Uop Lcc

Alliedsignal Inc.

Tai-Hsiang Chao

George J Antos

Fiona P Wilcher

Michael W Schoonover

Joseph A Kocal

Mark D Moser

Michael T Cleary

David C Martindale

Andrzej Z Ringwelski

Mark R Ford

William M Targos

Tamotsu Imai

Jeffery C Bricker

Maureen L Bricker

J W Adriaan Sachtler

Gerald T Stranford

Arthur A Foutsitzis

Nancy J Flint

Solveg S Kjell

This invention relates to hydrocarbon conversion processes using a catalytic composite which is an amorphous solid solution of phosphorus, silicon and aluminum oxides. The composite is characterized in that it contains from about 5 to about 50 weight percent Al.sub.2 O.sub.3, from about 10 to about 90 weight percent SiO.sub.2 and from about 5 to about 40 weight percent P.sub.2 O.sub.5 and has pores whose average diameters range from about 30 to about 200 Angstroms. The composite is further characterized in that it has a pore volume of about 0.35 to about 0.75 cc/g and a surface area of about 200 to about 420 m.sup.2 /g. The composite may be prepared by forming a mixture of sols of alumina and silica and a phosphorus compound, gelling the mixture to form particles and then calcining the particles to provide the amorphous solid solution. The amorphous composite may be used either as is or with additional catalytic metals (selected from the metals of Group VIB and VIII of the Periodic Table) dispersed thereon.

Hydrocarbon conversion process using an amorphous

This invention relates to a catalytic composite which is an amorphous solid solution of phosphorus, silicon and aluminum oxides. The composite is characterized in that it contains from about 5 to about 50 weight percent Al.sub.2 O.sub.3, from about 10 to about 90 weight percent SiO.sub.2 and from about 5 to about 40 weight percent P.sub.2 O.sub.5 and has pores whose average diameters range from about 30 to about 200 Angstroms. The composite is further characterized in that it has a pore volume of about 0.35 to about 0.75 cc/g and a surface area of about 200 to about 420 m.sup.2 /g. The composite may be prepared by forming a mixture of sols of alumina and silica and a phosphorus compound, gelling the mixture to form particles and then calcining the particles to provide the amorphous solid solution. The amorphous composite may be used either as is or with additional catalytic metals (selected from the metals of Group VIB and VIII of the Periodic Table) dispersed thereon to catalyze various hydrocarbon conversion processes such as hydrocracking and alkylation.

Amorphous silica/alumina/phosphate composition and uses thereof

A novel extruded catalyst and process use thereof is disclosed. The catalyst comprises a refractory inorganic oxide and halogen, platinum-group metal, and Group IVA(14) metal components, wherein the Group IVA(14) metal is homogeneously dispersed within a bed of catalyst particles relative to catalysts of the prior art. Utilization of this catalyst in the reforming of hydrocarbons results in significantly improved selectivity to the desired gasoline product.

Reforming catalyst with homogeneous metals dispersion

A novel solid phosphoric acid catalyst composition is disclosed. The composite comprises solid phosphoric acid and a refractory oxide binder. The composite is characterized in that 25.0 volume percent or less of the total catalyst pore volume consists of pores having a diameter of 10,000 .ANG. or greater. An improvement in catalyst activity and stability is observed when such a catalyst is utilized in a hydrocarbon conversion process.

Solid phosphoric acid catalyst

A hydrocarbon conversion process which utilizes a solid phosphoric acid catalyst having a total X-ray intensity of at least 40 percent relative to alpha-alumina. The solid phosphoric acid catalyst is produced by crystallizing an amorphous mixture of an acid oxide of phosphorus and a siliceous material at a temperature of from 350.degree. to 450.degree. C. and in the presence of from 10 to 50 mole percent water vapor based upon the total vapor rate to the crystallizing means. Embodiments of the new hydrocarbon conversion process include alkylation, oligomerization, and hydration, of hydrocarbons and oxygenated hydrocarbons.

Catalytic condensation process

This invention relates to a catalyst support structure, methods of preparing the support structure and a process for using the support structure. The catalyst support structure is composed of a substantially polycrystalline cordierite phase having a chemical composition by weight of 6-15% MgO, 33-40% Al.sub.2 O.sub.3 and 45-56% SiO.sub.2 and characterized in that it has a surface area of at least 2.7 m.sup.2 /g and preferably 8 m.sup.2 /g, a compressive strength of at least 31 MPa, a thermal expansion coefficient smaller than 5.2.times.10.sup.-6 m/m/.degree.C. and a porosity of at least 20%.

High surface area cordierite catalyst support structures

A solid phosphoric acid catalyst having a total X-ray intensity of at least 30 percent relative to alpha-alumina. The solid phosphoric acid catalyst is produced by crystallizing an amorphous mixture of an acid oxide of phosphorus and a siliceous material at a temperature of from 250.degree. to 450.degree. C. and in the presence of from 3 to 50 mole percent water vapor based upon the total vapor rate to the crystallizing means.

A novel solid phosphoric acid catalyst composition, and process for using the catalyst is disclosed. The composite comprises solid phosphoric acid and a refractory oxide binder. The composite is characterized in that 25.0 volume percent or less of the total catalyst pore volume consists of pores having a diameter of 10,000 .ANG. or greater. An improvement in catalyst stability is observed when such a catalyst is utilized in a hydrocarbon conversion process.

