US4584287A — Rare earth-containing Y zeolite compositions

Claim 1

Independent Claim 93 words

A zeolite produced by a process comprising: (a) cation-exchanging a crystalline aluminosilicate zeolite having an X-ray diffraction pattern indicative of the Y crystal structure with rare earth-containing cations; (b) calcining the resultant rare earth-exchanged zeolite in the presence of water vapor at a water vapor partial pressure of at least about 0.2 p.s.i.a.; (c) ion-exchanging the calcined zeolite from step (b) with ammonium ions; and (d) introducing, after said ammonium ion exchange of step (c), a metal component consisting essentially of one or more hydrogenation metal-containing cations into said zeolite by cation exchange.

Claim 2

Dependent Claim 93 words

A zeolite produced by a process comprising: (a) cation-exchanging a crystalline aluminosilicate zeolite having an X-ray diffraction pattern indicative of the Y crystal structure with rare earth-containing cations; (b) calcining the resultant rare earth-exchanged zeolite in the presence of water vapor at a water vapor partial pressure of at least about 0.2 p.s.i.a.; (c) ion-exchanging the calcined zeolite from step (b) with ammonium ions; and (d) introducing, after said ammonium ion exchange of step (c), a metal component consisting essentially of one or more hydrogenation metal-containing cations into said zeolite by cation exchange.

Claim 3

Dependent Claim 25 words

A zeolite as defined by claim 1 wherein the ammonium-exchanged zeolite from step (c) is calcined prior to introducing said metal component into said zeolite.

Claim 4

Dependent Claim 20 words

A zeolite as defined in claim 1 wherein said metal component consists essentially of one or more noble metal-containing cations.

Claim 5

Dependent Claim 14 words

A zeolite as defined by claim 3 wherein said noble metal-containing cations comprise palladium.

Claim 6

Dependent Claim 20 words

A zeolite as defined by claim 1 wherein said crystalline aluminosilicate zeolite in step (a) comprises a sodium Y zeolite.

Claim 7

Dependent Claim 33 words

A zeolite as defined by claim 5 wherein said crystalline aluminosilicate zeolite in step (a) contains less than about 0.5 weight percent sodium, calculated as Na 2 O, after said ammonium ion exchange.

Claim 8

Dependent Claim 34 words

A zeolite as defined by claim 1 wherein the unit cell size of said rare earth-exchanged zeolite after said calcination in the presence of water vapor is between about 24.20 and about 24.64 Angstroms.

Claim 9

Dependent Claim 29 words

A zeolite as defined by claim 1 wherein said calcination in the presence of water vapor is carried out at a water vapor partial pressure above about 1.0 p.s.i.a.

Claim 10

Dependent Claim 32 words

A zeolite as defined by claim 8 wherein said calcination in the presence of water vapor is carried out at a water vapor partial pressure between about 2.0 and about 15 p.s.i.a.

Claim 11

Dependent Claim 41 words

A zeolite as defined by claim 8 wherein said calcination in the presence of water vapor is carried out at a temperature between about 1100° F. and about 1350° F. and at a water vapor partial pressure above about 12 p.s.i.a.

Claim 12

Dependent Claim 143 words

A hydrocarbon conversion catalyst comprising a porous refractory oxide component and a crystalline aluminosilicate zeolite containing a rare earth metal and a hydrogenation metal, said catalyst having been prepared by a process comprising: (a) cation-exchanging a crystalline aluminosilicate zeolite having an X-ray diffraction pattern indicative of the Y crystal structure with rare earth-containing cations; (b) calcining the resultant rare earth-exchanged zeolite in the presence of water vapor at a water vapor partial pressure of at least about 0.2 p.s.i.a.; (c) ion-exchanging the calcined zeolite from step (b) with ammonium ions; (d) introducing, after said ammonium ion exchange of step (c), a hydrogenation metal component consisting essentially of one or more Group VIB or Group VIII metal-containing cations into said zeolite by cation exchange; and subsequently (e) mixing the zeolite from step (d) with a porous, refractory oxide component and calcining the resultant mixture.

