

Claim 2

A catalyst comprising a crystalline alumino-silicate zeolite prepared from a clay starting material, a residue derived from said clay, and an effective amount of phosphorus, said catalyst having been prepared by the steps which comprise: (a) ion exchanging a clay derived alkali metal-containing Y-type crystalline aluminosilicate zeolite and the clay derived residue with a cation other than an alkali metal to decrease the alkali metal content of said alkali metal-containing zeolite; (b) calcining the resulting ion exchanged zeolite and clay derived residue, and (c) contacting the resulting calcined zeolite and clay derived residue with an anion selected from the group consisting of a dihydrogen phosphate anion, a dihydrogen phosphite anion and mixtures thereof and with at least one ammonium salt other than a salt of an inorganic acid of phosphorus for a time sufficient to composite said effective amount of phosphorus with said calcined zeolite and residue and to decrease additionally the alkali metal content of said zeolite.

Claim 3

The catalyst of claim 1, wherein said anion and said ammonium salt of step (c) are present in the same medium and wherein said calcined zeolite and clay-derived residue are contacted simultaneously with said anion and said ammonium salt.

Claim 4

The catalyst of claim 1 wherein said calcined zeolite and clay-derived residue in step (c) are contacted separately with said anion and with said ammonium salt.

Claim 5

The catalyst of claim 1 wherein said catalyst additionally comprises clay.

Claim 6

The catalyst of claim 1 or claim 2 wherein said catalyst additionally comprises an inorganic oxide selected from the group consisting of silica, alumina, silica-alumina, zirconia, boria, titania, magnesia and mixtures thereof.

Claim 7

The catalyst of claim 1 wherein said catalyst comprises at least about 0.1 weight percent of said phosphorus, based on the weight of said zeolite plus residue.

Claim 8

The catalyst of claim 1 wherein said catalyst comprises at least about 0.2 weight percent of said phosphorus, based on the weight of said zeolite plus residue.

Claim 9

The catalyst of claim 1 wherein said catalyst comprises less than about 1.5 weight percent alkali metal, calculated as alkali metal oxide, based on the weight of said zeolite.

Claim 10

The catalyst of claim 1 wherein said catalyst comprises from about 2 to about 70 weight percent of said zeolite.

Claim 11

The catalyst of claim 1 wherein said calcination is conducted at conditions such as to decrease the unit cell size of said zeolite by an amount ranging from about 0.05 to 0.10 angstroms from its initial unit cell size of about above 24.5 angstroms.

Claim 12

The catalyst of claim 1 wherein said calcination is conducted at a temperature ranging from about 500° F. to about 1400° F.

Claim 13

The catalyst of claim 1 wherein said anion is derived from a phosphorus-containing component selected from the group consisting of inorganic acids of phosphorus, salts of an inorganic acid of phosphorus and mixtures thereof.

Claim 14

The catalyst of claim 12 wherein said anion is derived from a phosphorus-containing component selected from the group consisting of phosphorus acid (H 3 PO 3 ), phosphoric acid (H 3 PO 4 ), salts of phosphorous acid, salts of phosphoric acid and mixtures thereof.

Claim 15

The catalyst of claim 1 wherein said contacting step with said anion is conducted at a pH ranging from 2 to 8.

Claim 16

The catalyst of claim 1 wherein said anion of step (c) is present in a medium in an amount ranging from about 0.2 to about 10 weight percent.

Claim 17

In the process of preparing a Y-type crystalline aluminosilicate zeolite from a clay starting material and an additional source of silica and wherein an alkali metal-containing crystalline aluminosilicate zeolite derived from clay and a clay derived residue are ion exchanged with a cation other than an alkali metal to decrease the alkali metal content of said zeolite and the ion exchanged zeolite the clay derived residue are calcined, the improvement which comprises contacting the calcined ion exchanged zeolite and residue with an anion selected from the group consisting of dihydrogen phosphite anion, dihydrogen phosphate anion and mixtures thereof and with at least one ammonium salt other than a salt of an inorganic acid of phosphorus, to composite at least a portion of phosphorus with said zeolite and residue and to decrease additionally the alkali metal content of said zeolite.

Claim 18

In the process of preparing a Y-type crystalline aluminosilicate zeolite from a clay starting material and an additional source of silica and wherein an alkali metal-containing crystalline aluminosilicate zeolite derived from clay and a clay derived residue are ion exchanged with a cation other than an alkali metal to decrease the alkali metal content of said zeolite and the ion exchanged zeolite the clay derived residue are calcined, the improvement which comprises contacting the calcined ion exchanged zeolite and residue with an anion selected from the group consisting of dihydrogen phosphite anion, dihydrogen phosphate anion and mixtures thereof and with at least one ammonium salt other than a salt of an inorganic acid of phosphorus, to composite at least a portion of phosphorus with said zeolite and residue and to decrease additionally the alkali metal content of said zeolite.

