Production of attrition-resistant catalyst binders through use of delaminated clay

A process for preparing attrition-resistant clay/phosphate/catalyst particles, said process comprising:

• (1) preparing a clay slurry having from about 20 to about 50 weight percent delaminated and calcined clay;
• (2) adjusting the pH of the clay slurry to a level which places an aluminum component of the clay in an oxidation state which is conducive to formation of an ammonium aluminum phosphate complex;
• (3) providing the clay slurry with ammonium ions and with phosphate ions by introducing therein an ammonium phosphate compound selected from the group consisting of monoammonium acid orthophosphate, diammonium acid ortho phosphate and triammonium ortho-phosphate and thereby producing a clay slurry having ammonium aluminum phosphate complex units in a quantity such that the attrition-resistant binder particles ultimately made from the slurry will be comprised of from about 1 to about 20 weight percent phosphate and from about 80 to about 99 weight percent clay;
• (4) mixing catalyst particles into the clay/phosphate-containing compound slurry to form a clay/phosphate-containing compound/catalyst particle slurry having a quantity of catalyst particles which is such that the attrition-resistant clay/phosphate/catalyst particles made from said slurry will comprise from about 3 to about 60 weight percent of said particles;
• (5) drying the slurry to produce solid particles;
• and
• (6) calcining said solid particles in order to produce attrition-resistant clay/phosphate/catalyst particles.

A process for preparing attrition-resistant binder particles, said process comprising:

• (1) preparing a clay slurry having from about 20 to about 50 weight percent delaminated and calcined clay;
• (2) bringing the clay slurry to a pH of from about 1.0 to about 3.0;
• (3) mixing a phosphate-containing compound into the clay slurry to form a clay/phosphate-containing compound slurry having a quantity of the phosphate-containing compound which is such that the attrition-resistant binder particles ultimately made from the clay/phosphate-containing compound slurry will be comprised of from about 2 to about 20 weight percent phosphate and from about 80 to about 98 weight percent clay;
• (4) drying the clay/phosphate-containing compound slurry to produce solid particles;
• and
• (5) calcining said solid particles in order to produce attrition-resistant binder particles.

A process for preparing attrition-resistant clay/phosphate/catalyst particles, said process comprising:

• (1) preparing a clay slurry having from about 20 to about 50 weight percent delaminated and calcined clay;
• (2) bringing the clay slurry to a pH of from about 1.0 to about 3.0;
• (3) mixing a phosphate-containing compound into the clay slurry to form a clay/phosphate-containing compound slurry which has sufficient phosphate to form a clay/phosphate-containing compound slurry having a pH from about 4.0 to about 8.0 and provide a quantity of phosphate which is such that the clay/phosphate/catalyst particles ultimately made from said slurry will be comprised of from about 2 to about 20 weight percent phosphate;
• (4) mixing catalyst particles into the clay/phosphate-containing compound slurry to form a clay/phosphate-containing compound/catalyst particle slurry having a quantity of catalyst particles which is such that the attrition-resistant clay/phosphate/catalyst particles made from said slurry will comprise from about 3 to about 60 weight percent of said particles;
• (5) drying said clay/phosphate-containing compound/catalyst particle slurry to produce solid particles;
• and
• (6) calcining said solid particles to produce attrition-resistant clay/phosphate/catalyst particles which comprise from about 3 to about 60 weight percent of the catalyst particles, from about 2 to about 20 weight percent of phosphate and from about 20 to about 95 weight percent clay.

A process for preparing attrition-resistant clay/phosphate/catalyst particles, said process comprising:

• (1) preparing a clay slurry having from about 20 to about 50 weight percent delaminated and calcined clay;
• (2) bringing the clay slurry to a pH of from about 14.0 to about 10.0;
• (3) mixing a phosphate-containing compound into the clay slurry to form a clay/phosphate-containing compound slurry having a quantity of phosphate which is such that the attrition-resistant binder particles ultimately made from the slurry will be comprised of from about 2 to about 20 weight percent of phosphate and from about 80 to about 98 weight percent clay;
• (4) drying the clay/phosphate-containing slurry to produce solid particles;
• (5) calcining said solid particles in order to produce attrition-resistant binder particles.

