Abstract: Hydrothermally stable intercalated clays having interlayer (gallery) spacings greater than 21 angstroms are provided by pillars comprising a rare earth metal. The pillars preferably also contain a metal such as aluminum. Other pillaring metal/rare earth combinations and differing preparation conditions, such as pH, result in different interlayer spacings. Interlayer spacings of up to 50 angstroms may be produced.

Abstract: Catalyst compositions are described which comprise crystalline molecular sieve zeolites and an aluminum phosphate component having a surface area of less than about 50 m.sup.2 /g and a high degree of attrition resistance. The catalysts are particularly effective for the catalytic cracking of high molecular hydrocarbon feedstocks to obtain enhanced yields of C.sub.3 and C.sub.4 olefins such as isobutylene.

Abstract: Catalyst compositions and a process for making the same are disclosed. The composition finds application in the cracking of heavy hydrocarbon feedstock containing vanadium and other metal contaminants. It essentially comprises a crystalline zeolite, a metal trapping or passivating agent and an inorganic oxide matrix precursor and is characterized by minimum elution of an alkaline earth metal in the catalyst.

Abstract: Attrition-resistant binders can be prepared by a process wherein a slurry of clay particles is brought to either a low pH level (e.g., 1.0 to 3.0) or to a high pH level (e.g., 14.0 to 10.0) and mixed with a phosphate-containing compound in a concentration of from about 2.0 to about 20.0 weight percent. Preferably, the resulting slurry is spray dried and the particulate products of the spray drying are then calcined to produce attrition-resistant binder particles.

Abstract: Method of producing a cellular body for adsorption of preferably organic substances in purification plants, to which end a cellular structure is impregnated with a hydrophobic zeolite.Impregnation takes place using a sludge of the hydrophobic zeolite and an inorganic binder, the impregnated cellular structure being heated to a temperature at which the constituents thereof begin to sinter together.

Abstract: A layered catalyst suited to the catalytic cracking of heavy feeds comprises a core and a shell. The shell comprises at least 5 wt % of at least 1 molecular sieve having openings of at least 8 angstroms. The core comprises at least 10 wt % of at least 1 molecular sieve having openings comprising a 12 or less-membered ring and has a reduced, if any, content of said molecular sieve having openings of at least 8 angstroms, relative to its concentration in the shell. Suitable molecular sieve materials having openings of at least 8 angstroms include MCM-41, VPI-5, MCM-9 and layered metal oxides, e.g., pillared clays. The required molecular sieve of the core can include zeolite Y, Ultrastable Y or intermediate pore size zeolites such as ZSM-5. The shell which may further contain a metals passivator can act as a metals sink, and can remove metals from the unit by attrition. The catalyst is preferably prepared by forming the core and then coating or encapsulating the core with a shell material.

Abstract: An industrial shaped adsorbent for the non-cryogenic separation of gases from air, comprising from 70 to 95% by weight zeolites, and, correspondingly, from 30 to 5% by weight of a clay binder,(a) said zeolites consisting essentially of mixtures of X and A zeolites having an X crystallinity greater than or equal to 95% and an A crystallinity less than or equal to 5%, a toleune standard adsorption of 23.+-.1% and an X-ray spectrum characteristic of a practically pure faujasite, and with the Si/Al ratio of the crystalline component being 1.+-.0.03, and(b) with the adsorbent having a 2Ca/Al ratio between about 80 and 99%, a nitrogen adsorption between 16 and 23.5 L/kg and a ratio of the nitrogen to the oxygen adsorption capacities under 1 bar between 3.5 and 4.5 and the process of making such adsorbents.

Abstract: To obtain an improved catalyst for fluid cracking purposes, kaolin or metakaolin is reacted with an acid of the group of phosphoric, sulphuric and acetic acids by mixing and heating to 25.degree.-110.degree. C., after which the slurry is washed. The thus obtained kaolin is then mixed with a crystalline aluminosilicate and, optionally, with a clay (e.g. kaolin), an active matrix and, as balance, a synthetic matrix, such as silican, silica-alumina or aluminan. The improved catalyst gives a better performance in terms of conversion and gasoline-yield.

