W. R. Grace Co.

W.r. Grace & Co. -conn.

Grant C Edwards

David E Vaughan

Alan W Peters

Carl V McDaniel

Jean-Pierre Gilson

Kuppuswamy Rajagopalan

Michael G Barrett

William A Welsh

Robert L Chiang

Edwin W Albers

Cracking catalysts which yield higher octane gasoline than conventional cracking catalysts are made with large pore size zeolites such as zeolite Beta and zeolite ZSM-20 in the low sodium, H.sup.+ form. These zeolites are mixed with a matrix which contains at least a binder and formed into catalyst particles. These catalysts are especially suitable to be used in fluid catalytic cracking.

Cracking catalysts with octane enhancement

Catalytic cracking catalyst compositions having a high degree of activity and selectivity for the production of high octane gasoline fractions which comprise stabilized crystalline molecular sieve SAPO-37 dispersed in an inorganic oxide matrix. The crystalline structure and activity of the SAPO-37 molecular sieve component is preserved by including a stabilizing amount of the organic template compound used in the manufacture of the molecular sieve within the pore structure thereof until such time as the catalyst is thermally activated during use.

Cracking catalyst

A sodium Y type faujasite having a high silica/alumina ratio is obtained by lowering the active soda content below the conventionally employed levels. This is done by adding an acid and/or an aluminum salt solution such as an aluminum sulfate solution to the sodium silicate in the zeolite synthesis slurry. Alternatively, the desired alumina and silica starting materials can be supplied in part by using an aluminum salt gelled mother liquor such as an alum gelled mother liquor. This permits the use of less reactants which are high in soda such as sodium silicate and sodium aluminate which in turn reduces the amount of soda present. The addition of these soda removers or the use of low soda reactants permits the production of NaY having a silica/alumina ratio of 5.0 and higher. These Y zeolites have a high degree of crystallinity as measured by an NMR sharpness index defined herein and they have an absence of occluded silica. The final product can be ion exchanged to a low level of Na.sub.2 O with rare earth or other metal cations or ammonium ions, to make a more thermally and steam stable zeolitic promoter for catalysts for treating petroleum fractions than can be made from conventional sodium Y.

High silica/alumina ratio faujasite type NaY

Hydrocarbon conversion catalysts are prepared from synthetic faujasite Type Y zeolites which have an initial (as synthesized) silica to alumina ratio in excess of 5.6 and preferably above 5.8. The catalysts are highly active for the catalytic cracking of hydrocarbons and are particularly resistant to deactivation by high temperature steam in the presence of metals such as nickel and vanadium.

Hydrocarbon conversion catalysts

A highly active hydrocarbon conversion catalyst is disclosed which by virtue of it being promoted by larger than conventional particle size zeolite exhibits significantly improved hydrothermal stability.

Large particle zeolite containing cracking catalyst exhibiting improved

A catalyst composition containing 5 to 50 weight percent of small particle type Y faujasite zeolite is described. A cracking process using the above catalyst can be used to obtain increased conversion of the heavier portion of commercial crudes as well as to generate increased yield of gasoline and distillate.

Small particle zeolite containing catalytic cracking catalyst

Synthetic crystalline alumino-silicate zeolites are prepared by combining reactant quantities of alumina, silica, sodium hydroxide and water with zeolite-forming alumino-silicate seeds having the composition 16 Na.sub.2 O: 2 to 9 Al.sub.2 O.sub.3 : 15 SiO.sub.2 : 500 to 2000 H.sub.2 O. The seed compositions may be used to produce Type A, X and Y crystalline alumino-silicate zeolites.

Preparation of zeolites

Type Y zeolite is prepared using a minimum excess of reactants by a method wherein required sodium hydroxide, silica, alumina and water reactants are combined in multi-stage procedure to obtain a uniform fluid reaction slurry. The procedure permits the efficient commercial production of high quality type Y zeolite and minimizes the formation of excess silicate containing by-product effluent.

Synthesis of type Y zeolite

A process for preparing a synthetic faujasite having a novel platelet-type crystalline shape and a silica to alumina ratio above 2.2 by adding potassium ions to a seeded faujasite synthesis slurry and heating to convert to the synthetic faujasite. The use of the novel zeolite form as a catalyst promoter and an adjuvant for strengthening formed zeolite such as beads, balls, pills and extrudates is also disclosed.

Method of preparing a novel platelet-type crystalline form of synthetic

An improved process for preparing synthetic ferrierites having the absorption and catalytic properties characteristic of 5 to 8 angstrom zeolites which comprises promoting an alkaline reaction mixture comprising Group I and/or Group II cations, a source of silica, a source of alumina with lithium cations. The promoted reaction mixture is seeded with natural or synthetic ferrierite seeds, and heated to convert the mass to the synthetic ferrierite. The product has the empirical formula, 0.1 to 0.9 Li.sub.2 O:0.1:0.9 R.sub.2 0:Al.sub.2 O.sub.3 :6 to 25 SiO.sub.2 wherein R.sub.2 O is Na.sub.2 O, K.sub.2 O, or Rb.sub.2 O and/or Cs.sub.2 O; 0.1 to 0.9 Li.sub.2 O:0.1 to 0.9 WO:Al.sub.2 O.sub.3 :6 to 25 SiO.sub.2 wherein WO is BaO, CaO, MgO or SrO; or (Li.sub.2 O:R.sub.2 O:WO):Al.sub.2 O.sub.3 :6-25 SiO.sub.2 where R.sub.2 O is any R.sub.2 O above and WO is any WO above.

Process for preparing synthetic ferrierite

A process for preparing a synthetic ferrierite having the absorption and catalytic properties characteristic of 5 to 8 angstrom zeolites which comprises treating a reaction mixture consisting of strontium, calcium and/or sodium, lithium or magnesium salts, a source of silica and a source of alumina and water with natural or synthetic ferrierite seeds and heating to convert the mass to the synthetic ferrierite.

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Silver Spring, MD, United States of America

Grant C Edwards