W. R. Grace Co.

Mark A Seese

Edwin W Albers

William A Welsh

John S Magee

Robert L Chiang

Alan W Peters

Joseph S Dumoulin

Catalytically active silica-alumina and silica-alumina-rare earth oxide cogels are prepared by reacting aluminate and silicate solutions to obtain a silica-alumina pregel, and then reacting the pregel with an acidic rare earth and/or aluminum salt solution under complete mixing conditions.

Co-gel catalyst manufacture

Zeolite containing catalysts and catalyst supports are prepared by forming and drying an aqueous slurry of zeolite, aluminum chlorhydrol and optimally clay to obtain particulate composites in which the zeolite component contains in excess of about 1 percent by weight alkali metal oxide. The particulate composites are calcined, and in some instances ion exchanged to obtain hard, attrition resistant catalytic particles.

Catalyst manufacture

A dense, highly attrition resistant catalyst is prepared by reacting an alkali-metal silicate and aluminate under conditions which produce a thermally and hydrothermally stable cogel having a substantial surface area in pores ranging from about 25 to 75A.degree.. The catalyst includes excess silicate obtained as a by-product from a Type Y zeolite synthesis.

Hydrocarbon conversion catalyst preparation

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.

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Ellicott City, MD, United States of America

Mark A Seese