Abstract: Catalytic cracking catalysts which contain bayerite and/or eta alumina are used to process hydrocarbon feedstocks that contain nickel.

Abstract: A catalytic composite and its use in the fluidized catalytic cracking of hydrocarbons in the absence of added hydrogen. The composite comprises a binder material, a crystalline aluminosilicate, preferably a Y-type zeolite, and diatomaceous earth. Optional ingredients are kaolin, barium titanate and discrete particles of porous alumina. Absent from the composite is a supported catalytically active metal or metal oxide. The catalytic composite of the invention achieves higher gasoline production with lower coke production as compared to FCC catalysts with no diatomaceous earth content.

Abstract: A catalyst composition comprises a molecular sieve material and a boron phosphate-containing matrix. The catalyst composition is used in a catalytic cracking process to produce higher octane gasoline.

Abstract: Catalytic cracking catalysts and catalyst additives which contain silica modified bayerite and/or eta alumina.

Abstract: In accordance with the present invention, there is now provided a hybrid catalyst suitable for the aromatization of light paraffins and olefins, comprising a mixture of a pentasil type zeolite having the structure of ZSM-5 or ZSM-11, and a cocatalyst consisting of gallium oxide supported by an oxide selected from the group consisting of silica, alumina particles and chromium oxide particles.

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: The present invention is directed to a novel catalyst useful in the cracking of hydrocarbons. The catalyst of the present invention is formed with at least one zeolite, a first clay having a first average particle size and a second clay having a smaller average particle size than the first clay, wherein at least one of the clays or the zeolite is first treated with a source of phosphorus, such as phosphoric acid. These components are mixed in a slurry and spray dried at a low pH. Thus the present invention is also directed to a process for preparing a zeolite catalyst. The catalysts of the present invention advantageously do not require calcination in order to obtain low attritability.

Abstract: Layered adsorbent-substrate composites are prepared by methods comprising heating the surface of an aluminum substrate, contacting the surface of the substrate with a slurry containing the adsorbent and a binder, and heating the coatings to form hardened surfaces which can have excellent adsorption and mechanical properties and have a variety of uses such as adsorbents in automobile mufflers and as desiccants in multiple pane windows.

Abstract: Clinoptilolites, including both natural and synthetic clinoptilolites which have been ion-exchanged with metal cations such as lithium, sodium, potassium, calcium, magnesium, barium, strontiun, zinc, copper, cobalt, iron and manganese, are useful for the removal of traces of ammonia from streams of hydrocarbons having kinetic diameters of not more than about 5 .ANG.. This invention relates to the process of producing the modified clinoptilolite adsorbent.

Abstract: The present invention relates to the production of catalysts and adsorbents which can be used for the removal of nitrogen oxides from exhaust gases containing the same.

Abstract: Stable aqueous suspensions of crystalline aluminosilicate molecular sieve particles, particularly hydrophobic crystalline siliceous molecular sieves, are provided in compositions having a consistency ranging from thin lotions to semi-solid "stick" formulations. The aqueous suspensions are maintained using hydrophilic colloids, particularly a mixture of a colloidal magnesium silicate having the structure of smectite and an alkali metal salt of the carboxymethoxy ether of cellulose.

Abstract: To obtain an improved catalyst for fluid cracking purposes, kaolin or metakaolin is reacted with an acid of the group of phosphoric, sulphuric and acetic acids by mixing and heating to 25.degree.-110.degree. C., after which the slurry is washed. The slurry is not neutralized prior to washing. The thus obtained kaolin is then mixed with a crystalline aluminosilicate and, optionally, with a clay (e.g. kaolin), an active matrix and, as balance, a synthetic matrix, such as a silica, silica-alumina or alumina. The improved catalyst gives a better performance in terms of conversion and gasoline-yield.

Abstract: A novel shell-coated FCC catalyst is disclosed wherein the shell is a mixture of at least one refractory metal oxide or silicate or precursor thereof (preferably clay) having a particle size of 0.3 to 5 microns and an inorganic refractory binder (preferably silica) having a particle size of less than 0.01 microns and the core is a zeolite-containing microsphere. FCC with the shell coated catalyst is also disclosed.

