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Structurally enhanced cracking catalysts

A catalyst, fluidized catalytic cracking technology, applied in the direction of physical/chemical process catalyst, molecular sieve catalyst, catalyst activation/preparation, etc., can solve the problem that zeolite microsphere catalyst is not considered as a problem, and no diffusion limitation is found.

Inactive Publication Date: 2004-05-19
ENGELHARD CORP
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

[0020] Although the present assignee has prepared zeolite microspheres with increased zeolite content and increased activity by increasing the macroporosity of the spray-dried microsphere zeolite precursor, since no diffusion limitation, the porosity of the formed zeolite microsphere catalysts has not been considered as an issue in the past

Method used

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Examples

Experimental program
Comparison scheme
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Embodiment 1

[0072] Prepare microspheres containing: 30 parts metakaolin (MK), 20 parts wet media milled Ansilex 93 TM , 20 parts of HiOpaque calcined to above 1050°C after media grinding TM Pigment and 30 parts of NuSurf directly calcined to above 1050°C TM For pigments, the microspheres are milled and jet milled. To this mixture of calcined kaolin was added 15 parts from N brand  Sodium silicate SiO 2 . The microspheres are not acid neutralized. Metakaolin source is Metamax TM (a ground powder), 55% solids in tap water, visbroken with 3 ml of Colloid 211 surfactant (Viking Industries, Atlanta, GA) per kg of calcined kaolin. An air driven Cowles mixer was used to add the dry kaolin in batches to the water already containing the surfactant. Add the kaolin to the water more slowly as the mixture thickens. Forms a very expansive slurry, but the viscosity can be reduced by continuous mixing. Gradual addition of kaolin and continuous mixing for 45 minutes or more resulted in a slurry...

Embodiment 2

[0080] Prepare microspheres containing: 30 parts MK, 20 parts wet media milled Ansilex 93 TM , 20 parts of NuSurf calcined to above 1050°C after ball milling TM Pigments and 30 parts of NuSurf prepared by grinding hydrated pigments and then calcining above 1050°C TM Aggregates of mullite, plus 15 parts from brand N  Sodium silicate SiO 2 . The microspheres were neutralized with acid.

[0081] MK source is second batch of Metamax visbroken with C211 dispersant at 55% solids TM . Ansilex 93 Media Milled TM Same as the slurry prepared in Example 1.

[0082] Ball milled NuSurf was prepared by calcining hydrated exfoliated pigments in cordierite discs at 2350°C for four hours in a preheated furnace TM Mullite. The material was crushed, ground and then wet ball milled at 46% solids. The final product was a low viscosity slurry with 92% < 2 [mu]m (measured by laser light scattering).

[0083] NuSurf in this example TM The preparation of mullite was aimed at ensuring the ...

Embodiment 3

[0089] A preparation containing 30 parts MK and 70 parts NuSurf TM Microspheres of mullite aggregates with unusually high pore volume and unusually wide macropores. NuSurf TM Mullite aggregates were prepared by grinding and calcining to 1050°C. Calcined kaolin mixture and 15 parts from N brand  Sodium silicate SiO 2 Spray dry together. The microspheres were neutralized with acid.

[0090] MK source is the Metamax of reduced viscosity in embodiment 2 TM of the same batch. NuSurf TM The mullite (aggregate) was also the same batch that was visbroken in Example 2. The two slurries were maintained in suspension by rolling in closed tanks until mixing was required.

[0091] The slurries for spray drying were obtained by mixing the two component slurries in a Cowles mixer in a ratio of 30:70 and 4.00 kg dry total of the main ingredient as described above. Add 2.14kg N brand directly to the slurry Sodium silicate to form a 48% solids mixture that is fluid enough to be pum...

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Abstract

A zeolite microsphere FCC catalyst with a novel morphology comprising a macroporous porous matrix and a free coating of crystalline zeolite on the matrix pore walls. The catalyst is formed from microspheres comprising metakaolin and kaolin calcined to undergo its exothermic process, wherein the kaolin calcined to undergo its exothermic process is made from kaolin having a high pore volume. The kaolin with high pore volume may be ground fine kaolin or ground kaolin with an initial slurry point of less than 57% solids.

Description

[0001] Cross References to Related Applications [0002] This application is a continuation-in-part of US Patent Application Serial No. 09 / 667,677, filed September 22,2000. background of the invention [0003] The present invention relates to a novel liquid catalytic cracking catalyst comprising microspheres containing Y-faujasite, having a particularly high activity and other favorable properties, a process for the preparation of the catalyst and the use of the catalyst in the cracking of petroleum feedstocks, especially at short residence time. Time craft use. [0004] Since the 1960s, most commercial liquid catalytic cracking catalysts have contained zeolites as active components. The catalyst takes the form of small particles called "microspheres", which contain active zeolitic and non-zeolitic components. The non-zeolitic component is often referred to as the matrix for the zeolitic component in the catalyst. The non-zeolitic components play a number of important roles...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): B01J21/16B01J29/08B01J35/00B01J35/10B01J37/00B01J37/02C10G11/05C10G11/18
CPCB01J21/16B01J35/002B01J37/0246B01J2229/64C10G2400/02B01J35/10B01J2229/42C10G11/05B01J29/084B01J37/0045B01J35/615B01J35/633B01J35/66B01J35/38B01J2235/15B01J35/70B01J2235/30B01J35/30
Inventor D·M·斯托克韦尔R·P·布朗S.H.布朗
Owner ENGELHARD CORP
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