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US 4,582,815 AGranted
Extrusion of silica-rich solids
AssigneeMobil Oil Corporation
InventorEmmerson Bowes
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AssigneeMobil Oil Corporation
InventorEmmerson Bowes
Estimating the term…
The present invention is directed to a method for extruding silica-rich solids. The method comprises mixing silica-rich solids with water in an alkali metal base or basic salt followed by mulling and extruding and subsequently drying the extrudate whereby the dried extrudate has a crush strength superior to that of the prior art. The silica-rich solids can be silica alone, zeolite alone or a mixture thereof. The alkali metal can be sodium hydroxide. The invention is also directed to a product which has a special attribute in that they have sufficient integrity to withstand treatments with acids so that it is now possible to steam, acid extract, or calcine such extrudates. The catalyst can be used in hydrocarbon conversions such as hydrocracking, isomerization, hydrogenation, dehydrogenation, polymerization, reforming, catalytic cracking, or catalytic hydrocracking. The invention also relates to a method for extruding silica-rich solids which comprises substituting an alkali metal for hydrogen in silanol groups on outside surfaces of the silica-rich solids, mulling and extruding the substituted silica-rich solids and drying the extrudate whereby the dried extrudate has a crush strength superior to that of the prior art. The invention is also directed to a method for increasing the silica to metal ratio of a zeolite. The method comprises mixing silica-rich solids with water and an alkali metal base or basic salt, mulling and extruding the silica-rich mixture, drying the extrudate, ion exchanging the extrudate and recovering the catalyst which can be substantially metal free.
A method for extruding silica-rich solids which comprises mixing the silica-rich solids with water and an alkali metal base or basic salt followed by mulling and extruding wherein the amount of water added being sufficient to have a total solids content of from 25 to 75 weight percent, the alkali metal compound being added in an amount of from 0.25 to 10 weight percent on a dry basis based on the total solids calculated as sodium hydroxide equivalent, and drying and calcining the extrudate, whereby the dried and calcined extrudate has a crush strength superior to that of the prior art.
A method of extruding a mixture of silica and crystalline aluminosilicate solids which comprises mixing silica and ZSM-5 zeolite with water and sodium hydroxide followed by mulling and extruding, wherein the amount of water added being sufficient to have a total solids content of from 25 to 75 weight percent, the sodium hydroxide being added in an amount from 0.25 to 10 weight percent on a dried basis based on the total solids calculated as sodium hydroxide equivalent, and drying and calcining the extrudate whereby the extrudate has a crush strength of at least 4 pounds for a 1/8 inch length having a diameter of 1/16 inch.
A method for extruding a mixture of silica and a crystalline aluminosilicate which comprises mixing silica and zeolite Y with water and sodium hydroxide followed by mulling and extruding, wherein the amount of water added being sufficient to have a total solids content of from 25 to 75 weight percent, the sodium hydroxide being added in an amount from 0.25 to 10 weight percent on a dried basis based on the total solids calculated as sodium hydroxide equivalent, and drying and calcining the extrudate whereby the extrudate has a crush strength of at least 4 pounds for a 1/8 inch length having a diameter of 1/16 inch.
A method for increasing the silica-to-alumina ratio of a zeolite, comprising:
The method according to claim 45, further comprising ion-exchanging the recovered catalyst.
The method according to claim 46, wherein ammonium, rare earth or other metals are used to ion-exchange the recovered catalyst.
A method for increasing the silica-to-alumina ratio of zeolite Y, comprising:
The support according to claim 50, containing a hydrogenation component.
The support according to claim 51, wherein the hydrogenation component being platinum, palladium, cobalt, molybdenum, iron or mixtures thereof.
The support according to claim 52, wherein the hydrogenation component being an oxide or salt.
The method according to claim 54, wherein the catalytic material being platinum, palladium, cobalt, molybdenum, iron or mixtures thereof.
The method according to claim 57, wherein the refractory oxides being alumina, zirconia, magnesia or titania.
A method for extruding silica-rich solids, which comprises substituting an alkali metal for hydrogen in silanol groups on outside surfaces of the silica-rich solids, mulling and extruding the substituted silica-rich solids and drying the extrudate, whereby the dried extrudate has a crush strength superior to that of the prior art.
A method for extruding silica-rich solids, which comprises mixing the silica-rich solids with water in an alkali metal base or basic salt followed by mulling and extruding wherein the amount of water added being sufficient to have a solids content of from 25 to 75 wt. %, the alkali metal compound being added in an amount from 0.25 to 10 wt. % on a dry basis based on the total solids calculated as sodium hydroxide equivalent, drying the extrudate, and neutralizing the base used as an extrusion aid after drying and prior to calcining the extrudate, whereby the calcined extrudate has a crush strength superior to that of the prior art.
Dependencies are inferred from the claim text.