Abstract: A hydrous aluminosilicate adsorbent composition in which the active adsorbent is a mixture of non-fibrous clay with non-fibrous zeolite. The composition is useful as a feed supplement in animal husbandry, and as a topical adsorbent for veterinary use. The mixture has a high capacity for adsorption of ammonium cations, and a synergistically high selectivity for their adsorption. Beneficial effects as feed supplement may arise from lowering the amount of ammonia passed to the liver from the alimentary canal.

Abstract: Catalytic cracking catalysts which comprise molecular sieves/zeolites dispersed in an inorganic oxide matrix that includes pollucite.

Abstract: A layered catalyst contains a core of at least one, and preferably three, molecular sieve components within a shell layer of reduced molecular sieve content. A preferred catalyst consists of a core of a large pore molecular sieve, preferably a dealuminized Y-type zeolite, a shape selective paraffin cracking/isomerization component, preferably HZSM-5, and a shape selective aliphatic aromatization component, preferably gallium ZSM-5, within a shell of an alumina-rich, matrix. The shell can capture metals from the feeds being processed, it can act as a metals sink, and can remove metals from the unit by attrition. The catalyst is preferably prepared by forming the core and then coating or encapsulating the core with a shell having a reduced molecular sieve content. The shell may contain a pillared clay or other very large pore cracking component. The shell may be an attritable coating of an amorphous rare earth oxide, aluminum oxide and aluminum phosphate composite, which traps metals.

Abstract: The present invention provides a composition in dry form, preferably in the form of a tablet, containing a combination of ingredients which upon addition to contaminated water effectively removes turbidity, metal and organic contaminants in the water and thereby makes the water safer for drinking. The composition is particularly useful for personal use so that safe drinking water can be obtained by the simple addition of the composition to the water to remove the turbidity and contaminating materials contained therein. Preferably the composition contains bentonite clay, attapulgite clay, polymeric coagulant and/or flocculent, biocide, zeolite and activated charcoal. The invention also provides a method for treating water with the composition as well as a method for making the composition.

Abstract: A composition for the catalytic cracking of a high metals content hydrocarbonaceous feedstock is disclosed, the catalyst comprising a magnesium-containing clay material, a silica-alumina cogel, and zeolite.

Abstract: Hydrothermally stable intercalated clays having interlayer (gallery) spacings of about 16 to 18 angstroms or more are provided by pillars comprising aluminum and cerium. Other pillaring metal/rare earth combinations and differing preparation conditions, such as pH, result in different interlayer spacings. Interlayer spacings of 16 to 40 or 18 to 50 angstroms may be produced.

Abstract: A catalytic cracking process especially useful for the catalytic cracking of high metals content feeds including resids in which the feed is cracked in the presence of a catalyst additive comprising an alkaline earth metal oxide and an alkaline earth metal spinel, preferably a magnesium aluminate spinel which acts as a trap for vanadium as well as an agent for reducing the content of sulfur oxides in the regenerator flue gas. The additive is used in the form of a separate additive from the cracking catalyst particles in order to keep the vanadium away from the cracking catalyst and so preserve the activity of the catalyst; in addition, use of separate additive particles permits the makeup rate for the additive to be varied relative to that of the cracking catalyst in order to deal with variations in the metals and sulfur content of the cracking feed.

Abstract: A composition for use as a road base or levee fill. The composition comprises catalytic cracking catalyst particles in the size range of 1 to 200 microns and a binder the type and amount of which depend on the end use. Hydrated lime is employed as the binder in road base construction while hydrated lime, portland cement, fly ash or mixtures of fly ash and portland cement can be used in levee construction. The catalyst particles are present in amounts of 80% to 96% and the binder is present in amounts of 4% to 20%,both percentage ranges being determiend according to the dry weight of the composition.

Abstract: A method for increasing the zeolite content of high zeolite content clay derived microspheres obtained by reacting porous precursor microspheres with a sodium silicate solution in the presence of seeds to crystallize zeolite Y in situ in macropores of precursor microspheres composed of a mixture of metakaolin and kaolin calcined to undergo the exotherm. The increased zeolite content is achieved by increasing macroporosity of the precursor microspheres and increasing the content of metakaolin in the precursor microspheres. The increase in zeolite is associated with an increase in catalytic activity and unexpectedly improved selectivity.

