Abstract: A method is described for preparing a molecular sieve-containing catalyst for use in a catalytic process conducted in a stirred tank reactor. The method comprises providing a mixture comprising a molecular sieve crystal and forming the mixture into catalyst particles having an average cross-sectional dimension of between about 0.01 mm and about 3.0 mm. The mixture may include a binder and the catalyst particles are then calcined to remove water therefrom and, after calcination and prior to loading the catalyst particles into a reactor for conducting the catalytic process, the catalyst particles are coated with a paraffin inert to the conditions employed in the catalytic process.

Abstract: A process for reducing the Bromine Index of a hydrocarbon feed containing bromine-reactive contaminants that has improved cycle length and utilizes a crystalline molecular sieve catalyst. The process is carried out by contacting the hydrocarbon feed under conversion conditions with a catalyst shaped in the form of an elongated aggregate comprising a crystalline molecular sieve having a MWW or *BEA framework type. The shortest cross-sectional dimension of the elongated aggregate is less about 1/10 inch (2.54 millimeters).

Abstract: A method is described for preparing a molecular sieve-containing catalyst for use in a catalytic process conducted in a stirred tank reactor. The method comprises providing a mixture comprising a molecular sieve crystal and forming the mixture into catalyst particles having an average cross-sectional dimension of between about 0.01 mm and about 3.0 mm. The mixture may include a binder and the catalyst particles are then calcined to remove water therefrom and, after calcination and prior to loading the catalyst particles into a reactor for conducting the catalytic process, the catalyst particles are coated with a paraffin inert to the conditions employed in the catalytic process.

Abstract: A method for recovering molecular sieve crystals from a synthesis mixture that comprises adding at least one flocculant having a certain molecular weight and a certain charge density that contribute to the acceleration of the settling rate of the molecular sieve crystals and compositions made from the method.

Abstract: A method for determining an amount of flocculant effective to recover a molecular sieve crystalline product that comprises the steps of (a) preparing a molecular sieve crystalline product mixture; (b) separating the molecular sieve crystalline product mixture into a plurality of samples; (c) mixing at least two of the plurality of samples with a quantity of flocculant to produce a plurality of flocculated samples, wherein at least two of the plurality of flocculated samples have a different ratio of flocculant to molecular sieve crystalline product mixture; (d) measuring the viscosity or zeta potential of at least two of the plurality of flocculated samples having a different ratio of flocculant to molecular sieve crystalline product mixture; (e) establishing a relationship between the quantity of flocculant and the viscosity or zeta potential measurements; and (f) determining from the relationship the amount of flocculant effective to recover the molecular sieve crystalline product.

Abstract: The present invention describes a method to increase the activity of a catalyst by first performing an ion exchange step with a potassium ion, followed by performing an ion-exchange step with an ammonium ion. Specifically, the present invention describes a method to increase the acidity of a zeolite by incorporating a potassium salt ion-exchange prior to an ammonium salt ion-exchange step. Even more specifically, the present invention is drawn to a method of increasing the activity of a zeolite by employing more than one potassium ion exchanges followed by at least one ammonium ion exchange. The present invention also describes a method to reduce the amount of sodium normally found in commercially produced zeolite by employing any of these methods. The present invention is also drawn to the catalysts produced by any of these methods.

Abstract: A process for reducing the Bromine Index of a hydrocarbon feed containing bromine-reactive contaminants that has improved cycle length and utilizes a crystalline molecular sieve catalyst. The process is carried out by contacting the hydrocarbon feed under conversion conditions with a catalyst shaped in the form of an elongated aggregate comprising a crystalline molecular sieve having a MWW or *BEA framework type. The shortest cross-sectional dimension of the elongated aggregate is less about 1/10 inch (2.54 millimeters).

Abstract: An ethylbenzene conversion catalyst is described which comprises a molecular sieve and a hydrogenation metal, wherein the catalyst exhibits a benzene hydrogenation activity at 100° C. of less than about 100 and a metal dispersion, as measured by hydrogen chemisorption, greater than 0.4 and wherein the molecular sieve is steamed to an alpha value of less than 400 prior to incorporation of the palladium with the molecular sieve.

Abstract: An ethylbenzene conversion catalyst is described which comprises a molecular sieve and a hydrogenation metal, wherein the catalyst exhibits a benzene hydrogenation activity at 100° C. of less than about 100 and a metal dispersion, as measured by hydrogen chemisorption, greater than 0.4 and wherein the molecular sieve is steamed to an alpha value of less than 400 prior to incorporation of the palladium with the molecular sieve.