Claim 13

Dependent Claim 143 words

A hydrocarbon conversion catalyst comprising a porous refractory oxide component and a crystalline aluminosilicate zeolite containing a rare earth metal and a hydrogenation metal, said catalyst having been prepared by a process comprising: (a) cation-exchanging a crystalline aluminosilicate zeolite having an X-ray diffraction pattern indicative of the Y crystal structure with rare earth-containing cations; (b) calcining the resultant rare earth-exchanged zeolite in the presence of water vapor at a water vapor partial pressure of at least about 0.2 p.s.i.a.; (c) ion-exchanging the calcined zeolite from step (b) with ammonium ions; (d) introducing, after said ammonium ion exchange of step (c), a hydrogenation metal component consisting essentially of one or more Group VIB or Group VIII metal-containing cations into said zeolite by cation exchange; and subsequently (e) mixing the zeolite from step (d) with a porous, refractory oxide component and calcining the resultant mixture.

Claim 14

Dependent Claim 22 words

A hydrocarbon conversion catalyst as defined by claim 11 wherein said crystalline aluminosilicate zeolite in step (a) comprises a sodium Y zeolite.

Claim 15

Dependent Claim 30 words

A hydrocarbon conversion catalyst as defined by claim 11 wherein said zeolite after said ammonium ion exchange contains less than about 0.5 weight percent sodium, calculated as Na 2 O.

Claim 16

Dependent Claim 21 words

A hydrocarbon conversion catalyst as defined by claim 11 wherein said hydrogenation metal component consists essentially of Group VIII metal-containing cations.

Claim 17

Dependent Claim 17 words

A hydrocarbon conversion catalyst as defined by claim 14 wherein said Group VIII metal containing-cations comprise palladium.

Claim 18

Dependent Claim 36 words

A hydrocarbon conversion catalyst as defined by claim 11 wherein the unit cell size of said rare earth-exchanged zeolite after said calcination in the presence of water vapor is between about 24.20 and about 24.64 Angstroms.

Claim 19

Dependent Claim 54 words

A hydrocarbon conversion catalyst as defined by claim 14 wherein the zeolite in the calcined product of step (e) contains at least about 2.0 weight percent rare earth metals, calculated as RE 2 O 3 , and at least about 0.1 weight percent of one or more Group VIII metals, calculated as the metals.

Claim 20

Dependent Claim 27 words

A hydrocarbon conversion catalyst as defined by claim 11 wherein said calcination of step (b) is accomplished in the presence of an atmosphere consisting essentially of steam.

Claim 21

Dependent Claim 97 words

A process for preparing an ammonia-stable and hydrothermally stable zeolite comprising: (a) cation-exchanging a crystalline aluminosilicate zeolite having an X-ray diffraction pattern indicative of the Y crystal structure with rare earth-containing cations; (b) calcining the resultant rear earth-exchanged zeolite in the presence of water vapor at a water vapor partial pressure of at least about 0.2 p.s.i.a.; (c) ion-exchanging the calcined zeolite from step (b) with ammonium ions; and (d) introducing, after said ammonium ion exchange of step (c), a metal component consisting essentially of one or more hydrogenation metal-containing cations into said zeolite by cation exchange.

Claim 22

Dependent Claim 97 words

A process for preparing an ammonia-stable and hydrothermally stable zeolite comprising: (a) cation-exchanging a crystalline aluminosilicate zeolite having an X-ray diffraction pattern indicative of the Y crystal structure with rare earth-containing cations; (b) calcining the resultant rear earth-exchanged zeolite in the presence of water vapor at a water vapor partial pressure of at least about 0.2 p.s.i.a.; (c) ion-exchanging the calcined zeolite from step (b) with ammonium ions; and (d) introducing, after said ammonium ion exchange of step (c), a metal component consisting essentially of one or more hydrogenation metal-containing cations into said zeolite by cation exchange.

Claim 23

Dependent Claim 20 words

A process as defined by claim 19 wherein said crystalline aluminosilicate zeolite in step (a) comprises a sodium Y zeolite.

Claim 24

Dependent Claim 28 words

A process as defined by claim 19 wherein said zeolite after said ammonium ion exchange contains less than about 0.5 weight percent sodium, calculated as Na 2 O.

Claim 25

Dependent Claim 20 words

A process as defined by claim 19 wherein said metal component consists essentially of one or more noble metal-containing cations.

