Abstract: A second-stage hydrocracking catalyst is provided, comprising: a) a zeolite beta having an OD acidity of 20 to 400 ?mol/g and an average domain size from 800 to 1500 nm2; b) a zeolite USY having an ASDI between 0.05 and 0.12; c) a catalyst support; and d) 0.1 to 10 wt % noble metal; wherein the second-stage hydrocracking catalyst provides a hydrogen consumption less than 350 SCFB across a range of synthetic conversions up to 37 wt % when used to hydrocrack hydrocarbonaceous feeds having an initial boiling point greater than 380° F. (193° C.). A second-stage hydrocracking process using the second-stage hydrocracking process is provided. A method to make the second-stage hydrocracking catalyst is also provided.

Abstract: A second-stage hydrocracking catalyst is provided, comprising: a) a zeolite beta having an OD acidity of 20 to 400 nmol/g and an average domain size from 800 to 1500 nm2; b) a zeolite USY having an ASDI between 0.05 and 0.12; c) a catalyst support; and d) 0.1 to 10 wt % noble metal; wherein the second-stage hydrocracking catalyst provides a hydrogen consumption less than 350 SCFB across a range of synthetic conversions up to 37 wt % when used to hydrocrack hydrocarbonaceous feeds having an initial boiling point greater than 380° F. (193° C.). A second-stage hydrocracking process using the second-stage hydrocracking process is provided. A method to make the second-stage hydrocracking catalyst is also provided.

Abstract: A monomer is added to a solvent containing metal salt and porous support materials and the solvent is stirred for a period of time to distribute and fix the metal in the pores of the support materials. The solids that are dispersed in the solvent are then separated from the liquid, dried and calcined to form heterogeneous catalysts. The monomer that is added is of a type that can be polymerized in the solvent to form oligomers or polymers, or both. When forming heterogeneous catalysts containing platinum, acrylic acid is selected as the preferred monomer.

Abstract: A second-stage hydrocracking catalyst is provided comprising: a. from 40 wt % to 70 wt % of a zeolite USY having an ASDI from 0.05 to 0.18; b. an amorphous silica alumina; c. a second alumina; and d. 0.1 to 10 wt % noble metal; wherein the second-stage hydrocracking catalyst has a BET surface area from 450 to 650 m2/g. A second-stage hydrocracking process is provided comprising using the second-stage hydrocracking catalyst to produce middle distillate. A method for making the second-stage hydrocracking catalyst is also provided.

Abstract: This disclosure relates to supported multi-metallic catalysts for use in the hydrotreating of hydrocarbon feeds, as well as a method for preparing such catalysts. The catalysts are prepared from a catalyst precursor comprised of at least one Group VIB metal, at least one Group VIII metal and an organic acid. The catalyst precursor is thermally treated to partially decompose the organic acid, then sulfided. The catalysts have a high carbon-as-carboxyl to total carbon ratio (Ccarboxy/Ctotal) as a result of a unique post-metal calcination method employed during the manufacture of the catalyst.

Abstract: This disclosure relates to supported multi-metallic catalysts for use in the hydrotreating of hydrocarbon feeds, as well as a method for preparing such catalysts. The catalysts are prepared from a catalyst precursor comprised of at least one Group VIB metal, at least one Group VIII metal and an organic acid. The catalyst precursor is thermally treated to partially decompose the organic acid, then sulfided. The catalysts have a high carbon-as-carboxyl to total carbon ratio (Ccarboxy/Ctotal) as a result of a unique post-metal calcination method employed during the manufacture of the catalyst. As a result, the hydrotreating catalysts have lower percent weight loss-on-ignition, higher activity and longer catalyst life.

