W. R. Grace Co.-conn.

Michael David Wallace

Richard Franklin Wormsbecher

Wu-Cheng Cheng

Roger Jean Lussier

Yuying Shu

This invention relates to a process of preparing an improved catalyst comprising a clay derived zeolite. In particular, the invention comprises combining an yttrium compound with a zeolite produced by treating clay with a silica source and under alkaline conditions. The clay derived zeolite can be further combined with conventional matrix and/or binder precursors to form particulates suitable for use as catalysts in fluid catalytic cracking (FCC). Alternatively, the clay that is treated with the silica source and alkaline conditions can be in particulate form having sizes suitable for use in FCC, and the zeolite is produced in situ within the particulate. Yttrium compound is then combined with the zeolite in the particulate, e.g., via impregnation. It has been shown that the addition of the yttrium compound improves zeolite surface area retention, and zeolite stability in catalysts comprising clay derived zeolites.

Process for making improved catalysts from clay-derived zeolites

Porous composite particles are provided which comprise an aluminum oxide component, e.g., crystalline boehmite having a crystallite size of from about 20 to about 200 Angstroms and additive component residue, e.g., silicate, phosphate, of a crystal size growth inhibitor, intimately dispersed within the aluminum oxide component. The aluminum oxide component of the composite particles are derived from a mixture of alumina trihydrate (e.g., gibbsite) and an alumina seed component, i.e., active alumina, which are both converted to crystalline boehmite in the presence of the additive component. Also provided is a method for making the composite particles, agglomerate particles derived therefrom, and a process for hydroprocessing petroleum feedstock using the agglomerates.

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Columbia, MD, United States of America

Michael David Wallace