W. R. Grace Co.

W. R. Grace Co.-conn.

John S Magee

David E Vaughan

Roger Jean Lussier

Lawrence L Upson

William E Cormier, Jr

Gerald M Woltermann

Fred J Baars

Edwin W Albers

Mark A Seese

An FCC catalyst system and a process using the catalyst system are disclosed. The catalyst system comprises a metal trap component, such as bastnaesite or barium titanate, and a sulfur oxide acceptor such as a magnesium spinel in addition to a zeolite. The metal trap and sulfur oxide components are preferably in separate particles. The catalyst formulation results in improved activity believed to result from the sulfur oxide acceptor protecting the metal trap component from the harmful effects of sulfur oxides such as the formation of stable metal oxides.

Increasing metal-tolerance of FCC catalyst by sulfur oxide removal

Pillared interlayered clays are reacted with a base such as ammonium hydroxide to increase the ion exchange capacity thereof. The pillared interlayered clays are prepared by reacting a smectite clay, such as bentonite, with a metal complex polymer, such as chlorhydrol, and calcining the resulting product.

Pillared interlayered clay products

Stable pillared interlayered clays are prepared by reacting smectite clays with high molecular weight cationic metal complexes of metals such as aluminum and zirconium. The high molecular weight complexes are prepared by hydrolysis of copolymerization of a metal complex such as aluminum chlorohydrol. The pillared, interlayered clays possess a high degree of thermal and hydrothermal stability and may be used in the preparation of catalysts and sorbents.

Stabilized pillared interlayered clays

A dense, attrition resistant catalyst is prepared by precipitating a silica alumina hydrogel at high pH, and subsequently reacting the alkaline hydrogel with sufficient acid aluminum salt at a pH below 4 to obtain an acidic hydrogel slurry. The slurry is then processed into a catalyst by spray drying, washing and ion exchanging. The catalyst may include substantial quantities of clay and/or crystalline aluminosilicate zeolites.

Silica-alumina hydrogel catalyst

Stable pillared interlayered clay compositions are prepared by reacting smectite type clays with polymeric cationic hydroxy metal complexes of metals such as aluminum, zirconium, and/or titanium. These novel interlayered clay compositions which possess substantial surface area in pores of less than 30 A in diameter are used as catalysts, catalytic supports, and sorbents.

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Ellicott City, MD, United States of America

John S Magee