Claim 19

The process of preparation of claim 16 wherein said anion and said ammonium salt of step (c) are present in the same medium.

Claim 20

The process of preparation of claim 16 wherein said calcined zeolite and clay residue in step (c) are contacted separately with said anion and with said ammonium salt.

Claim 21

The process of preparation of claim 16 wherein said contacting step with said anion is conducted for a time sufficient to composite at least about 0.1 weight percent phosphorus with said zeolite and residue.

Claim 22

The process of preparation of claim 16 wherein said contacting step with said anion is conducted for a time sufficient to composite at least about 0.2 weight percent phosphorus with said zeolite and residua.

Claim 23

The process of preparation of claim 16 wherein said catalyst comprises less than about 1.5 weight percent alkali metal, calculated as alkali metal oxide, based on the weight of said zeolite.

Claim 24

The process of preparation of claim 16 wherein said anion is derived from a phosphorus-containing component selected from the group consisting of inorganic acids of phosphorus, salts of inorganic acids of phosphorus and mixtures thereof.

Claim 25

The process of preparation of claim 16 wherein said anion is derived from a phosphorus-containing component selected from the group consisting of phosphoric acid, salts of phosphoric acid, phosphorous acid, salts of phosphorous acid and mixtures thereof.

Claim 26

The process of preparation of claim 16 wherein said anion is a dihydrogen phosphate anion derived from monoammonium phosphate, diammonium phosphate and mixtures thereof.

Claim 27

The process of preparation of claim 16 wherein said ammonium salt other than a salt of an inorganic acid of phosphorus is selected from the group consisting of ammonium sulfate, ammonium nitrate, ammonium nitrite, ammonium chloride, ammonium acetate, organic quaternary ammonium compounds and mixtures thereof.

Claim 28

The process of preparation of claim 16 wherein said contacting step with said anion is conducted at pH ranging from about 2 to about 8.

Claim 29

The process of preparation of claim 16 wherein said anion is present in a medium in an amount ranging from about 0.2 to about 10 weight percent.

Claim 30

The preparation process of claim 16 wherein said cation other than an alkali metal cation is selected from the group consisting of hydrogen, hydrogen ion precursors and mixtures thereof.

Claim 31

The process of preparation of claim 16 wherein said calcination is conducted at conditions such as to decrease the unit cell size of said zeolite by an amount ranging from about 0.05 to 0.10 angstroms from its initial unit cell size of above about 24.5 angstroms.

Claim 32

The process of preparation of claim 16 wherein said calcination is conducted at a temperature ranging from about 500° F. to about 1400° F.

Claim 33

The process of preparation of claim 16 wherein said source of additional silica is selected from the group consisting of alkali metal silicate, exothermed, kaolin, aqueous silica sol and mixtures thereof.

Claim 34

The process of preparation of claim 16 wherein said clay starting material is a calcined clay which has undergone the kaolin exotherm.

Claim 35

The process of preparation of claim 16 wherein said Y-type crystalline aluminosilicate is prepared by the steps which comprise: reacting particles comprising: (1) calcined kaolin clay which has undergone the kaolin exotherm; (2) powdered metakaolin and (3) a sodium hydroxide solution until a sodium form crystalline aluminosilicate Y-type zeolite crystallite is in said particles and a sodium silicate mother liquor is produced, separating from said mother liquor the resulting particles comprising the sodium Y-type crystalline aluminosilicate crystals and a silica-alumina residue of the calcined kaolin clay, decreasing the sodium content of said particles by ion exchange with a cation other than an alkali metal cation, calcining the resulting exchanged particles, the improvement which comprises contacting the calcined ion exchanged particles with an anion selected from the group consisting of dihydrogen phosphite anion, a dihydrogen phosphate anion and mixtures thereof and with at least one ammonium salt other than a salt of an inorganic acid of phosphorus, to composite with said particles at least a portion of phosphorus, and decrease additionally the alkali metal content of said zeolite, and recovering particles having increased catalytic activity.

Claim 36

The process of preparation of claim 33 wherein said particles are microspheres.

Claim 37

The catalyst of claim 1 wherein said catalyst comprises from about 0.1 weight percent to about 0.8 weight percent of said phosphorus, based on the weight of said zeolite plus residue.