United Catalysts Inc.

Exxon Research and Engineering Company

Edward K Dienes

Arthur L Hausberger

Thomas H Vanderspurt

Arie Bortinger

Jar-Lin Kao

Freddie L Tungate

Virginia R Cross

Mark J Potter

Robert E Riley

Jon P Wagner

David L Williams

Karl J Russ

Dinah C Huang

George A Laufer

Ray L Coleman

A process for producing zeolite aggregates involves providing a formable paste composed of zeolite, a binder composed of an organic/metal oxide containing aluminum, a peptizing agent and water; forming the paste into an aggregate, preferably by extruding into an extrudate; curing the aggregate; hydro-thermally calcining the aggregate; and washing the hydro-thermally calcined aggregate with a washing medium, preferably followed by rinsing with a rinsing medium to remove residual washing medium from the aggregate. The washed and rinsed aggregate may then be permitted to equilibrate or is subjected to a drying procedure. Preferably, the washed and rinsed aggregate is again subjected to curing/hydro-thermal calcining. The resultant aggregates, such as extrudates, have an exterior surface with openings and interstitial spaces between particles of binder and zeolite which communicate by such openings between the exterior surface of the aggregate and micropores of the zeolite; the aggregates also exhibit characteristics of crush strength greater than about 0.9 pounds per millimeter and a loss by attrition of less than about 3.0%. Regenerable catalysts, such as reforming catalysts, based on such aggregate also exhibit a catalyst activity pass through to the zeolite bound in the aggregate of at least 70% of the initial catalyst activity of freshly prepared zeolite, as well as exhibiting more than about 70% of the reforming benzene yield that the reforming catalyst exhibited when similarly tested prior to being exposed to a hydrocarbon stream under specified reforming conditions of the catalyst activity test procedures.

Zeolite aggregates and catalysts

An extruded nickel oxide on refractory oxide hydrogenation catalyst, having, in its reduced state, a nickel surface area greater than 30 m.sup.2 /gm of reduced nickel in the catalyst and 15 to about 65 volume percent of pores having diameters of about 300 to about 1000 angstroms, is highly active for the hydrogenation of aromatics in heavy hydrocarbon streams and is relatively resistant to sulfur poisoning.

Nickel hydrogenation catalyst

Improved iron oxide catalysts for the dehydrogenation of ethylbenzene to styrene are made by forming a blend of chromium oxide and yellow iron hydrate and heating the blend to convert the yellow iron hydrate to red iron oxide prior to forming the catalyst.

Dehydrogenation catalyst and process for its preparation

A methanol synthesis catalyst which comprises a major portion by weight of the oxides of copper and zinc and a minor portion by weight of a thermal stabilizing metal oxide is useful for the synthesis of methanol from the oxides of carbon and hydrogen at relatively low temperatures. The catalyst is characterized in that the ratio of copper oxide to zinc oxide, each expressed as a metal by weight, is in the range of from 2:1 to 3.5:1 and by the intimate association with each other of copper and zinc oxides and with said thermal stabilizing oxide. Further, the catalyst is characterized in that the amount of iron oxides, as an impurity, is less than 150 parts per million.

Catalyst for the synthesis of methanol

A process for the conversion of carbon monoxide in synthesis gas mixtures to hydrogen and CO.sub.2 utilizes a catalyst which is active in the presence of sulfur compounds, and which comprises the oxides or sulfides of cobalt and molybdenum, supported on a shaped, relatively high surface area aluminous carrier. The carrier is stabilized by admixture with one or more rare earth metal oxides while the alumina is in the hydrated condition. The mixture of hydrated alumina and rare earth metal oxide is formed into a desired shape and calcined to convert the hydrated alumina to the oxide. Thereafter, the calcined, high surface area alumina is impregnated with the desired salts of cobalt and molybdenum and the impregnated catalyst is thereafter calcined and placed into service. The stabilized catalyst exhibits good activity at relatively low temperatures with synthesis gas mixtures containing sulfur compounds and retains its surface area and the aluminous carrier is not converted over to the alpha phase.

Process for the conversion of carbon monoxide

A catalyst for the conversion of carbon monoxide in synthesis gas mixtures to hydrogen and CO.sub.2 and which is active in the presence of sulfur compounds, comprises the oxides or sulfides of cobalt and molybdenum, supported on a shaped, relatively high surface area aluminous carrier. The carrier is stabilized by admixture with one or more rare earth metal oxides while the alumina is in the hydrated condition. The mixture of hydrated alumina and rare earth metal oxide is formed into a desired shape and calcined to convert the hydrated alumina to the oxide. Thereafter, the calcined, high surface area alumina is impregnated with the desired salts of cobalt and molybdenum and the impregnated catalyst is thereafter calcined and placed into service. The stabilized catalyst exhibits good activity at relatively low temperatures with synthesis gas mixtures containing sulfur compounds and retains its surface area and the aluminous carrier is not converted over to the alpha phase.

Growing community of inventors

Louisville, KY, United States of America

Edward K Dienes