Intercat, Inc.

Bulldog Technologies U.s.a., Inc.

Other

Intercat-savannah, Inc.

Edward J Demmel

Albert A Vierheilig

Regis B Lippert

Terrance J Velten

Louis M Magnabosco

The useful life of SO,additives having a SO,&rarr;SO,oxidation catalyst component and a SO,absorption component can be extended by employing each of these components as separate and distinct physical particles, pellets, etc.

SOx additive systems based upon use of multiple particle species

Zeolite/clay/phosphate catalysts can be prepared by a process wherein a composition of zeolite-clay-phosphate is brought to a pH level of about 7.0 to about 14.0. The resulting slurry is then age reacted for about 0.5 to about 24 hours. Thereafter the slurry is dried to produce a zeolite/clay/phosphate catalyst particles that are particularly characterized by their high levels of zeolite stability.

Alkaline phosphate-activated clay/zeolite catalysts

The useful life of SO.sub.X additives having a SO.sub.2 .fwdarw.SO.sub.3 oxidation catalyst component and a SO.sub.3 absorption component can be extended by employing each of these components as separate and distinct physical particles, pellets, etc., with each component having large proportions of certain ingredients and having small proportions of certain other ingredients.

SO.sub.x additive systems based upon use of multiple particle species

Bastnaesite and magnesium-containing materials can be chemically reacted by use of reactions wherein alumina is made into a sol by use of a mono-protonic acid and then reacted with a magnesium-containing ingredient (e.g., magnesium acetate) and a bastnaesite ingredient such that, upon spray drying and calcination of the resulting composition, the bastnaesite is chemically reacted with magnesia to form a bastnaesite/magnesia/alumina compound having SO.sub.x activity.

Processes for reacting bastnaesite with alkaline-earth metals

Bastnaesite materials and Mg A! (and/or Al B!) materials can be chemically reacted by use of reactions wherein a Al B! ingredient such as alumina is made into a sol by use of a mono-protonic acid before Mg A! (and/or Al B!) materials is (are) reacted with the bastnaesite material. The resulting compounds are then used as SO.sub.x catalyst/absorbent materials in fluid catalytic cracking units and/or in fixed bed units.

Processes for using bastnaesite/metal oxide compounds

Bastnaesite materials and Mg[A] (and/or Al[B]) materials can be chemically reacted by use of reactions wherein a Al[B] ingredient such as alumina is made into a sol by use of a mono-protonic acid before Mg[A] (and/or Al[B]) materials is (are) reacted with the bastnaesite material.

Processes for reacting bastnaesite with metal oxides

Attrition-resistant binders can be prepared by a process wherein a slurry of delaminated and calcined clay particles is brought to either a low pH level (e.g., 1.0 to 3.0) or to a high pH level (e.g., 14.0 to 10.0) and mixed with a phosphate-containing compound in a concentration of from about 2.0 to about 20.0 weight percent. Preferably, the resulting slurry is spray dried and the particulate products of the spray drying are then calcined to produce attrition-resistant binder particles.

Production of attrition-resistant catalyst binders through use of

Attrition-resistant binders can be prepared by a process wherein a slurry of clay particles is brought to either a low pH level (e.g., 1.0 to 3.0) or to a high pH level (e.g., 14.0 to 10.0) and mixed with a phosphate-containing compound in a concentration of from about 2.0 to about 20.0 weight percent. Preferably, the resulting slurry is spray dried and the particulate products of the spray drying are then calcined to produce attrition-resistant binder particles.

Method for producing attrition-resistant catalyst binders

Spinels can be synthesized by uniformly dispersing predetermined quantities of ingredient compounds whose particles have sizes no greater than about 5 nanometers in a liquid medium, arresting the ingredient compounds in a solid matrix by spray drying said liquid medium and then calcining the resulting particles to form a solid solution of oxides of said compounds in a crystalline lattice which is substantially free of undesired complex compounds of the ingredient compounds.

Synthetic spinels and processes for making them

High concentrations of small (&lt;4 microns) crystalline catalyst ingredients such as ZSM-5, low-soda exchanged Y-zeolite, ultra-stable Y-zeolite etc., can be incorporated into a durable matrix by use of binder formulations prepared from amorphous silica, alumina and zirconia, particularly those of colloidal dimensions. The binder formulations are slurried and associated with at least one active catalyst ingredient, which preferably is up to 60% ZSM-5. The resulting material is then spray-dryed and calcined to form binder matrices which are particularly resistant to attrition and particle density change.

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Newport Beach, CA, United States of America

Edward J Demmel