Abstract: A midbarrel hydrocracking catalyst for use in producing middle distillate products from hydrocarbon feedstocks via hydrocracking comprises at least one hydrogenation component, preferably one containing a metal selected from Group VIB and/or Group VIII of the Periodic Table of Elements, a layered magnesium silicate such as sepiolite, an intercalated clay such as pillared clay, and, optionally, a crystalline molecular sieve, preferably a zeolitic molecular sieve such as the modified Y zeolite known as LZ-10 zeolite.

Abstract: A process for making self-bound monolithic bodies of chabazite by mixing finely divided chabazite and a sodium aluminosilicate gel into monolithic bodies, the gel having a molar ratio of silica to aluminum between 1.0 and 1.5 and a molar ratio of sodium to silica from 0.35 to 0.55, and heating the monolithic bodies in the presence of water to convert the gel to additional chabazite.

Abstract: An artificial stone wick material for a burner which comprising SiO.sub.2 7-21 weight percent, Al.sub.2 O.sub.3 2-5 weight percent, Fe.sub.2 O.sub.3 1-3 weight percent, CaO 50-27 weight percent, MgO 0.5-3 weight percent, K.sub.2 O 0.5-3 weight percent, Na.sub.2 O 0-2 weight percent, and TiO.sub.2 0-2 weight percent, and processes for preparing the artificial stone wick from the raw materials of clay, portland cement, and zeolite are disclosed.

Abstract: A catalytic cracking process is disclosed employing a dual component cracking catalyst system comprising zeolite as a first component and a mixture of a calcium/magnesium-containing material and a magnesium-containing material as a second component. The preferred calcium/magnesium-containing material is dolomite and the preferred magnesium-containing material is sepiolite.

Abstract: Adsorbent material well adapted for the purification of gases (notably by the PSA and TSA methods) by adsorbing impurities therefrom that are more polar or polarizable than the gases to be purified, e.g., nitrogen, the oxides of carbon and hydrocarbons, comprises a matrix of a type 5A zeolite molecular sieve and a kaolinite clay binder therefor, the clay binder having a concentration of at least 75% by dry weight of kaolinite and a maximum quartz concentration of 20% by dry weight.

Abstract: Novel hydrocarbon conversion catalysts and methods for their preparation are disclosed. The catalysts are particularly appropriate for the conversion of hydrocarbon feeds to high octane gasoline, while increasing light cycle oil and decreasing heavy cycle oil yield. The catalyst comprises a zeolite, a cogelled silica-alumina matrix, and clay.

Abstract: A silica-magnesia cogelled material is usable as a base for petroleum cracking catalysts based on zeolites. Invention described provides cogel base in which the silica and magnesia components are intimately mixed. This feature is achieved by controlling the pH during the mixing procedure.

Abstract: A hydrocarbon conversion catalyst useful for converting hydrocarbon feeds to midbarrel products is prepared by extruding a mixture of an inorganic refractory oxide component and a crystalline aluminosilicate zeolite having cracking activity to form extrudates which are broken into particles normally ranging in length between 1/16 and 1/2 inch. The extruded particles are then calcined in the presence of steam at a water vapor partial pressure greater than about 2.0 p.s.i.a., preferably greater than about 5.0 p.s.i.a. The calcination step is carried out in the presence of sufficient steam for a sufficient amount of time at a sufficient temperature to convert the crystalline aluminosilicate zeolite in the extrudates into an ultrahydrophobic zeolite having a unit cell size between about 24.20 and about 24.45 Angstroms and a sorptive capacity for water vapor less than about 5 weight percent of the zeolite at 25.degree. C. and a p/p.degree. value of 0.10.

Abstract: Hydrocarbons containing vanadium are converted to lower boiling fractions employing a zeolitic cracking catalyst containing a significant concentration of a vanadium passivator.

