Abstract: A process for significantly improving the physical and catalytic properties of fluid cracking catalysts (FCC) is disclosed. The invention is a process for manufacturing a fluid cracking catalyst. The process includes adding an effective amount of an acid stable surfactant or an alkaline stable surfactant to a slurry of clay particles and sodium silicate particles. The process then includes forming a sol binder and spray drying the particles. Forming of the dried particles into a catalyst product then occurs.

Abstract: This invention provides alkali metal bicarbonate powder consisting of a narrow size distribution range of ultrafine particles. The ultrafine powder has a large surface area, and provides enhanced reactivity in applications such as deodorization or neutralization, and exhibits increased antibacterial/antifungal activity. The ultrafine powder also has an exceptional capability to form a homogenous solid-phase suspension in a liquid medium which has long term stability.

Abstract: A process is described for the production of a suspension of cyanuric chloride in an aqueous liquid, more particularly, water. Molten cyanuric chloride is sprayed using a spray arrangement comprising a spray nozzle immersed in the aqueous liquid. Blockages in the nozzle during the critical start and stop phases are avoided by passing superheated steam through those parts of the spray arrangement which come into contact with the cyanuric chloride melt before and after the spraying process. A particularly reactive cyanuric chloride suspension is obtained by spraying a mixture of cyanuric chloride melt and superheated steam.

Abstract: This invention relates to an improved process for producing gypsum calcium sulfate dihydrate flakes from powdered gypsum calcium sulfate dihydrate obtained from the desulfurization of flue gas by the wet limestone process. The flakes have sufficient size and strength such that the gypsum calcium sulfate dihydrate can be handled and processed in conventional equipment commonly used by wallboard manufacturers and others in the construction industry, The intermediate calcium sulfate dihydrate from the desulfurization process is dewatered to about 5 to 12% by weight and then compressed into a thin sheet under a compaction or compression load of 4 tons force to 15 tons force per linear inch of sheet width. A linear speed of from 0.5 to 2.5 feet per second is maintained during compaction providing a compaction residence time of from about 0.2 to 1.2 seconds.

Abstract: The invention relates to a process in which a melt is mixed with, and emulsified in a colder aqueous phase at a temperature below the crystallization point of the molten compound, the melt only solidifying in the form of the dispersed particles after the emulsification step. To this end, the melt is sprayed into the aqueous phase to form a preliminary emulsion (12) and the preliminary emulsion is finely dispersed for 0.005 s to 0.15 s in a following homogenization nozzle (8) to form an emulsion (15) which then solidifies to form the final crystal suspension. The particle size can be clearly and reproducibly adjusted through the nozzle pressure during the emulsification step. The process may be used in particular for the production of highly concentrated dispersions of high-melting organic materials.

Abstract: A combined spray dryer and gas filter vessel in which a solution containing sulphuric acid and solids, and a hot drying gas, are introduced vertically through the top of the vessel into a spray zone. Solids are removed at a single point at the bottom of the vessel. Filters located above the spray zone clean gas leaving the vessel, and the cleaned gas exits at the top of the vessel. The compact design reduces insulation requirements while avoiding condensation which would create corrosion and yet it provides good separation of solids from gases.

Abstract: A high-velocity jet of solvent is introduced through a nozzle into one end of a passage. A slurry of ore particles is feed into the passage through a narrow inlet port extending across the width of the passage in front of the nozzle of the jet. The resulting high-energy impact of the solvent jet on the ore particles causes a rapid, turbulent flow of the mixture of solvent and ore particles through the remaining length of the passage and into a mixing chamber. This flow impinges on the back wall of the mixing chamber further increasing abrasion and mixing between the solvent and ore particles.

Abstract: A method of preparing droplets wherein a dispersion phase, insoluble or sparingly soluble in water, is injected in the form of a laminar flow into an aqueous continuous phase through an orifice. The viscosity ratio between the two phases is adjusted to a specific range to produce droplets of uniform diameter at a specified jet velocity.

Abstract: Process for the preparation of a powder suitable for fritting.The process comprises the stages of forming an emulsion, fractionating the emulsion into microdroplet form, which are solidified, dried and heat treated. According to the invention, the emulsion is formed from at least one powder suspended in a solution of at least one precursor salt, i.e. whereof the cation or cations are constituent elements of the powder to be formed.Application to the replacement of metal parts by ceramic parts in heat motors.

Abstract: A method for producing and distributing wet zinc dust to a zinc sulfate purification system or other zinc plant operation is disclosed. The method comprises atomizing molten zinc with high pressure water or other suitable medium, and feeding a predetermined amount of the wet zinc dust to at least one zinc sulphate purification tank or any other zinc plant operation.

Abstract: A process for making improved synthetic surfactant flakes from a water-wet paste which is dried on a heated roll drum dryer. Hot surfactant flakes are made from drum drying a water-wet paste containing sodium alkyl sulfate (AS), sodium alkyl benzene sulfonate (LAS), and water-soluble inorganic salts, preferably sodium chloride and magnesium chloride blends. The hot flakes are cooled in a low moisture environment having a dewpoint of up to 10.degree. C., e.g., under a dry nitrogen or dry air blanket. The low moisture environment prevents undesirable, insidious hydration and stabilizes the AS/LAS flakes. The stable AS/LAS surfactant flakes can be used to make more economical, more processable, firmer improved surfactant cakes. One advantage is that cakes made with the flakes of this invention can contain larger amounts of perfume than cakes made with comparable AS/LAS flakes cooled above said dewpoint.

