FCC catalyst prepared by a process involving more than one silica material

Patent metadata

Field	Value
Publication number	US-11458456-B2
Application number	US-201916960927-A
Country	US
Kind code	B2
Filing date	Jan 11, 2019
Priority date	Jan 12, 2018
Publication date	Oct 4, 2022
Grant date	Oct 4, 2022

Abstract

Process for the preparation of a catalyst and a catalyst comprising more than one silica 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 10 to about 45 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 colloidal silica, greater than about 0 to about 30 wt % silica from ammonia stabilized or lower sodium colloidal silica, and the balance clay and the process for making the same. This process results in attrition resistant catalysts with good performance.

First claim

The invention claimed is:

1. A process for manufacturing an FCC catalysts comprising:
a. Adding; clay, boehmite, and a first sodium stabilized colloidal silica to form a slurry;
b. Digesting the slurry with a monoprotic acid to a pH of less than 4;
c. Adding one or more zeolites to the slurry;
d. Adding a second silica that is either an ammonia stabilized or sodium stabilized colloidal silica, wherein the sodium content is less than the first sodium stabilized 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. Shaping and collecting the resulting FCC Catalyst.

2. The process of claim 1 further comprising adding about 5 to about 60 wt % one or more zeolites.

3. The process of claim 1 further comprising adding greater than 0 to about 15 wt % of the first sodium stabilized colloidal silica.

4. The process of claim 1 further comprising adding greater than 0.5 wt % to about 10 wt % of the first sodium stabilized colloidal silica.

5. The process of claim 1 further comprising adding greater than 0 to about 30 wt % of the second silica.

6. The process of claim 1 further comprising adding greater than 1 wt % to about 25 wt % of the second silica.

7. The process of claim 1 further comprising adding greater than 5 wt % to about 20 wt % of the second silica.

Assignees

• Albemarle Corp

Inventors

• Sabahi Amir
• Loebl Andrew
• Gavalda Sandra
• Francis Julie
• Iyyamperumal Eswaramoorthi
• Li Min
• Marcinkova Andrea

Classifications

• B01J35/40

  characterised by dimensions, e.g. grain size (in a colloidal state B01J35/23; crystallite size B01J35/77) · CPC title

• B01J2029/081

  Increasing the silica/alumina ratio; Desalumination · CPC title

• B01J37/088

  Decomposition of a metal salt · CPC title

• C10G2300/70

  Catalyst aspects · CPC title

• C10G11/18

  according to the "fluidised-bed" technique · CPC title