A process for preparing attrition-resistant clay/phosphate/catalyst particles, said process comprising:

• (1) preparing a clay slurry having from about 20 to about 50 weight percent delaminated and calcined clay;
• (2) bringing the clay slurry to a pH of from about 14.0 to about 10.0;
• (3) mixing a phosphate-containing compound and an auxiliary binder material (which collectively constitute an auxiliary binder component of the attrition-resistant binder particles) into the clay slurry to form a clay/phosphate-containing compound/auxiliary binder material slurry having a quantity of auxiliary binder component which is such that the attrition-resistant binder particles ultimately made from the clay/phosphate-containing compound/auxiliary binder material slurry will be comprised of from about 5.25 to about 60 weight percent of the auxiliary binder component and from about 40 to about 94.75 weight percent of a clay component and wherein said auxiliary binder component contains an amount of phosphate which is sufficient to provide the attrition-resistant binder particles with at least about 0.25 weight percent phosphate;
• (4) drying the clay/phosphate/auxiliary binder material slurry to produce solid particles;
• and
• (5) calcining said solid particles to produce attrition-resistant binder particles.

A process for preparing attrition-resistant binder particles, said process comprising:

• (1) preparing a clay slurry having from about 20 to about 50 weight percent delaminated and calcined clay;
• (2) bringing the clay slurry to a pH of from about 14.0 to about 10.0;
• (3) mixing a phosphate-containing compound, an auxiliary binder material (which will collectively constitute an auxiliary binder component of the attrition-resistant binder particles) and an acid into the clay slurry which are collectively sufficient to form a clay/phosphate-containing compound/auxiliary binder material/acid slurry having a quantity of phosphate which is such that the attrition-resistant binder particles ultimately made from said slurry will be compressed of from about 5.25 to about 40 weight percent of an auxiliary binder component and from about 40 to about 94.75 weight percent clay and wherein said auxiliary binder component contains sufficient phosphate to make the attrition-resistant binder particles comprise at least about 0.25 weight percent phosphate;
• (4) drying the clay/phosphate-containing compound slurry to produce solid particles;
• and
• (5) calcining said solid particles to produce attrition-resistant binder particles.

A process for preparing attrition-resistant clay/phosphate/auxiliary binder material/catalyst particles, said process comprising:

• (1) preparing a clay slurry having from about 20 to about 50 weight percent delaminated and calcined clay;
• (2) bringing the clay slurry to a pH of from about 10.0 to about 14.0;
• (3) mixing a phosphate-containing compound and an auxiliary binder material (which will collectively constitute an auxiliary binder component of the attrition-resistant clay/phosphate/auxiliary binder material/catalyst matrix particles) into the clay slurry in an amount which is such that the clay/phosphate/auxiliary binder material/catalyst particles produced from said slurry will be comprised of from about 5.0 to about 40 weight percent of the auxiliary binder component and wherein said auxiliary binder component contains an amount of phosphate which is sufficient to provide the attrition-resistant clay/phosphate/auxiliary binder material/catalyst particles with at least about 0.25 weight percent phosphate;
• (4) mixing a sufficient amount of catalyst particles into the clay/phosphate-containing/auxiliary binder material slurry to form a clay/phosphate-containing compound/auxiliary binder material/catalyst particle slurry which has a quantity of catalyst particles which is such that the attrition-resistant clay/phosphate/auxiliary binder material/catalyst matrix particles ultimately made from this process will comprise from about 3 to about 60 weight percent of said catalyst particles;
• (5) drying said clay/phosphate compound/catalyst particle slurry to produce solid particles;
• (6) calcining the solid particles to produce attrition-resistant clay/phosphate/auxiliary binder material/catalyst particles which comprise between about 3 and about 60 percent by weight of the catalyst particles, between about 20 and about 91.75 weight percent clay and between about 5.25 and about 40 percent auxiliary binder component and wherein said auxiliary binder component contains sufficient phosphate-containing compound to make the attrition-resistant clay/phosphate/auxiliary binder material/catalyst particles comprise at least about 0.25 weight percent phosphate.

