# US 5,346,875 A · Method of manufacturing fluid catalytic cracking catalyst

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- Number: US 5,346,875 A
- Document ID: US5346875A
- Status: Granted
- Kind: A
- Application number: 08/095,612
- Filed: 1993-07-21
- Granted: 1994-09-13
- Earliest claimed: 1993-07-21
- Assignees: Exxon Research & Engineering Co.
- Inventors: William A. Wachter; Stuart L. Soled
- Web page: https://patentgrep.com/patent/US5346875A

## CPC

- C10G 11/05: Crystalline alumino-silicates, e.g. molecular sieves
- B01J 29/084: {Y-type faujasite}
- B01J 35/38: Abrasion or attrition resistance
- B01J 35/615: {100-500 m2/g}
- B01J 35/633: {less than 0.5 ml/g}
- B01J 35/70: characterised by their crystalline properties, e.g. semi-crystalline (catalysts comprising carbon B01J21/18; molecular sieves B01J29/00)
- B01J 2229/42: Addition of matrix or binder particles
- 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
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS

## Abstract

This invention is to a method of manufacturing fluid catalytic cracking catalyst. In particular, the invention is to a method of manufacturing a catalytic cracking catalyst which incorporates a step of matching the isoelectric point of each component of the catalyst framework structure to the pH of an inorganic oxide sol used to form the matrix component of the catalyst. The resulting catalyst product has a controlled pore size and is extremely durable.

## Claims

### Claim 1

A method of manufacturing a catalytic cracking catalyst comprising:
providing a framework structure having a measurable isoelectric point, wherein the framework structure is at least one component selected from the group consisting of a crystalline tetrahedral framework oxide component, an active porous inorganic oxide catalyst framework component, and an inert catalyst framework component;
providing an inorganic oxide sol having a measurable pH;
measuring the isoelectric point of each component of the framework structure;
measuring the pH of the inorganic oxide sol;
matching the isoelectric point of each component of the framework structure to the pH of the inorganic oxide sol;
combining in solution the inorganic oxide sol with each component of the framework structure; and
drying the combined solution.

### Claim 2 (depends on 1)

The method of claim 1, wherein the inorganic oxide sol is a silica sol or alumina sol.

### Claim 3 (depends on 1)

The method of claim 1, wherein the inorganic oxide sol is provided by reacting a solution of sodium silicate with a solution of aluminum sulfate and sulfuric acid.

### Claim 4 (depends on 1)

The method of claim 1, wherein the inorganic oxide sol is an aluminum chlorhydrol sol.

### Claim 5 (depends on 1)

The method of claim 1, wherein the inorganic oxide sol has a pH of about 2-10.

### Claim 6 (depends on 1)

The method of claim 1, wherein the framework structure includes at least one component selected from the group consisting of an active porous inorganic oxide catalyst framework component and an inert catalyst framework component, and the isoelectric point of the framework structure component is matched to within about 2 pH units of the inorganic oxide sol.

### Claim 7 (depends on 1)

The method of claim 1, wherein the framework structure includes the tetrahedral framework oxide component and the isoelectric point of the tetrahedral framework oxide component is matched to within about 0.5 pH units of the inorganic oxide sol.

### Claim 8 (depends on 1)

The method of claim 1, wherein the framework structure comprises a crystalline tetrahedral framework oxide component of silicon and aluminum having a Si/Al surface ratio of at least 0.5/1 and a Si/Al bulk ratio of at least about 2/1.