US4761391A
Expired / Lapsed
US
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Delaminated clays and their use in hydrocarbon conversion processes
Assignee: Honeywell UOP LLC
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Filing: 1986-06-30
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Granted: 1988-08-02
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Expires: 2006-06-30
Abstract
Abstract Delaminated clays whose X-ray diffraction patterns do not contain a distinct first order reflection are prepared from synthetic and natural swelling clays whose particles have a length-to-width rati greater than about 2.0, a length-to-thickness ratio greater than about 5.0 and are comprised of randomly oriented platelets by reacting the clay with a pillaring agent selected from the group consisting of polyoxymetal cations, mixtures of polyoxymetal cations, colloidal particles comprising alumina, silica, titania, chromia, tin oxide, antimony oxide or mixtures thereof, and cationic metal clusters comprising nickel, molybdenum, cobalt or tungsten and the subjecting the resulting reaction products to drying in a gaseous medium, preferably spray drying. The resulting acidic delaminated clays, which contain the microporosity associated with zeolites and pillared clays the the macroporosity associated with amorphous aluminosilicates, may be used as the active component of cracking and hydroprocessing catalysts.
Inventors
- 👤 Mario L. Occelli
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 03:26
CPC Classifications
B; B01; B01J; B01J21/00; B01J21/16
Claims Analysis
Total Claims: 39
Claim 1
Independent Claim
149 words
A process for preapring a delaminated clay having an X-ray diffraction pattern which does not contain a first order reflection, which process comprises: (a) reacting a natural or synthetic swelling clay with a reactant selected from the group consisting of colloidal silica particles, colloidal alumina particles, colloidal titania particles, colloidal chromia particles, colloidal tin oxide particles, colodial antimony oxide particles, cationic molybdenum clusters, cationic tungsten clusters, cationic nickel clusters, cationic cobalt clusters and mixtures thereof to form a flocculated reaction product, said swelling clay being comprised of particles at least about 20 percent of which have a length-to-width ratio greater than about 2.0 and a length-to-thickness ratio greater than about 5.0 and wherein said particles are comprised of platelets; and (b) drying said floccculated reaction product in the presence of air to form said delaminated clay having an X-ray diffraction pattern which does not contain a first order reflection.
Claim 2
Dependent Claim
149 words
A process for preapring a delaminated clay having an X-ray diffraction pattern which does not contain a first order reflection, which process comprises: (a) reacting a natural or synthetic swelling clay with a reactant selected from the group consisting of colloidal silica particles, colloidal alumina particles, colloidal titania particles, colloidal chromia particles, colloidal tin oxide particles, colodial antimony oxide particles, cationic molybdenum clusters, cationic tungsten clusters, cationic nickel clusters, cationic cobalt clusters and mixtures thereof to form a flocculated reaction product, said swelling clay being comprised of particles at least about 20 percent of which have a length-to-width ratio greater than about 2.0 and a length-to-thickness ratio greater than about 5.0 and wherein said particles are comprised of platelets; and (b) drying said floccculated reaction product in the presence of air to form said delaminated clay having an X-ray diffraction pattern which does not contain a first order reflection.
Claim 3
Dependent Claim
18 words
A process as defined by claim 1 wherein said natural or synthetic swelling clay comprises Laponite B clay.
Claim 4
Dependent Claim
36 words
A process as defined by claim 1 wherein greater than about 50 percent of the particles comprising said swelling clay have a length-to-width ratio greater than about 5.0 and a length-to-thickness ratio greater than about 7.0.
Claim 5
Dependent Claim
20 words
A process as defined by claim 1 wherein said platelets comprising the particles of said swelling clay are randomly oriented.
Claim 6
Dependent Claim
15 words
A process as defined by claim 1 wherein said flocculated reaction product is spray dried.
Claim 7
Dependent Claim
15 words
A process as defined by claim 1 wherein said flocculated reaction product is oven dried.
Claim 8
Dependent Claim
40 words
A process as defined by claim 1 wherein said reactant is selected from the group consisting of colloidal silica particles, colloidal alumina particles, colloidal titania particles, coloidal chromia particles, colloidal tin oxide particles, colloidal antimony oxide particles and mixtures thereof.
Claim 9
Dependent Claim
32 words
A process as defined by claim 1 wherein said reactant is selected from the group consisting of cationic molybdenum clusters, cationic tungsten clusters, cationic nickel clusters, cationic cobalt clusters and mixtures thereof.