Abstract: A reduced pollutant-containing salt mixture and method of making same is provided wherein a salt mixture partially comprised of calcium acetate and partially comprised of at least one other pollutant salt is produced by mixing a pollutant salt-containing solution and a calcium acetate-containing solution and converting said mixture into a solid salt containing both the pollutant salt and the nonpollutant calcium acetate. A process option involves chemically reacting calcium chloride and calcium acetate in a calcium chloride-to-calcium acetate mole ratio in the range from 0 to 1 to produce a non-deliquescent salt. A further process option includes mixing either dry calcium chloride or dry sodium chloride with dry calcium acetate to obtain a reduced pollutant-containing salt mixture.

Abstract: Aqueous solutions containing phosphate, aluminum and iron are evaporated. Thus, acidic phosphates having an atomic ratio Al:Fe of 95:5 to 5:95 and an atomic ratio P:(Al+Fe) of 1.1:1 to 3:1 are obtained. These are thermally treated by heating them in a first step to a temperature not exceeding 400.degree. C. until their weight remains constant, and in a second step to a temperature not exceeding 750.degree. C., likewise until their weight remains constant. The tempered phosphate so obtained is suitable as hardener for water glass cements.

Abstract: A process for producing particles of a non-friable eutectic mixture of sodium nitrate and potassium nitrate for solar power station use is disclosed. In one embodiment of the invention, the particles are produced by shock chilling a molten stream of mixed nitrate material and crushing the resulting flakes to a size range of between about -5 mesh and about +30 mesh. In a second embodiment, particles of this size are produced by spray granulation of a concentrated solution of mixed nitrate salts onto a fluidized bed to produce dry, free-flowing, solid spheres. In both embodiments, the particles are extremely hard, resistant to moisture pickup and adaptable to being readily shipped by bulk containers.

Abstract: Granular particles of an available chlorine-containing compound such as sodium dichloroisocyanurate are prepared by conveying a flowing stream of an aqueous slurry of the compound through a tubular chamber under pressure, injecting jets of an atomizing medium such as air into the flowing stream of said slurry to agitate and aerate said slurry, conveying the aerated slurry to an exit port in said tubular chamber, discharging the aerated slurry through said exit port into a zone of reduced pressure and enlarged area, impinging additional jets of an atomizing medium into said slurry as it passes through said exit port, whereby free expansion of said slurry into a cone of aerated droplets of said slurry is effected. The resulting droplets are contacted with a heated gas in said zone to effect evaporation of water from the aerated droplets and thereby produce dry granules of the available chlorine-containing compound.

Abstract: A process for preparing thermally stable ammonium nitrate-containing granules having high bulk density, high impact resistance, high crushing resistance and little or no tendency to cake by spraying a composition containing at most 5% by weight water, about 0.5% to 5% by weight of a insoluble and chemically inert silica-containing material, ammonium nitrate, and other components into a fluidized bed of ammonium nitrate seed particles thereby forming granules and recovering the thus formed ammonium nitrate-containing granulated product.

Abstract: The granulation of molten material, blast furnace slag for example, is accomplished by wetting the slag with a stream of water and thereafter transporting the thus formed granules away from the point of granulation with the water stream. Water consumption is minimized and average grain size increased by employing a multi-layer water stream defined by currents having different temperatures and pressures.

Abstract: A process for the reduction of the particle size of coarse grain, crystalline zeolitic sodium aluminosilicate of the NaA type obtained in an aqueous alkaline suspension by crystallization of a reaction mixture suspension formed from sodium aluminate solution and sodium silicate solution, said sodium aluminosilicate having a large cation exchange capacity consisting essentially of subjecting said aqueous alkaline suspension of the crystallized sodium aluminosilicate to treatment on a vibrating screen having a substantially uniform mesh size between 25 to 100 .mu.m, the number of vibrations per minute and the amplitude of oscillation of said screen being so selected that at least 99.95 percent by weight, based on the anhydrous weight, of sodium aluminosilicate particles recovered have a particle size of less than 100 .mu.m, the said aqueous alkaline suspension of the crystallized sodium aluminosilicate having a molar ratio of 2.5-5 Na.sub.2 O:1 Al.sub.2 O.sub.3 :1.8 to 2 SiO.sub.2 :50-100 H.sub.2 O.