Abstract: This disclosure relates to supported multi-metallic catalysts for use in the hydrotreating of hydrocarbon feeds. The catalysts are prepared from a catalyst precursor comprised of at least one Group VIB metal, at least one Group VIII metal and an organic acid. The catalyst precursor is thermally treated to partially decompose the organic acid, then sulfided. The catalysts have a high carbon-as-carboxyl to total carbon ratio (Ccarboxy/Ctotal) as a result of a unique post-metal calcination method employed during the manufacture of the catalyst.

Abstract: Alumina support compositions comprising at least 0.1 wt % of silica are disclosed. The alumina support are characterized by a pore volume of greater than 0.60 cc/g, a median pore size ranging from about 70 to about 120, a pore size distribution such that at least 90% of the total pore volume falls within the range of about 20 to about 250, and a pore size distribution width of no less than about 40. Alumina compositions of the present invention exhibit a primary peak mode at a pore diameter less than the median pore diameter. Also provided are catalysts made from the alumina supports, and processes of preparing and using the supports and catalysts.

Abstract: An emission control catalyst that exhibits improved CO and HC reduction performance includes a supported platinum-based catalyst, and a supported palladium-gold catalyst. The two catalysts are coated onto different layers, zones, or monoliths of the substrate for the emission control catalyst such that the platinum-based catalyst encounters the exhaust stream before the palladium-gold catalyst. Zeolite may be added to the emission control catalyst as a hydrocarbon absorbing component to boost the oxidation activity of the palladium-gold catalyst.

Abstract: A method for preparing a catalyst that involves continuously supplying a first stream containing a solvent, one or more metal precursors, and one or more support materials, and a second stream containing at least one reducing agent and/or precipitating agent. The first and second streams are combined to form a combined stream. In one embodiment, the combined stream may be fed to a mixing vessel. In another embodiment, the streams are combined in a mixing vessel. After the streams are combined, one or more metal precursors is reduced or precipitated within the pores of the one or more support materials. Thereafter, solids are separated from the combined stream and processed to produce the supported metal, mixed-metal, metal oxide, or mixed-metal oxide catalyst. In another embodiment, ceramic or metallic monoliths may be coated with the catalytic material after the stream combination and before or after the solid separation and subsequent processing.

Abstract: An engine exhaust catalyst exhibits improved CO oxidation performance relative to conventional engine exhaust catalysts and includes a first supported catalyst comprising platinum and a second supported catalyst comprising palladium and gold species in close contact. The first supported catalyst may be a platinum catalyst, a platinum—palladium catalyst, or a platinum catalyst promoted with bismuth, and the second supported catalyst preferably has a palladium to gold weight ratio of about 0.85:1.0. To improve aged catalyst performance, the first and second supported catalysts are coated onto different layers, zones, or monoliths of the substrate for the engine exhaust catalyst.

Abstract: An engine exhaust catalyst containing precious metal nanoparticles is promoted with bismuth. The bismuth promotion improves the catalyst's CO oxidation performance. Also, by varying the amount of bismuth that is added, the NO conversion rate that can be realized with the catalyst can be controlled. The control over the NO conversion rate is important because the passive regenerative performance of a particulate filter used in engine exhaust systems is based on the amount NO2 that is present in the exhaust stream that reaches the particulate filter. The amount of NO2 being produced needs to be optimized (not necessarily maximized) so that adequate particulate filter regeneration performance can be maintained while avoiding unused, toxic NO2 from being exhausted into the atmosphere.

Abstract: An engine exhaust catalyst containing precious metal nanoparticles is promoted with bismuth. The bismuth promotion improves the catalyst's CO oxidation performance. Also, by varying the amount of bismuth that is added, the NO conversion rate that can be realized with the catalyst can be controlled. The control over the NO conversion rate is important because the passive regenerative performance of a particulate filter used in engine exhaust systems is based on the amount NO2 that is present in the exhaust stream that reaches the particulate filter. The amount of NO2 being produced needs to be optimized (not necessarily maximized) so that adequate particulate filter regeneration performance can be maintained while avoiding unused, toxic NO2 from being exhausted into the atmosphere.

