# US 2023/0264175 A1 · Fcc catalyst prepared by a process involving more than one silica material

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- Number: US 2023/0264175 A1
- Document ID: US20230264175A1
- Status: Published application
- Kind: A1
- Application number: 17/821,827
- Filed: 2022-08-24
- Published: 2023-08-24
- Earliest claimed: 2018-01-12
- Assignees: Ketjen Limited Liability Company
- Applicants: Albemarle Corporation
- Inventors: Amir SABAHI; Andrew LOEBL; Sandra GAVALDA; Julie FRANCIS; Eswaramoorthi IYYAMPERUMAL; Min LI; Andrea MARCINKOVA
- Web page: https://patentgrep.com/patent/US20230264175A1

## CPC

- B01J 21/12: Silica and alumina
- B01J 21/04: Alumina
- B01J 21/16: Clays or other mineral silicates
- B01J 29/04: having base-exchange properties, e.g. crystalline zeolites {(B01J29/005 takes precedence)}
- B01J 29/084: {Y-type faujasite}
- B01J 29/40: of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively
- B01J 29/65: of the ferrierite type, e.g. types ZSM-21, ZSM-35 or ZSM-38, as exemplified by patent documents US4046859, US4016245 and US4046859, respectively
- B01J 29/7007: {Zeolite Beta}
- B01J 35/40: characterised by dimensions, e.g. grain size (in a colloidal state B01J35/23; crystallite size B01J35/77)
- B01J 37/0009: {Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst}
- B01J 37/0018: {Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat)}
- B01J 37/0045: {Drying a slurry, e.g. spray drying}
- B01J 37/04: Mixing {(B01J37/0009, B01J37/0018 take precedence)}
- B01J 37/088: {Decomposition of a metal salt}
- C10G 11/02: characterised by the catalyst used
- C10G 11/05: Crystalline alumino-silicates, e.g. molecular sieves
- C10G 11/18: according to the "fluidised-bed" technique
- B01J 2029/081: {Increasing the silica/alumina ratio; Desalumination}
- C10G 2300/70: Catalyst aspects
- Y02P 20/52: using catalysts, e.g. selective catalysts
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- C10G: CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION (cracking to hydrogen or synthesis gas C01B; cracking or pyrolysis of hydrocarbon gases to individual hydrocarbons or mixtures thereof of definite or specified constitution C07C; cracking to cokes C10B); RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

Process for the preparation of a catalyst and a catalyst comprising more than one silica 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 10 to about 45 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 colloidal silica, greater than about 0 to about 30 wt % silica from ammonia stabilized or lower sodium colloidal silica, and the balance clay and the process for making the same. This process results in attrition resistant catalysts with good performance.

## Claims

### Claim 1

An FCC catalyst composition comprising about 5 to about 60 wt % one or more zeolites, about 10 to about 45 wt % quasicrystalline boehmite, about 0 to about 35 wt % microcrystalline boehmite, greater than 0 wt % to about 15 wt % silica from sodium stabilized colloidal silica, greater than 0 wt % to about 30 wt % silica from ammonia stabilized or lower sodium colloidal silica, and the balance clay.

### Claim 2 (depends on 1)

The FCC Catalyst of claim 1 with greater than 0.5 wt % to about 10 wt % silica from sodium stabilized colloidal silica.

### Claim 3 (depends on 2)

The FCC Catalyst of claim 2 with greater than 1 wt % to about 8 wt % silica from sodium stabilized colloidal silica.

### Claim 4 (depends on 1)

The FCC Catalyst of claim 1 with greater than 1 wt % to about 25 wt % silica from ammonia stabilized or lower sodium colloidal silica.

### Claim 5 (depends on 4)

The FCC Catalyst of claim 4 with greater than 5 wt % to about 20 wt % silica from ammonia stabilized or lower sodium colloidal silica.

### Claim 6

An FCC catalyst made from process comprising:
a. Adding clay, boehmite, and a first sodium stabilized 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 a second silica that is either an ammonia stabilized or sodium stabilized colloidal silica, wherein the sodium content is less than the first sodium stabilized 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.
wherein the catalyst comprises about 5 to about 60 wt % one or more zeolites, about 10 to about 45 wt % quasicrystalline boehmite, about 0 to about 35 wt % microcrystalline boehmite, greater than 0 to about 15 wt % of the first silica, greater than 0 to about 30 wt % of the second silica, and the balance clay.

### Claim 7 (depends on 6)

The FCC catalyst of claim 6 further comprising adding greater than 0.5 wt % to about 10 wt % of the first sodium stabilized colloidal silica.

### Claim 8 (depends on 6)

The FCC catalyst of claim 6 further comprising adding greater than 1 wt % to about 25 wt % of the second silica.

### Claim 9 (depends on 6)

The FCC catalyst of claim 6 further comprising adding greater than 5 wt % to about 20 wt % of the second silica.

### Claim 10 (depends on 1, 2, 3, 4, 5, 6, 7, 8, 9)

A process for producing more liquid components from a hydrocarbon feedstock, said process comprising the steps of:
a. providing an FCC catalyst composition of claims 1-9;
b. contacting the FCC particulate catalyst composition with the hydrocarbon feedstock, at one or more temperatures in the range of about 400 to about 650° C., with a dwell time in the range of about 0.5 to about 12 seconds; such that propylene is formed with a conversion efficiency in the range of about 4 to about 20 wt %, based upon the weight of the hydrocarbon feedstock.