In-situ produced Y-faujasite from kaolin-derived, pre-shaped particles and the method of preparation and the use thereof

Patent metadata

Field	Value
Publication number	US-9433934-B2
Application number	US-201313899816-A
Country	US
Kind code	B2
Filing date	May 22, 2013
Priority date	Mar 2, 2006
Publication date	Sep 6, 2016
Grant date	Sep 6, 2016

Abstract

A zeolite-containing fixed bed catalyst is formed by pre-shaping a mixture of a reactive aluminum-containing component and a matrix component into pre-shaped particles, and contacting the pre-shaped particles with a reactive liquid containing a silicate for a sufficient time and temperature to form an in-situ zeolite within the pre-shaped particles. The contacting of the pre-shaped particles and the liquid is achieved such that there is relative movement between the pre-shaped particles and the liquid.

First claim

The invention claimed is:

1. A process for preparing a zeolite-containing fixed bed catalyst, the process comprising:
shaping a first mixture of a reactive aluminum-containing component and one or more matrix-forming components into pre-shaped particles having a size suitable for fixed bed catalysis, wherein said shaping comprises extrusion; and
contacting said pre-shaped particles with a liquid containing a reactive silicate component for a time and a temperature sufficient to crystallize zeolite Y on said pre-shaped particles, wherein said contacting comprises providing velocity of at least one of said pre-shaped particles relative to said liquid or said liquid relative to said pre-shaped particles.

2. The process of claim 1 , wherein said reactive aluminum-containing component is metakaolin.

3. The process of claim 2 , wherein said pre-shaped particles comprise hydrous kaolin, and said pre-shaped particles are calcined so as to convert said hydrous kaolin to metakaolin.

4. The process of claim 1 , wherein said one or more matrix-forming components comprise at least one of kaolin calcined through exotherm of the kaolin to spinel, mullite, or alumina.

5. The process of claim 1 , wherein said liquid is contacted with said pre-shaped particles by circulating said liquid through a stationary bed of said pre-shaped particles.

6. The process of claim 1 , wherein said liquid is contacted with said pre-shaped particles by forming a second mixture of said pre-shaped particles in said liquid, and providing movement to said second mixture.

7. The process of claim 1 , wherein said liquid is contacted with said pre-shaped particles by providing said pre-shaped particles in a porous container, and moving said porous container within said liquid.

8. The process of claim 7 , wherein said porous container is a basket and said basket is rotated within said liquid.

9. The process of claim 1 , wherein said pre-shaped particles have a diameter of from about 0.05 to 0.5 inch, and a length of from about 0.05 to 1 inch.

10. The process of claim 1 , wherein said pre-shaped particles have a diameter of about 1/16th inch.

11. The process of claim 1 , wherein said one or more matrix-forming components are such to provide macropores within said pre-shaped particles, and wherein said zeolite Y is crystallized as a layer on walls of said macropores.

12. The process of claim 1 , wherein said catalyst comprises, subsequent to crystallization of said zeolite Y, at least 10 to 65 percent by weight of said zeolite Y.

13. The process of claim 1 , wherein said liquid comprises an aqueous solution of sodium silicate and sodium hydroxide.

14. The process of claim 13 , wherein said liquid further includes zeolite seeds.

15. The process of claim 1 , wherein said temperature sufficient to crystallize said zeolite Y on said pre-shaped particles is 70-120° Celsius, and said time sufficient to crystallize said zeolite Y on said pre-shaped particles is from 2 hours to 1 week.

16. The process of claim 1 , wherein said zeolite-containing fixed bed catalyst is treated to remove sodium ions from said crystallized zeolite Y.

17. The process of claim 15 , wherein said reactive aluminum-containing component is metakaolin.

18. The process of claim 17 , wherein said one or more matrix-forming components comprise at least one of kaolin calcined through exotherm of the kaolin to spinel, mullite, or alumina.

Assignees

• Basf Corp

Inventors

• Gao Xingtao
• Stockwell David
• Smith Gary M

Classifications

• B01J2235/15

  X-ray diffraction · CPC title

• B01J2235/30

  Scanning electron microscopy; Transmission electron microscopy · CPC title

• B01J29/084 Primary

  Y-type faujasite · CPC title

• B01J29/064

  containing iron group metals, noble metals or copper · CPC title

• B01J35/026

  Operations & Transport · mapped topic