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

Patent metadata

Field	Value
Publication number	US-11926796-B2
Application number	US-202217865555-A
Country	US
Kind code	B2
Filing date	Jul 15, 2022
Priority date	Aug 4, 2016
Publication date	Mar 12, 2024
Grant date	Mar 12, 2024

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. A process for manufacturing an FCC catalyst comprising:
a. Adding, clay, boehmite and 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 one or more zeolites to the slurry;
d. Adding 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. Shaping and collecting the resulting FCC Catalyst.

2. The process of claim 1 further comprising a calcination step and post washing step to remove excess sodium as necessary.

3. A process for manufacturing an FCC catalysts comprising:
a. Adding, clay, boehmite, 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 one or more zeolites to the slurry;
d. Adding an 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. Shaping and collecting the resulting FCC Catalyst.

Assignees

• Albemarle Corp
• Ketjen Llc

Inventors

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

Classifications

• C10G11/05 Primary

  Crystalline alumino-silicates, e.g. molecular sieves · CPC title

• B01J29/005

  Mixtures of molecular sieves comprising at least one molecular sieve which is not an aluminosilicate zeolite, e.g. from groups B01J29/03 - B01J29/049 or B01J29/82 - B01J29/89 · CPC title

• B01J29/06

  Crystalline aluminosilicate zeolites; Isomorphous compounds thereof · CPC title

• B01J29/061

  containing metallic elements added to the zeolite · CPC title

• B01J29/084

  Y-type faujasite · CPC title