Engelhard Corporation

Basf Corporation

Mitchell J Willis

Raymond H Young

Sanjay Behl

Kenneth Warren Folmar

Saad Nemeh

Michael B Sigman

George E Gantt

Ellen S Forbus

Joseph P Berberich

Patrick D Canavan

Larry W Donaldson

David M Stockwell

Fred Mitchell Allen

Jordan K Lampert

Richard R Berube

Richard A Slepetys

Joseph H Wu

Clark W Gibson

Michael G Londo

John S Babiec, Jr

Danny L Williams

M Phillip Jameson

Glen A Hemstock

Richard J Pratt

Andrew R Negele

Charles Keweshan

Russell R Crumbley

Raymond G Downey

Robert E Barnes

James T Palmer

Michael Pavol

Tracey A Burbank

Rene S Guermonprez

This application discloses a mesoporous catalyst formed by combining a matrix precursor treated with a polyphosphate, and a metallic oxide treated with a cationic electrolyte. The combined treatment with the polyphosphate and cationic polyelectrolyte yields unexpected improvements in attrition resistance, while maintaining high overall pore volume, even as the ratio of meso pore volume to macro pore volume of the formed FCC catalyst increases.

Mesoporous FCC catalysts with excellent attrition resistance

FCC catalysts having improved attrition resistance are provided by mixing a cationic polyelectrolyte with either zeolite crystals or a zeolite-forming nutrient and/or a matrix material, prior to or during formation of a catalyst microsphere.

Method of producing FCC catalysts with reduced attrition rates

A catalyst particle which comprises a metallic oxide such as kaolin is provided with the unique structure by mixing small amounts of a polyphosphate structuring agent with the metallic oxide and heating the mixture of metallic oxide and polyphosphate to allow reaction of the structuring agent with the metallic oxide.

Thermochemical structuring of matrix components for FCC catalysts

A metal trap particle used for passivation of metals during FCC cracking comprises a calcined spray dried particle formed from kaolin, magnesium oxide or magnesium hydroxide and calcium carbonate. The metal trap particle contains at least 10 wt. % magnesium oxide which improves metals passivation during FCC cracking.

Heavy metals trapping co-catalyst for FCC processes

An in situ process for making improved zeolitic fluid cracking catalysts by spray drying a mixture of (i) hydrous kaolin and/or metakaolin, and (ii) calcined aluminum source, said calcined aluminum source being derived from a pulverized, ultrafine kaolin, calcining the resulting microspheres to convert hydrous kaolin to metakaolin, and reacting microspheres composed of a mixture of metakaolin and calcined aluminum source with an alkaline sodium silicate solution. The weight percent of metakaolin in the calcined microspheres is greater than the calcined aluminum source content.

Fluid catalytic cracking catalyst manufacturing process

A method for reducing the abrasion of a silica-containing calcined kaolin pigment by the controlled leaching of silica from the pigment, preferably by the use of a caustic solution to dissolve the silica out of the calcined kaolin. In another aspect of the invention, the brightness, opacity, or both of a calcined kaolin is increased by increasing the fineness of the kaolin feed supplied to the calciner. The combination of these methods results in the production of a calcined kaolin with low abrasion and high brightness and opacity. Another aspect of the invention concerns an improved method of filtration of dilatent materials such as the leached calcined clay.

Low abrasion calcined kaolin pigments and enhanced filtration method

This invention pertains to the use of a combination of polyvalent cations, clay dispersant and high molecular weight anionic polymer to preferentially remove colloidal fines (slimes) from a kaolin slurry, leaving the remainder of the kaolin in the slurry in the form of a coherent gelatinous mass.

Chemical process for fractionating mineral particles based on particle

A process for filtering kaolin clay slurries in the presence of a filter aid which increases the percent solids in the filter cake, decreases the product solids in the waste filtrate, increases the rate of filtration, and yet does not interfere with redispersal of the filter cake after filtration. The process utilizes high molecular weight, highly anionic polyacrylic acid homopolymers or copolymers, or water soluble salts thereof, as filter aids for thickening and dewatering kaolin clay slurries. The flocculated clay may be redispersed after the separation process by normal means, such as the addition of low molecular weight anionic polymers with mixing.

Filter aid for clay processing

Paper coating pigments comprising a product obtained by the controlled mechanical delamination of kaolin particles. The pigments provide improved opacification, brightness, printing properties and gloss compared to conventional delaminated kaolin pigments. The pigment of the invention is particularly useful for coating light weight printed paper and provides a unique combination of high opacity, brightness and gloss not available when using other kaolin pigments. The novel pigment is specifically designed to replace plastic pigments and (or) titanium dioxide in coating formulations while maintaining or improving desired paper properties.

Delaminated kaolin pigments their preparation and use in paper coating

Described is a process for separating a mixture of finely divided minerals into constituents thereof. In particular, the invention relates to a procedure for effecting such separation by a novel selective flocculation technique wherein a dispersed aqueous pulp containing the mixture of minerals is preconditioned for selective flocculation with an anionic polymer by addition of both a fatty acid such as oleic acid and source of polyvalent cation such as calcium chloride. The fatty acid and cation of the salt selectively coat the component of the mixture that is subsequently flocculated with the anionic polymer. A polyacrylate salt dispersant is preferably used in the process. The invention is especially adapted to the separation of colored titaniferous impurities from kaolin clay in which case both a white purified kaolin product and a strongly flocculated dun-colored titania/kaolin mixture are recovered and then dispersed producing a material useful as a paper coating pigment.

Colored titaniferous coating pigment obtained as a flocculated

This invention relates to paper filling pigments comprising novel mechanically delaminated kaolin particles having controlled narrow particle size distribution and shape. The pigments provide improved opacification compared to conventional and engineered kaolin particles in fine paper making.

Delaminated kaolin pigments, their preparation and use in paper filling

A selective flocculation process that uses a mixture of dispersants including soda ash to disperse a slimed ore pulp prior to conditioning with a fatty acid, salt and then a polymeric flocculating agent.

Method for separating mixture of finely divided minerals

This invention relates to a process for separating a mixture of finely divided minerals into constituents thereof. In particular, the invention relates to a procedure for effecting such separation by a novel selective flocculation technique wherein a dispersed aqueous pulp containing the mixture of minerals is preconditioned for selective flocculation with an anionic polymer by addition of both a fatty acid such as oleic acid and source of polyvalent cation such as calcium chloride. The fatty acid and cation of the salt selectively coat the component of the mixture that is subsequently flocculated with the anionic polymer. A polyacrylate salt dispersant is preferably used in the process. The invention is especially adapted to the separation of colored titaniferous impurities from kaolin clay.

Growing community of inventors

Macon, GA, United States of America

Mitchell J Willis