Claim 10
Dependent Claim
16 words
A catalyst composition comprising a delaminated clay prepared in accordance with the process of claim 1.
Claim 11
Dependent Claim
16 words
A catalyst composition comprising a delaminated clay prepared in accordnace with the process of claim 5.
Claim 12
Dependent Claim
89 words
A process for preparing a delaminated clay having an X-ray diffraction pattern which does not contain a first order reflection, which process comprises: (a) reacting Laponite B clay with a reactant selected from the group consisting of colloidal silica particles, coloidal alumina particles, colloidal titania particles, and colloidal tin oxide particles to form a flocculated reaction product; and (b) drying said flocculated reaction product in the presence of a gaseous medium to form said delaminated clay having an X-ray diffraction pattern which does not contain a first order reflection.
Claim 13
Dependent Claim
89 words
A process for preparing a delaminated clay having an X-ray diffraction pattern which does not contain a first order reflection, which process comprises: (a) reacting Laponite B clay with a reactant selected from the group consisting of colloidal silica particles, coloidal alumina particles, colloidal titania particles, and colloidal tin oxide particles to form a flocculated reaction product; and (b) drying said flocculated reaction product in the presence of a gaseous medium to form said delaminated clay having an X-ray diffraction pattern which does not contain a first order reflection.
Claim 14
Dependent Claim
13 words
A process as defined by claim 11 wherein said gaseous medium comprises air.
Claim 15
Dependent Claim
16 words
A catalyst composition comprising a delaminated clay prepared in accordance with the process of claim 11.
Claim 16
Dependent Claim
139 words
A delaminated clay having an X-ray diffraction pattern which does not contain a first order reflection produced by the process comprising: (a) reacting a natural or synthetic swelling clay with a reactant selected from the group consisting of colloidal silica particles, colloidal tin oxide particles, colloidal antimony oxide particles, cationic molybdenum clusters, cationic tungsten clusters, cationic nickel clusters, cationic cobalt clusters and mixtures thereof to form a flocculated reaction product, said swelling clay being comprised of particles at least 20 percent of which have a length-to-width ratio greater than about 2.0 and a length-to-thickness ratio greater than about 5.0 and wherein said particles are comprised of platelets; and (b) drying said flocculated reaction product in the presence of a gaseous medium to form said delaminated clay having an X-ray diffraction pattern which does not contain a first order reflection.
Claim 17
Dependent Claim
139 words
A delaminated clay having an X-ray diffraction pattern which does not contain a first order reflection produced by the process comprising: (a) reacting a natural or synthetic swelling clay with a reactant selected from the group consisting of colloidal silica particles, colloidal tin oxide particles, colloidal antimony oxide particles, cationic molybdenum clusters, cationic tungsten clusters, cationic nickel clusters, cationic cobalt clusters and mixtures thereof to form a flocculated reaction product, said swelling clay being comprised of particles at least 20 percent of which have a length-to-width ratio greater than about 2.0 and a length-to-thickness ratio greater than about 5.0 and wherein said particles are comprised of platelets; and (b) drying said flocculated reaction product in the presence of a gaseous medium to form said delaminated clay having an X-ray diffraction pattern which does not contain a first order reflection.
Claim 18
Dependent Claim
14 words
A delaminated clay as defined by claim 14 wherein said gaseous medium comprises air.
Claim 19
Dependent Claim
18 words
A delaminated clay as defined by claim 15 wherein said natural or synthetic clay comprises Laponite B clay.
Claim 20
Dependent Claim
24 words
A delaminated clay as defined by claim 15 wherein said platelets comprising the particles of said natural or synthetic swelling clay are randomly oriented.
Claim 21
Dependent Claim
26 words
A delaminated clay as defined by claim 15 wherein said reactant is selected from the group consisting of colloidal silica particles and colloidal tin oxide particles.
Claim 22
Dependent Claim
15 words
A delaminated clay as defined by claim 18 wherein said flocculated reaction product is spray-dried.
Claim 23
Dependent Claim
10 words
A catalyst composition comprising the delaminated clay of claim 14.
Claim 24
Dependent Claim
10 words
A catalyst composition comprising the delaminated clay of claim 15.
Claim 25
Dependent Claim
19 words
A delaminated clay as defined by claim 18 wherein said natural or synthetic swelling clay comprises Laponite B clay.
Claim 26
Dependent Claim
10 words
A catalyst composition comprising the delaminated clay of claim 22.