Abstract: A catalytic cracking catalyst mixture and process are disclosed. The mixture comprises (a) a cracking catalyst containing a matrix and a large pore molecular sieve and (b) separate particles of additive catalyst comprising at least one of a shape selective paraffin cracking/isomerization zeolite and a shape selective aliphatic aromatization zeolite. An exemplary catalyst mixture comprises dealuminized zeolite Y, optionally containing rare earth elements, in an alumina rich matrix and an additive catalyst of HZSM-5, and gallium ZSM-5 in a matrix. The alumina matrix of the cracking catalyst acts as a sodium and metals sink. The large pore molecular sieve catalyst cracks large hydrocarbons to lighter paraffins and olefins. The shape selective paraffin cracking/isomerization component cracks the paraffins produced by the large pore molecular sieve. The shape selective aliphatic aromatization catalyst converts light paraffins and olefins into aromatics. A single shape selective zeolite, e.g.

Abstract: A dual component cracking catalyst system is disclosed comprising zeolite as a first component and a mixture of a calcium/magnesium-containing material and a magnesium-containing material as a second component. The preferred calcium/magnesium-containing material is dolomite and the preferred magnesium-containing material is sepiolite.

Abstract: An attrition resistant catalytic cracking catalyst is prepared by spray drying an aqueous slurry containing a molecular sieve having cracking activity, a clay such as kaolin, a silica sol and aluminum chlorhydroxide. The resultant catalyst has a high attrition resistance as compared to commercially available cracking catalysts.

Abstract: A catalyst is provided which comprises a crystalline zeolite, discrete particles of phosphorus containing alumina, particularly an alkaline earth metal phosphate containing alumina, dispersed in a non-zeolitic inorganic oxide matrix. A catalytic cracking process utilizing the catalyst is also provided. Such phosphate treated catalysts exhibit increased attrition resistance.

Abstract: An aromatization catalyst is obtained by physical mixing of a pentasil type zeolite, for example H-ZSM-5 and a zinc oxide-alumina co-precipitate. The weight ratio of the zeolite to the co-precipitate ranges from 4.3 to 28.3. The Zn/Al atomic ratio in the co-precipitate may range from about 0.16 to 25.0. The composite catalyst yields greater amounts of aromatics, particularly BTX aromatics, when contacted with an olefinic and/or paraffinic feedstock than the respective zeolite alone.

Abstract: The composition obtained by mixing a Y faujasite, having a phosphorus component into a water suspension of precursor of a porous matrix, and spray-drying said mixture, is a heavy hydrocarbon catalytic cracking catalyst which produces gasoline in high yield and is superior in thermally stability.

Abstract: A novel improved process for maunfacturing fluid cracking cataylsts by an in situ procedure. Sodium zeolite Y (synthetic faujasite) is crystallized in pores of a physical mixture of preformed, highly porous precursor microspheres, one portion of the microspheres is composed of metakaolin and the other portion of the mixture of microspheres being composed of kaolin calcined to undergo the exotherm (the latter somethimes being referred to as spinel calcined clay or simply spinel). In particular, by the present invention the precursor microspheres have enhanced porosity (e.g., 0.3 to 0.5 cc/g as measured by mercury porosimetry) and are obtained by spray drying a slurry of hydrous (raw) kaolin clay which is characterized by presence of a major amount of large (plus 2 micron) kaolin stacks, which when spray dried, result in microspheres having the desired high content of macropores in which zeolite Y can grow. Relatively high levels of metakaolin containing microspheres are used in the synthesis.

Abstract: Aluminum-rare earth element-oxygen oligomers, having unprecedented hydrothermal stability and disclosed such materials having utility as precursors in the preparation of large pore intercalated clays.

Abstract: Large-pore intercalated clays, for example, smectites, with pillars of aluminum-rare earth element-oxygen oligomers, having unprecedented hydrothermal stability. Product distributions demonstrate desirable synergistic effects (less gas, more gasoline, higher activity) using a mixture of intercalated clay and zeolite.

Abstract: The invention provides a catalyst composition useful in treating hydrocarbons contaminated with vanadium residues, the catalyst comprising a zeolite, a matrix and certain heavier alkaline earth metal oxides.

Abstract: Hydrocarbons containing vanadium are converted to lower boiling fractions employing a zeolitic cracking catalyst containing a significant concentration of a vanadium passivator.