Abstract: A shape-selective catalyst comprises a synthetic porous crystalline material having the structure of ZSM-5 and a composition involving the molar relationship: X2O3:(n)YO2, wherein X is a trivalent element, such as aluminum, boron, iron and/or gallium, preferably aluminum; Y is a tetravalent element such as silicon and/or germanium, preferably silicon; and n is greater than about 12, and wherein the crystals have a major dimension of at least about 0.5 micron and a surface YO2/X2O3 ratio which is no more than 20% less than the bulk YO2/X2O3 ratio of the crystal. The crystals have a diffusion-modifying surface coating of a refractory material such as silica or coke. The catalyst is useful in a wide variety of selective hydrocarbon conversion processes, particularly the selective disproportionation of toluene to para-xylene.

Abstract: A process for toluene disproportionation which obtains high xylene yields while minimizing ethylbenzene production employs a dual catalyst bed. The first bed employs an acid zeolite, e.g., ZSM-5 which disproportionates toluene and the downstream second bed uses an acid zeolite having hydrogenation-dehydrogenation activity, e.g., PtZSM-5, to selectively eliminate ethylbenzene.

Abstract: MCM-56 and MCM-49 have been demonstrated to be effective catalysts for the reduction of nitrogen oxide (NO.sub.x) emissions in a net oxidizing environment such as Selective Catalytic Reduction or lean burn engine exhaust applications. MCM-56 and MCM-49 can be utilized as a component of a spherical or cylindrical catalyst particle or as a wash coat on a ceramic or metallic monolith. Optionally, a transition metal such as copper, can be added to the catalyst for improved activity.

Abstract: There is provided a process and a catalyst for hydrocracking hydrocarbons, such as gas oils. The catalyst comprises a hydrogenating metal and small crystal size zeolite Y. The zeolite Y may have a crystal size of less than one micron. Examples of hydrogenating metals include nickel and tungsten.

Abstract: Relatively short chain alkyl aromatic compounds are prepared by alkylating an alkylatable aromatic compound with a relatively short chain alkylating agent under sufficient reaction conditions in the presence of a catalyst comprising zeolite MCM-56. The liquid phase syntheses of ethylbenzene and cumene are particular examples of such MCM-56 catalyzed reactions.

Abstract: This invention relates to use of synthetic layered material MCM-56 as a sorbent and as a catalyst component in catalytic conversion of organic compounds. Examples of sorbent use include rapid sorption of hydrocarbons and separating at least one hydrocarbon component from a mixture of hydrocarbon components having differential sorption characteristics with respect to MCM-56. Examples of catalytic use include acid catalyzed reactions, such as cracking, aromatic compound alkylation, and isoalkane alkylation.

Abstract: A process is disclosed for the highly selective skeletal isomerization of linear olefin-containing organic feeds to iso-olefins at high levels of feed conversion wherein linear olefins, e.g., n-butenes, are contacted with catalyst comprising ZSM-35 under skeletal isomerization conditions which can include temperatures of 100.degree. to 750.degree. C. and linear olefin space velocities of less than 30 WHSV. The process uses a catalyst composition comprising 5 to 40 wt % ZSM-35, and 60 to 95 wt % inorganic oxide matrix, e.g., silica.

Abstract: A process is disclosed for the highly selective skeletal isomerization of linear olefin-containing organic feeds to iso-olefins at high levels of feed conversion wherein linear olefins, e.g., n-butenes, are contacted with catalyst comprising ZSM-35 under skeletal isomerization conditions which can include temperatures of 100 to 750.degree. C. The process uses a catalyst composition comprising ZSM-35, e.g., microcrystalline ZSM-35 having a crystal size whose largest dimension is no greater than 0.5 micron and whose ratio of its second largest dimension to said largest dimension ranges from 0.5 to 1. The process exhibits enhanced catalyst cycle life where the ZSM-35 is composited with a silica-containing matrix to provide a catalyst composite having a total pore volume greater than 0.6 cc/g or 300.sup.+ angstroms pore volume of greater than 0.1 cc/g.

Abstract: There are provided a catalyst, a method for making this catalyst, and a process for using this catalyst in the alkylation of an isoparaffin with an olefin to provide an alkylate. The catalyst may be made from an as-synthesized material which, upon calcination, is capable of generating zeolites designated MCM-22. The as-synthesized material is then combined with a binder material, such as alumina, by an extrusion process. The uncalcined bound material may then be ammonium exchanged, followed by a calcination treatment. The as-synthesized material may also be swollen with a suitable swelling agent, such as a cetyltrimethylammonium compound, prior to the binding process.

Abstract: This invention relates to use of MCM-49 in catalytic cracking. Large amounts of light olefins are produced.

Abstract: Relatively short chain alkyl aromatic compounds are prepared by alkylating an alkylatable aromatic compound with a relatively short chain alkylating agent under sufficient reaction conditions in the presence of a catalyst comprising zeolite MCM-56. The liquid phase syntheses of ethylbenzene and cumene are particular examples of such MCM-56 catalyzed reactions.