Attrition-resistant binder particles, made by a process comprising:

• (1) preparing a clay slurry having from about 20 to about 50 weight percent delaminated and calcined clay;
• (2) adjusting the pH of the clay slurry to a level which places an aluminum component of the clay in an oxidation state which is conducive to formation of an ammonium/aluminum/phosphate complex;
• (3) providing the clay slurry with ammonium ions and with phosphate ions by introducing therein an ammonium phosphate compound selected from the group consisting of monoammonium acid orthophosphate, diammonium acid ortho phosphate and triammonium ortho-phosphate and thereby producing a clay slurry having ammonium aluminum phosphate complex units in a quantity such that the attrition-resistant binder particles ultimately made from the slurry will be comprised of from about 1 to about 20 weight percent phosphate and from about 80 to about 99 weight percent clay;
• (4) drying the slurry to produce solid particles;
• and
• (5) calcining said solid particles in order to produce attrition-resistant binder particles.

Attrition-resistant clay/phosphate/catalyst particles, made by a process comprising:

• (1) preparing a clay slurry having from about 20 to about 50 weight percent clay delaminated and calcined clay;
• (2) adjusting the pH of the clay slurry to a level which places an aluminum component of the clay in an oxidation state which is conducive to formation of an ammonium aluminum phosphate complex;
• (3) providing the clay slurry with ammonium ions and with phosphate ions by introducing therein an ammonium phosphate compound selected from the group consisting of monoammonium acid orthophosphate, diammonium acid ortho phosphate and triammonium ortho-phosphate and thereby producing a clay slurry having ammonium aluminum phosphate complex units in a quantity such that the attrition-resistant binder particles ultimately made from the slurry will be comprised of from about 1 to about 20 weight percent phosphate and from about 80 to about 99 weight percent clay;
• (4) mixing catalyst particles into the clay/phosphate-containing compound slurry to form a clay/phosphate-containing compound/catalyst particle slurry having a quantity of catalyst particles which is such tat the attrition-resistant clay/phosphate/catalyst particles made from said slurry will comprise from about 3 to about 60 weight percent of said particles;
• (5) drying the slurry to produce solid particles;
• and
• (6) calcining said solid particles in order to produce attrition-resistant clay/phosphate/catalyst particles.

Attrition-resistant binder particles, made by a process comprising:

• (1) preparing a clay slurry having from about 20 to about 50 weight percent delaminated and calcined clay;
• (2) bringing the clay slurry to a pH of from about 1.0 to about 3.0;
• (3) mixing a phosphate-containing compound into the clay slurry to form a clay/phosphate-containing compound slurry having a quantity of the phosphate-containing compound which is such that the attrition-resistant binder particles ultimately made from the clay/phosphate-containing compound slurry will be comprised of from about 2 to about 20 weight percent phosphate and from about 80 to about 98 weight percent clay;
• (4) drying the clay/phosphate-containing compound slurry to produce solid particles;
• and
• (5) calcining said solid particles in order to produce attrition-resistant binder particles.

Attrition-resistant clay/phosphate/catalyst particles, made by a process comprising:

• (1) preparing a clay slurry having from about 20 to about 50 weight percent delaminated and calcined clay;
• (2) bringing the clay slurry to a pH of from about 1.0 to about 3.0;
• (3) mixing a phosphate-containing compound into the clay slurry to form a clay/phosphate-containing compound slurry which has sufficient phosphate to form a clay/phosphate-containing compound slurry having a pH from about 4.0 to about 8.0 and provide a quantity of phosphate which is such that the clay/phosphate/catalyst particles ultimately made from said slurry will be comprised of from about 2 to about 20 weight percent phosphate;
• (4) mixing catalyst particles into the clay/phosphate-containing compound slurry to form a clay/phosphate-containing compound/catalyst particle slurry having a quantity of catalyst particles which is such that the attrition-resistant clay/phosphate/catalyst particles made from said slurry will comprise from about 3 to about 60 weight percent of said particles;
• (5) drying said clay/phosphate-containing compound/catalyst particle slurry to produce solid particles;
• and
• (6) calcining said solid particles to produce attrition-resistant clay/phosphate/catalyst particles which comprise from about 3 to about 60 weight percent of the catalyst particles, from about 2 to about 20 weight percent of phosphate and from about 20 to about 95 weight percent clay.

Attrition-resistant clay/phosphate/catalyst particles, made by a process comprising:

• (1) preparing a clay slurry having from about 20 to about 50 weight percent delaminated and calcined clay;
• (2) bringing the clay slurry to a pH of from about 14.0 to about 10.0;
• (3) mixing a phosphate-containing compound into the clay slurry to form a clay/phosphate-containing compound slurry having a quantity of phosphate which is such that the attrition-resistant binder particles ultimately made from the slurry will be comprised of from about 2 to about 20 weight percent of phosphate and from about 80 to about 98 weight percent clay;
• (4) drying the clay/phosphate-containing slurry to produce solid particles;
• (5) calcining said solid particles in order to produce attrition-resistant binder particles.

