Patent ID: 6362128
Filing Date: 2002-03-26
Classification: B01J,C07C

Abstract:
Process for manufacture of an attrition resistant catalyst having an oxide-rich surface layer comprising the steps of:a) forming a slurry comprising; i) catalyst, catalyst precursor or catalyst support particles, ii) a colloidal oxide sol wherein oxide particles in the sol have an average particle size greater than 10 nm; and, iii) a solution of a solvent and solute wherein the solute is selected from the group consisting essentially of a precursor of said oxide-rich surface layer with average particle size no greater than 5 nm, a colloidal oxide sol wherein oxide particles in the sol have an average size below 10 nm, and mixtures thereof, wherein 50 to 95 percent of the weight of the oxide-rich surface layer is derived from said colloidal oxide sol (ii) and remaining 50 to 5 percent of the weight of the oxide-rich surface layer is derived from the solute of said solution (iii), and wherein 3 to 15 percent weight of the attrition resistant catalyst is from the oxide-rich surface layer and the remainder is from said catalyst, catalyst precursor or catalyst support particles (i); b) spray drying the slurry from step (a) to form porous microspheres of the attrition resistant catalyst; and c) calcining the spray dried microspheres of step (b) to produce attrition resistant catalyst.