FCC catalyst with more than one silica, its preparation and use

Patent metadata

Field	Value
Publication number	US-11427764-B2
Application number	US-201716322779-A
Country	US
Kind code	B2
Filing date	Aug 4, 2017
Priority date	Aug 4, 2016
Publication date	Aug 30, 2022
Grant date	Aug 30, 2022

Abstract

Process for the preparation of a catalyst and a catalyst comprising the use of more than one silica source is provided herein. Thus, in one embodiment, the invention provides a particulate FCC catalyst comprising about 5 to about 60 wt % one or more zeolites, about 15 to about 35 wt % quasicrystalline boehmite (QCB), about 0 to about 35 wt % microcrystalline boehmite (MCB), greater than about 0 to about 15 wt % silica from sodium stabilized basic colloidal silica, greater than about 0 to about 30 wt % silica from acidic colloidal silica or polysilicic acid, and the balance clay and the process for making the same. This process results in attrition resistant catalysts with a good accessibility.

First claim

The invention claimed is:

1. An FCC catalyst precursor composition comprising about 5 to about 60 wt % one or more zeolites, about 15 to about 35 wt % quasicrystalline boehmite, about 0 to about 35 wt % microcrystalline boehmite, greater than 0 wt % to about 15 wt % silica from sodium stabilized basic colloidal silica, greater than 0 wt % to about 30 wt % silica from acidic colloidal silica or polysilicic acid, and the balance clay.

2. The FCC Catalyst precursor of claim 1 with greater than 0.5 wt % to about 10 wt % silica from sodium stabilized basic colloidal silica.

3. The FCC Catalyst precursor of claim 2 with greater than 1 wt % to about 8 wt % silica from sodium stabilized basic colloidal silica.

4. The FCC Catalyst precursor of claim 1 with greater than 1 wt % to about 25 wt % silica from acidic colloidal silica or polysilicic acid.

5. The FCC Catalyst precursor of claim 4 with greater than 5 wt % to about 20 wt % silica from acidic colloidal silica or polysilicic acid.

6. The FCC Catalyst precursor of claim 1 with an attrition index measurement of less than about 2.0.

7. A process for manufacturing an FCC catalysts comprising:
a. Adding, clay, about 15 to about 35 wt % quasicrystalline boehmite, about 0 to about 35 wt % microcrystalline boehmite, greater than 0 wt % to about 15 wt % silica from sodium stabilized basic colloidal silica to form a slurry;
b. Digesting the slurry with a monoprotic acid to a pH of less than 4.0;
c. Adding about 5 to about 60 wt % one or more zeolites to the slurry;
d. Adding greater than 0 wt % to about 30 wt % polysilicic acid made separately and added inline;
e. Mixing the slurry and then destabilizing the slurry by raising the pH to above 4.0
f. Spray drying and collecting the resulting FCC Catalyst.

8. The process of claim 7 further comprising a calcination step and post washing step to remove excess sodium as necessary.

9. A process for manufacturing an FCC catalysts comprising:
a. Adding, clay, about 15 to about 35 wt % quasicrystalline boehmite, about 0 to about 35 wt % microcrystalline boehmite, greater than 0 wt % to about 15 wt % silica from sodium stabilized basic colloidal silica to form a slurry;
b. Digesting the slurry with a monoprotic acid to a pH of less than 4;
c. Adding about 5 to about 60 wt % one or more zeolites to the slurry;
d. Adding greater than 0 wt % to about 30 wt % acidic colloidal silica at any time during or after steps (a)-(c) but before step (e);
e. Mixing the slurry and then destabilizing the slurry by raising the pH to above 4.0;
f. Spray drying and collecting the resulting FCC Catalyst.

10. A catalyst made from the process of:
a. Adding, about 15 to about 35 wt % quasicrystalline boehmite, about 0 to about 35 wt % microcrystalline boehmite, greater than 0 to about 15 wt % silica from sodium stabilized basic colloidal silica and an amount of clay to form a slurry;
b. Digesting the slurry with a monoprotic acid to a pH of less than 4.0;
c. Adding about 5 to about 60 wt % one or more zeolites to the slurry;
d. Adding greater than 0 to about 30 wt % polysilicic acid made separately and added inline;
e. Mixing the slurry and then destabilizing the slurry by raising the pH to above 4.0
f. Spray drying and collecting the resulting FCC Catalyst.

11. A catalyst made from the process of:
a. Adding, about 15 to about 35 wt % quasicrystalline boehmite, about 0 to about 35 wt % microcrystalline boehmite, greater than 0 to about 15 wt % silica from sodium stabilized basic colloidal silica and an amount of clay to form a slurry;
b. Digesting the slurry with a monoprotic acid to a pH of less than 4;
c. Adding about 5 to about 60 wt % one or more zeolites to the slurry;
d. Adding greater than 0 to about 30 wt % acidic colloidal silica at any time during or after steps (a)-(c) but before step (e);
e. Mixing the slurry and then destabilizing the slurry by raising the pH to above 4.0;
f. Spray drying and collecting the resulting FCC Catalyst.

12. The FCC Catalyst of claim 10 or 11 with greater than 0.5 wt % to about 10 wt % silica from sodium stabilized basic colloidal silica.

13. The FCC Catalyst of claim 10 or 11 with greater than 1 wt % to about 8 wt % silica from sodium stabilized basic colloidal silica.

14. The FCC Catalyst of claim 10 or 11 with greater than 1 wt % to about 25 wt % silica from acidic colloidal silica or polysilicic acid.

15. The FCC Catalyst of claim 10 or 11 with greater than 5 wt % to about 20 wt % silica from acidic colloidal silica or polysilicic acid.

16. The FCC Catalyst of claim 10 or 11 with an attrition index measurement of less than about 2.0.

Assignees

• Albemarle Corp

Inventors

• Sabahi Amir
• Loebl Andrew J
• Gavalda Sandra
• Francis Julie A
• Iyyamperumal Eswaramoorthi

Classifications

• B01J29/85

  Silicoaluminophosphates [SAPO compounds] · CPC title

• B01J2229/42

  Addition of matrix or binder particles · CPC title

• C07C2527/167

  Phosphates or other compounds comprising the anion (PnO3n+1)(n+2)- · CPC title

• B01J37/0045

  Drying a slurry, e.g. spray drying · CPC title

• B01J37/28

  Phosphorising · CPC title