Attrition-resistant clay/phosphate/catalyst particles, made by a process comprising:

• (1) preparing a clay slurry having from about 20 to about 50 weight percent delaminated and calcined clay;
• (2) bringing the clay slurry to a pH of from about 14.0 to about 10.0;
• (3) mixing a phosphate-containing compound and an auxiliary binder material (which collectively constitute an auxiliary binder component of the attrition-resistant binder particles) into the clay slurry to form a clay/phosphate-containing compound/auxiliary binder material slurry having a quantity of auxiliary binder component which is such that the attrition-resistant binder particles ultimately made from the clay/phosphate-containing compound/auxiliary binder material slurry will be comprised of from about 5.25 to about 60 weight percent of the auxiliary binder component and from about 40 to about 94.75 weight percent of a clay component and wherein said auxiliary binder component contains an amount of phosphate which is sufficient to provide the attrition-resistant binder particles with at least about 0.25 weight percent phosphate;
• (4) drying the clay/phosphate/auxiliary binder material slurry to produce solid particles;
• and
• (5) calcining said solid particles to produce attrition-resistant binder particles.

Attrition-resistant binder particles, made by a process comprising:

• (1) preparing a clay slurry having from about 20 to about 50 weight percent delaminated and calcined clay;
• (2) bringing the clay slurry to a pH of from about 14.0 to about 10.0;
• (3) mixing a phosphate-containing compound, an auxiliary binder material (which will collectively constitute an auxiliary binder component of the attrition-resistant binder particles) and an acid into the clay slurry which are collectively sufficient to form a clay/phosphate-containing compound/auxiliary binder material/acid slurry having a quantity of phosphate which is such that the attrition-resistant binder particles ultimately made from said slurry will be comprised of from about 5.25 to about 40 weight percent of an auxiliary binder component and from about 40 to about 94.75 weight percent clay and wherein said auxiliary binder component contains sufficient phosphate to make the attrition-resistant binder particles comprise at least about 0.25 weight percent phosphate;
• (4) drying the clay/phosphate-containing compound slurry to produce solid particles;
• and
• (5) calcining said solid particles to produce attrition-resistant binder particles.

Attrition-resistant clay/phosphate/auxiliary binder material/catalyst particles, made by a process comprising:

• (1) preparing a clay slurry having from about 20 to about 50 weight percent delaminated and calcined clay;
• (2) bringing the clay slurry to a pH of from about 10.0 to about 14.0;
• (3) mixing a phosphate-containing compound and an auxiliary binder material (which will collectively constitute an auxiliary binder component of the attrition-resistant clay/phosphate/auxiliary binder material/catalyst matrix particles) into the clay slurry in an amount which is such that the clay/phosphate/auxiliary binder material/catalyst particles produced from said slurry will be comprised of from about 5.0 to about 40 weight percent of the auxiliary binder component and wherein said auxiliary binder component contains an amount of phosphate which is sufficient to provide the attrition-resistant clay/phosphate/auxiliary binder material/catalyst particles with at least about 0.25 weight percent phosphate;
• (4) mixing a sufficient amount of catalyst particles into the clay/phosphate-containing/auxiliary binder material slurry to form a clay/phosphate-containing compound/auxiliary binder material/catalyst particle slurry which has a quantity of catalyst particles which is such that the attrition-resistant clay/phosphate/auxiliary binder material/catalyst matrix particles ultimately made from this process will comprise from about 3 to about 60 weight percent of said catalyst particles;
• (5) drying said clay/phosphate compound/catalyst particle slurry to produce solid particles;
• (6) calcining the solid particles to produce attrition-resistant clay/phosphate/auxiliary binder material/catalyst particles which comprise between about 3 and about 60 percent by weight of the catalyst particles, between about 20 and about 91.75 weight percent clay and between about 5.25 and about 40 percent auxiliary binder component and wherein said auxiliary binder component contains sufficient phosphate-containing compound to make the attrition-resistant clay/phosphate/auxiliary binder material/catalyst particles comprise at least about 0.25 weight percent phosphate.