Patent GB-1315553-A (GB)
Title: Hydrocarbon conversion catalysts and their production
IPC: B01J29/06
Filed: 1970-07-27
Abstract: 1315553 Zeolite-promoted hydrocarbon conversion catalyst W R GRACE & CO 27 July 1970 [28 July 1969] 36336/70 Heading B1E Crystalline aluminosilicate zeolite-promoted hydrocarbon conversion catalyst is prepared by a process which comprises shaping a mixture containing (a) finely divided zeolite, (b) an alumina sol comprising aluminium hydroxide and aluminium trichloride in relative amounts such as to provide an Al(OH) 3 / AlCl 3  molar ratio of between 4.5 to 7.0, (c) clay and, optionally, (d) artificial amorphous material selected from silica, alumina and silica-alumina composite, drying the shaped mixture, for example at a temperature of from 200 to 300‹F, and calcining the dried mixture, for example at a temperature of from 700 to 1700‹F. The mixture may be shaped by extruding or pelleting into beads for fixed bed or moving bed use or by spray drying into microspheres for fluidised bed use. The zeolite, which may constitute (on a dry solids bases) from 5 to 20 weight per cent of the mixture, may be a faujasite having a uniform pore dimension of from 6 to 15 Angstroms, for example a synthetic faujasite having a SiO 2 / Al 2 O 3  mole ratio of from 2.5 to 6 and a Na 2 O content of less than 1 weight per cent. The alumina sol may constitute (calculated as Al 2 O 3  on a dry solids basis) from 5 to 15 weight per cent of the mixture. The clay, which may constitute (on a dry solids basis) from 50 to 80 weight per cent of the mixture, may comprise kaolin or helloysite, either in its native state or thermally or chemically modified. Alumina may constitute from 10 to 30 weight per cent of the artificial amorphous material which may constitute up to 30 weight per cent of the mixture. The catalyst additionally may comprise metal selected from Groups VI to VIII; specified metals are molybdenum, cobalt and platinum. As exemplified, alumina sol having an Al(OH) 3 /RlCl 3  molar ratio of 6.746 is prepared by heating aluminium metal with aqueous molar hydrogenchloride (Example 1), such alumina sol being used in the preparation of catalyst containing 5.5 weight per cent zeolite, 51.5 weight per cent clay, 10 weight per cent alumina and 33 weight per cent artificial silica-alumina composite by dry mixing kaolin and a milled commercial catalyst containing calcined rare earth metalexchanged zeolite X, clay and artificial silicaalumina composite having an alumina content of 26 weight per cent, adding the alumina sol to the resulting mixture, milling the resulting composition to a plastic consistency, extending the milled composition, drying the resulting extrudates at 275‹F and calcining the dried extrudates at 1200‹F (Example 2), of catalyst containing 10 weight per cent zeolite, 82 weight per cent clay and 8 weight per cent alumina by dry mixing calcined rare earth metalexchanged zeolite containing 0.3 weight per cent Na 2 O, kaolin and Avery clay, compositing the resulting mixture with the alumina sol, forming the resulting composition into beads, drying the beads at 250‹F and calcining the dried beads at 1200‹F (Example 3) and of catalyst containing 12 weight per cent zeolite, 77 weight per cent clay and 11 weight per cent alumina by dry mixing calcined rare earth metal-exchanged zeolite Y, kaolin and Avery clay, compositing the resulting mixture with the alumina sol, slurrying the resulting composition in water containing tetrasodium pyrophosphate, homogenizing the slurry by passage through a colloid mill, spray drying the homogenized slurry at 275-300‹F and calcining the resulting microspheroidal product at 1000‹F (Example 4).