Abstract: A sample preparation method for characterization of nanoparticles embedded in the supports of heterogeneous catalysts, with improved particle dispersion, is introduced. The supported catalyst is first ground or milled into fine powder. Then, the powder is mixed into an organic solvent, and an etchant is added to the solvent to digest the supports and release metallic nanoparticles. The resulting solution is then placed in an ultrasonic bath where ultrasonic waves are generated and applied to the solution. The ultrasonic waves suppress agglomeration of the particles and also break up those particle clusters resulting from agglomeration during the prior steps. Subsequently, a sample is extracted from the solution and prepared for analysis.

Abstract: The catalytic efficiency of supported catalysts containing metal nanoparticles is strongly related to the chemical softness at the surfaces of such nanoparticles. Supported catalysts containing platinum nanoparticles having average surface softness values (expressed in scaled units ranging from 0 to 1) between 0.07198 and 0.09247 exhibit high catalytic efficiency. The catalytic efficiency of such platinum nanoparticles for CO oxidation, expressed as the turn-over frequency (TOF), was observed to be on or above 0.03062 s?1. The supported catalysts containing platinum nanoparticles with tighter average surface softness ranges exhibit even higher catalytic efficiencies. The TOF for CO oxidation of platinum nanoparticles having average surface softness values between 0.08031 and 0.08679 was observed to be on or above 0.06554 s?1.

Abstract: The catalytic efficiency of supported catalysts containing metal nanoparticles is strongly related to the chemical softness at the surfaces of such nanoparticles. The chemical softness of a nanoparticle is obtained using results from Density Functional Theory modeling, an extended version of Embedded Atom Method modeling, and continuum modeling based on size and shape of the nanoparticle. A metal nanoparticle of a certain size and shape is first modeled using the extended EAM and EAM parameters that have been validated with results from DFT modeling, to obtain atomic energy densities at each atom location. The chemical softness value at each atom location is then calculated from the atomic energy densities and various parameters that are derived based on results from DFT modeling. The surface chemical softness value is derived from the local chemical softness values based on the geometry and atomistic structure of the metal nanoparticle.

Abstract: A method for producing highly dispersed catalysts is disclosed. The method includes contacting a support material with a solvent for a period of time, adding a metal salt to the solvent and support mixture, and then adding a reducing agent to the solution to reduce the metal salt to nanometer sized metal particles on the surface of the support. Excess solvent is used in the process, the volume of solvent being greater than two times the pore volume of the support.

Abstract: Supported catalysts are produced with nanometer sized particles comprised of different metals dispersed throughout the catalyst support material. The supported catalysts reduce substantially or completely the amount of platinum that is required without sacrificing catalytic performance. In place of platinum, the supported catalysts employ palladium, silver, or copper, all of which costs significantly less than platinum.

Abstract: A monomer is added to a solvent containing metal salt and porous support materials and the solvent is stirred for a period of time to distribute and fix the metal in the pores of the support materials. The solids that are dispersed in the solvent are then separated from the liquid, dried and calcined to form heterogeneous catalysts. The monomer that is added is of a type that can be polymerized in the solvent to form oligomers or polymers, or both. When forming heterogeneous catalysts containing platinum, acrylic acid is selected as the preferred monomer.

Abstract: An engine exhaust catalyst containing precious metal nanoparticles is promoted with bismuth. The bismuth promotion improves the catalyst's CO oxidation performance. Also, by varying the amount of bismuth that is added, the NO conversion rate that can be realized with the catalyst can be controlled. The control over the NO conversion rate is important because the passive regenerative performance of a particulate filter used in engine exhaust systems is based on the amount NO2 that is present in the exhaust stream that reaches the particulate filter. The amount of NO2 being produced needs to be optimized (not necessarily maximized) so that adequate particulate filter regeneration performance can be maintained while avoiding unused, toxic NO2 from being exhausted into the atmosphere.