A honeycombed structure is extruded and wash coat applied to the interior channels of the structure before the honeycomb structure is separated from the die in which it is formed. This method produces the honeycombed structure using a die that includes a die body having an inlet and an outlet side, a plurality of parallel pins defined by the body that correspond to the shape of the channels in the honeycombed structure, and a discharge zone that communicates directly with the outlet side of the die and is defined by the open area between the pins. The extrudable material enters the discharge zone from a series of feed passages defined by the pins and a plurality of webs that interconnect the pins. Each pin has an interior duct with an opening at the end of each pin. A series of internal passages in the die body receive fluid from one or more ports on the periphery of the die and distribute the fluid to the ducts. Spraying the wash coat from the ends of the pins eliminates the need for a separate wash coat step after the honeycombed structure has been formed. In addition, wash coat is continually applied to the interior walls of the channel by the duct as the channel passes the end of the pin so that the entire length of the channel is covered with wash coat. This invention can be used in a wide variety of die configurations, but is especially suited for a die having segmented slots for feed passages and square channel forming pins defined in part by the segmented slots.

Die for extruding and wash coating

A die for forming honeycomb structures has an arrangement that facilitates fabrication and the support of channel forming pins across the surface of the die by the use of multiple die sections. The die is used for forming multi-channeled honeycomb structures from extrudable materials. The die has a first die body that has an inlet face and outlet face and integrally formed channel forming pins that extend past the outlet face of the die. A set of integrally formed links interconnect the channeled pins and support the channeled pins from the die body. Together the channel forming pins and links define a set of cavity for passing extrudable material through the die body. The die includes at least one additional die body, which is at least partially superimposed above the inlet face of the first die body. The additional die body has an inlet face, an outlet face, and an integrally formed set of channel forming pins that extend through the cavities in the first die body and past the outlet face of the first die body. Another set of integral links interconnect the channel forming pins of the additional die body. The extension of the pins from the first die body and any additional die body together define a discharge zone which completes the formation of a multi-channeled honeycomb structure as the extrudable material passes through the die. Each set of pins in the die bodies have a minimum pitch between all adjacent pins that exceeds the minimum pitch between all the adjacent pins in the discharge zone. The die is particularly useful in the formation of ultrafine honeycomb structures having a channel density of 600 channels per square inch or more.

Die for extruding ultrafine honeycomb structures

A method for forming honeycomb structures by stepwise formation of channel walls reduces the pressure loading imposed by the extrudable material on a die that uses this method, facilitates the formation of well knitted channel walls, and requires only a minimum amount of lateral flow in the discharge zone to perform final interconnections between channel walls that have been substantially formed upstream of the discharge zone. The method presses extrudable material in substantially axial flow through a fist partitioning zone and subdivides the material into a series of flow segments having on their outer surfaces a portion of the channel wall surfaces formed. The extrudable material passes from the first partitioning zone in substantially axial flow while at least a portion of the channel walls formed in the first partitioning zone are maintained on the surface of the segments. Next, the extrudable material passes through one or more additional partitioning zones that again subdivide the feed material into additional flow segments by displacing at least a portion of the extrudable material from the axial flow path of the upstream flow segments, thereby forming additional portions of the channel walls on the surface of the segments. As the extrudable material continues to flow through subsequent partitioning zones, the portion of the channel walls formed in upstream partitioning zones are substantially maintained. The extrudable material passes through a discharge zone located downstream of the partitioning zones which causes the extrudable material to flow laterally and fill minor gaps in the channel walls that were left after passage of the extrudable material through the partitioning zones. An extruded honeycomb structure having a plurality of intersecting channels is recovered from the discharge zone. The method can be used with as few as two partitioning zones or as many as four or more partitioning zones.

Stepwise formation of channel walls in honeycomb structures

A process for catalytic dehydrocyclodimerization and regeneration of the catalyst. C.sub.2 to C.sub.5 aliphatic hydrocarbons are reacted to produce aromatics, using a catalyst of a composition especially adapted to minimize deposition of coke on the catalyst. The catalyst is comprised of alumina which contains phosphorus, gallium, and a crystalline aluminosilicate having a silica to alumina ratio of at least 12. The use of this catalyst has resulted in a five-fold reduction in the rate of coke deposition, compared to a conventional dehydrocyclodimerization catalyst. However, the activity of this catalyst once it becomes deactivated is only recovered by burning the coke accumulated upon the deactivated catalyst at catalyst regeneration conditions in the presence of an oxygen-containing gas.

Regeneration of dehydrocyclodimerization catalyst

An extrusion die for producing multichanneled structures from an extrudable material. The die is composed of a series of pins that correspond to the shape of the channels in the structure. At one end of the pins, the area between the pins is open to define a discharge zone having the shape of the structure. At their opposite ends, the pins are connected about adjacent corners by a series of webs. Slots bordered by the pins and the webs define a series of feed passages that communicate with the discharge zone at areas of reduced width between adjacent pins.

Die and method for forming honeycomb structures

A multipiece die for extruding honeycomb structures that facilitates a variation of geometries in the formation of honeycomb structures by reducing the amount of machining necessary to change die configurations for different honeycomb arrangements. The die has at least two sets of channel forming pins which are supported from separate die bodies. The channel forming pins when brought together with the separate die bodies define a series of discharge slots by which the extrudable structure is ejected from the die. A plurality of cavities communicate extrudable material from inlet and outlet sides of each die body. The cavities in downstream die bodies, downstream being taken with respect to the flow of extrudable material, are made with sufficient size to allow pins depending from upstream die bodies through the cavities while still allowing enough open area to provide a feed passage for the extrudable material. The die bodies can be secured with ordinary fasteners to maintain relative spacing between the pins and the desired geometry of the discharge slots. Manufacturing the die in multiple pieces allows geometry parameters of the die to be easily varied with at most only partial manufacturing of new die components. Geometric features such as slot width, relative pin depth, and alternate pin geometries are examples of the types of modifications that are facilitated by this die design.

Growing community of inventors

Mt. Prospect, IL, United States of America

Tai-Hsiang Chao