Claim 26

Dependent Claim 14 words

A process as defined by claim 22 wherein said noble metal-containing cations comprise palladium.

Claim 27

Dependent Claim 33 words

A process as defined by claim 19 wherein said calcination in the presence of water vapor is carried out at a water vapor partial pressure between about 2.0 and about 15 p.s.i.a. PG,48

Claim 28

Dependent Claim 32 words

A process as defined by claim 19 wherein said rare earth cation exchange introduces a mixture of rare earth cations into said zeolite, said mixture containing cerium, lanthanum, praseodymium and neodymium cations.

Claim 29

Dependent Claim 49 words

A process as defined by claim 19 wherein said calcination in the presence of water vapor is carried out so as to effect at least some reduction in the unit cell size of said zeolite with the resultant unit cell size being between about 24.20 and about 24.64 Angstroms.

Claim 30

Dependent Claim 68 words

A process as defined by claim 22 wherein after said ammonium-exchanged zeolite from step (c) is exchanged with noble metal cations, the resulting zeolite contains at least 2.0 percent by weight rare earth metals, calculated as RE 2 O 3 , less than about 0.5 percent by weight sodium, calculated as Na 2 O, and at least 0.1 weight percent of total noble metals, calculated as the metals.

Claim 31

Dependent Claim 79 words

A zeolite produced by a process consisting essentially of: (a) cation-exchanging a crystalline aluminosilicate zeolite having an X-ray diffraction pattern indicative of the Y crystal structure with rare earth-containing cations; (b) calcining the resultant rare earth-exchanged zeolite in the presence of water vapor at a water vapor partial pressure of at least about 0.2 p.s.i.a.; (c) ion-exchanging the calcined zeolite from step (b) with ammonium ions; and (d) ion-exchanging the ammonium-exchanged zeolite from step (c) with hydrogenation metal-containing cations.

Claim 32

Dependent Claim 79 words

A zeolite produced by a process consisting essentially of: (a) cation-exchanging a crystalline aluminosilicate zeolite having an X-ray diffraction pattern indicative of the Y crystal structure with rare earth-containing cations; (b) calcining the resultant rare earth-exchanged zeolite in the presence of water vapor at a water vapor partial pressure of at least about 0.2 p.s.i.a.; (c) ion-exchanging the calcined zeolite from step (b) with ammonium ions; and (d) ion-exchanging the ammonium-exchanged zeolite from step (c) with hydrogenation metal-containing cations.

Claim 33

Dependent Claim 17 words

A hydrocarbon conversion catalyst comprising the zeolite of claim 28 and a porous, inorganic refractory oxide component.

Claim 34

Dependent Claim 17 words

A zeolite as defined by claim 28 wherein said hydrogenation metal-containing cations comprise Group VIII metal-containing cations.

Claim 35

Dependent Claim 15 words

A zeolite as defined by claim 30 wherein said Group VIII metal-containing cations comprise palladium.

Claim 36

Dependent Claim 20 words

A zeolite as defined by claim 28 wherein said crystalline aluminosilicate zeolite in step (a) comprises a sodium Y zeolite.

Claim 37

Dependent Claim 33 words

A zeolite as defined by claim 28 wherein said crystalline aluminosilicate zeolite in step (a) contains less than about 0.5 weight percent sodium, calculated as Na 2 O, after said ammonium ion exchange.

Claim 38

Dependent Claim 29 words

A zeolite as defined by claim 28 wherein said calcination in the presence of water vapor is carried out at a water vapor partial pressure above about 1.0 p.s.i.a.

Claim 39

Dependent Claim 32 words

A zeolite as defined by claim 28 wherein said calcination in the presence of water vapor is carried out at a water vapor partial pressure between about 2.0 and about 15 p.s.i.a.

Claim 40

Dependent Claim 26 words

A zeolite as defined by claim 28 wherein said calcination of step (b) is carried out in the presence of an atmosphere consisting essentially of steam.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1989-04-21	1989-10-21	1990-04-22	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1993-04-21	1993-10-21	1994-04-22	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1997-04-21	1997-10-21	1998-04-22	$7700.00	Window Closed / Lapsed

Rare earth-containing Y zeolite compositions

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