Structurally enhanced cracking catalysts
AssigneeEngelhard Corporation
InventorsDavid M. Stockwell, Randall P. Brown, Stephen H. Brown
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Abstract
Zeolite microsphere FCC catalysts having a novel morphology comprising a macroporous matrix and crystallized zeolite freely coating the walls of the pores of the matrix. The catalysts are formed from microspheres containing a metakaolin and kaolin calcined through its exotherm, the latter calcined kaolin being derived from a kaolin having a high pore volume. Kaolin having a high pore volume can be a pulverized ultrafine kaolin or a kaolin which has been pulverized to have an incipient slurry point less than 57% solids.
Claims86
A macroporous, zeolite FCC catalyst comprising zeolite crystallized as a layer on the surface of a porous alumina-containing matrix, said zeolite-layered matrix arranged in a configuration to provide macropores in which the zeolite layer is provided on the walls of the macropores.
A fluid catalytic cracking catalyst comprising microspheres containing in-situ crystallized Y-faujasite, and having a mercury porosity of greater than about 0.27 cc/g for pores having diameters in the range of 40-20,000 Å, said microspheres comprising:
- a non-zeolitic, alumina-matrix derived from a kaolin calcined through the characteristic exotherm, said calcined kaolin being derived from a pulverized ultrafine kaolin wherein 90 wt. % of said ultrafine kaolin is in particles having a diameter of less than 2 microns.
A fluid catalytic cracking catalyst comprising microspheres containing in-situ crystallized Y-faujasite, and having a mercury porosity of greater than about 0.27 cc/g for pores having diameters in the range of 40-20,000 Å, said microspheres comprising:
- a non-zeolitic, alumina matrix derived from a calcined alumina, said calcined alumina having an incipient slurry point of less than 57% solids.
A method of making a fluid catalytic cracking catalyst comprising the steps of:
- (a) making microspheres comprising about 25-60% by weight metakaolin, and about 40-75% by weight of a calcined alumina source, said calcined alumina source having an incipient slurry point of less than 57% solids;
- (b) mixing the microspheres of step (a) with one or more sources of sodium silicate and water to obtain an alkaline slurry of said microspheres in an aqueous solution containing sodium silicate;
- and
- (c) heating said alkaline slurry of microspheres to a temperature and for a time sufficient to crystallize Y-faujasite in the microspheres, said Y-faujasite being in the sodium form, and said microspheres obtained from step (c) have a mercury pore volume of greater than 0.27 cc/g for pores having a diameter of 40-20,000 Å.
Dependencies are inferred from the claim text.