Claim 27
Dependent Claim
110 words
A delaminated clay having an X-ray diffraction pattern which does not contain a first order reflection produced by the process comprising: (a) reacting a natural or synthetic swelling clay whose particles are composed of randomly oriented platelets with a reactant selected from the group consisting of colloidal silica particles, colloidal tin oxide particles, colloidal antimony oxide particles, cationic molybdenum clusters, cationic tungsten clusters, cationic nickel clusters, cationic cobalt clusters and mixtures thereof to form a flocculated reaction product; and (b) drying said flocculated reaction product in the presence of a gaseous medium to form said delaminated clay having an X-ray diffraction pattern which does not contain a first order reflection.
Claim 28
Dependent Claim
110 words
A delaminated clay having an X-ray diffraction pattern which does not contain a first order reflection produced by the process comprising: (a) reacting a natural or synthetic swelling clay whose particles are composed of randomly oriented platelets with a reactant selected from the group consisting of colloidal silica particles, colloidal tin oxide particles, colloidal antimony oxide particles, cationic molybdenum clusters, cationic tungsten clusters, cationic nickel clusters, cationic cobalt clusters and mixtures thereof to form a flocculated reaction product; and (b) drying said flocculated reaction product in the presence of a gaseous medium to form said delaminated clay having an X-ray diffraction pattern which does not contain a first order reflection.
Claim 29
Dependent Claim
14 words
A delaminated clay as defined by claim 24 wherein said gaseous medium comprises air.
Claim 30
Dependent Claim
36 words
A delaminated clay as defined by claim 25 wherein greater than about 40 percent of the particles comprising said clay have a length-to-width ratio greater than about 2.0 and a length-to-thickness ratio greater than about 5.0.
Claim 31
Dependent Claim
26 words
A delaminated clay as defined by claim 25 wherein said reactant is selected from the group consisting of colloidal silica particles and colloidal tin oxide particles.
Claim 32
Dependent Claim
10 words
A catalyst composition comprising the delaminated clay of claim 24.
Claim 33
Dependent Claim
10 words
A catlayst composition comprising the delaminated clay of claim 25.
Claim 34
Dependent Claim
99 words
A delaminated clay containing both micropores and macropores comprising a plurality of platelets propped apart with inorganic metal oxide clusters to form platelet aggregates containing said micropores, said inorganic metal clusters selected from the group consisting of mixed zirconium and aluminum oxide clusters, silicon oxide clusters, mixed silicon and aluminum oxide clusters, nickel oxide clusters, cobalt oxide clusters, molybdenum oxide clusters, tungsten oxide clusters, tin oxide clusters and antimony oxide clusters, and wherein said platelet aggregates are randomly oriented to form said macropores such that the X-ray diffraction pattern of said clay does not contain a first order reflection.
Claim 35
Dependent Claim
99 words
A delaminated clay containing both micropores and macropores comprising a plurality of platelets propped apart with inorganic metal oxide clusters to form platelet aggregates containing said micropores, said inorganic metal clusters selected from the group consisting of mixed zirconium and aluminum oxide clusters, silicon oxide clusters, mixed silicon and aluminum oxide clusters, nickel oxide clusters, cobalt oxide clusters, molybdenum oxide clusters, tungsten oxide clusters, tin oxide clusters and antimony oxide clusters, and wherein said platelet aggregates are randomly oriented to form said macropores such that the X-ray diffraction pattern of said clay does not contain a first order reflection.
Claim 36
Dependent Claim
41 words
A delaminated clay as defined by claim 30 wherein said micropores comprise between about 5 and about 70 percent of the pore volume of said clay and said macropores comprise between about 30 and about 95 percent of said pore volume.
Claim 37
Dependent Claim
36 words
A delaminated clay as defined by claim 30 wherein said inorganic metal clusters are selected from the group consisting of mixed zirconium and aluminum oxide clusters, mixed silicon and aluminum oxide clusters, and tin oxide clusters.
Claim 38
Dependent Claim
10 words
A catalyst composition comprising the delaminated clay of claim 30.
Claim 39
Dependent Claim
10 words
A catalyst composition comprising the delaminated clay of claim 32.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1991-08-02 | 1992-02-01 | 1992-08-02 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1995-08-02 | 1996-02-01 | 1996-08-02 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1999-08-02 | 2000-02-01 | 2000-08-02 | $7700.00 | Window Closed / Lapsed |