Abstract: A process for the production of sodium aluminate comprising drying an aluminate solution containing from 45 to 350 g/l of caustic Na.sub.2 O with a molecular ratio of caustic Na.sub.2 O to Al.sub.2 O.sub.3 from 1.1 to 1.8 in a fluidized bed of solid particles at 250.degree.-400.degree. C. of sodium aluminate using a gas heated to 750.degree.-950.degree. C. containing no carbon dioxide as a fluidizing medium and a heat carrier in an amount from 2000 to 25000 nm.sup.3 per 1 m.sup.3 of aluminate solution; feeding said aluminate, solution for drying by atomizing it at a velocity from 25 to 35 m/s thereby obtaining sodium aluminate in the form of pellets of a size from 0.5 to 8 mm with a bulk weight from 1.2 to 1.4 t/m.sup.3 completely soluble in water and alkaline solutions, with a maximum content of hygroscopic moisture of 0.3% by weight and a maximum content of water of crystallization of 5% by weight.

Abstract: A process for the production of granular sulfur in a rotating drum in which molten sulfur at a temperature within the range of about 110.degree. to 160.degree. C. is sprayed in a contact zone onto a bed of moving sulfur particles and a continuous curtain of said particles and resulting particles are passed to a cooling zone prior to discharge. A countercurrent flow of substantially inert cooling gas at a temperature in the range of about 10.degree. to 50.degree. C. and containing not more than 8% by volume oxygen is introduced to the cooling zone and a portion or all of said cooling gas is passed through the contact zone. The contact and cooling zones can be formed in a single rotating drum and separated from each other by a retaining ring or formed in separate vessels.Discharge particles from the cooling zone are separated according to size and undersized particles are recycled as fines to the contact zone at a ratio of 4:1 to 2:1 of fines to product granules.

Abstract: A dry, brittle detergent product of cellular particulate structure is produced with a bulk density between 0.25 and 0.40 gms/cc by forming the components of the detergent composition into an aqueous slurry mass and subjecting such mass to microwave irradiation for a sufficient period to cause boiling of labile water, intumescense of the mass and the formation of the product in question. Boiling of the labile water under the action of microwaves effects evaporation of such labile water but does not affect water of crystallization.

Abstract: An agglomerating unit having a rotatable, conical, downwardly, narrowing section on the interior surface of which moistened powder is deposited. Close to said interior surface a stationary scraper is mounted. When the conical section is rotated the powder is dislodged from said surface by the scraper. A very efficient removal of powder is obtained whereby the risk of biological or chemical deterioration of the powder is reduced.

Abstract: Metal hydroxides such as Fe(OH).sub.2, Fe(OH).sub.3 and Sn(OH).sub.2 are prepared in the form of spherical particles of uniform and controlled size suitable for tagging with a radioactive element such as technetium-99m. Aqueous suspensions of such tagged particles are useful in scintigraphy as lung scanning agents.

Abstract: An apparatus for recovering higher melting organic materials which is an upright column containing a gas inlet at a lower portion thereof and a gas outlet at the upper portion thereof. The apparatus has a wall disposed in the flow of the gas between the gas inlet and the gas outlet which wall is perforated to allow gas to flow therethrough. Cooling means are provided on the side of the wall away from the gas inlet to cool components of a gas flowing therethrough.

Abstract: A process for preparing low bulk density, highly absorbent, amorphous, hydrous, water-soluble alkali metal silicate particles having high internal porosity by spray drying a mixture of an aqueous sodium or potassium silicate solution and hydrogen peroxide.

Abstract: A process is described for purifying liquids by cryogenic sublimation. This process involves solidifying the liquid by reducing the temperature and pressure to below the triple point. Purification is then carried out by direct transformation from the solid to the vapor phase. Because of increased differentials in vapor pressures at the low temperature at which the procedure is carried out, this purification process is highly efficient and is also particularly suitable for liquids that are susceptible to decomposition with ordinary purification procedures requiring elevated temperatures. The procedure is also advantageous in separating azeotropes, structurally similar compounds, as well as treating flammable, hydroscopic, corrosive and fuming compounds.

Abstract: An anti-foaming agent is added to magnesium chloride containing brine prior to spray drying to produce a spray dried product comprising discrete particles of relatively high bulk density.

Abstract: A gelling agent is added to a brine containing magnesium chloride to convert the brine into a gel which is spray dried to produce dried magnesium chloride comprising substantially solid discrete particles of magnesium chloride having bulk densities in the range from about 12 to 45 pounds per cubic foot.

Abstract: Method of hardening powdered titania (titanium dioxide) so as to make it attrition-resistant and to enhance its properties as a catalyst carrier. The method involves thoroughly dispersing powdered titanium dioxide in water, removing the excess water, drying and then calcining the product at a temperature between 650.degree.C and 900.degree.C. Preferably a large excess of water is used, at least 37% to effect dispersion; and dispersion may be aided by use of a surfactant, a water soluble organic compound or a highly polar inorganic compound. The excess water may be removed by filtration or the use of flocculants.The resultant powdered material is particularly useful as a carrier for oxidising ortho-xylene to phthalic anhydride.

Abstract: Spheroidal aggregates of highly absorbent, low bulk density, readily soluble, high surface area, hydrated, amorphous alkali metal silicate are provided by contacting discrete alkali metal silicate particles with an aqueous solution of hydrogen peroxide, absorbing the peroxide into the alkali metal silicate hydrated structure and heating the silicate to destroy substantially all of the hydrogen peroxide.