Abstract: Catalytic cracking catalysts which contain a basic alkaline earth metal component in amounts greater than 5 percent by weight (expressed as the oxides) are used to crack hydrocarbon feedstocks that contain substantial quantities of metals such as vanadium, nickel, copper and iron. In a particularly preferred embodiment natural or synthetic particulate magnesium oxide (MgO) containing composites such as dolomite or a formed particulate coprecipitated magnesia-silica cogel (MgO.SiO.sub.2) having a substantial intra-particle pore volume in pores ranging from about 200-10,000 .ANG. in diameter and an average pore diameter greater than about 400 .ANG. in the 200-10,000 .ANG. diameter range is mixed with a zeolite containing fluid cracking catalyst (FCC) either as an integral component of the catalyst particle or as a separate additive.

Abstract: A synthetic faujasite molded body having high purity and high crystallinity is prepared with a good reproducibility by a process wherein a structure-inducing substance is incorporated in a starting material mixture comprising as main components a silica source, an alumina source, an alkali source and water; the mixture is kneaded and molded into a desired shape; and the molded body is heated in an aqueous solution of an alkali metal silicate or hydroxide. The structure-inducing material has a composition defined by the following oxide molar ratios:SiO.sub.2 /Al.sub.2 O.sub.2 =14 to 60,M.sub.2 O/Al.sub.2 O.sub.3 =15 to 40 andH.sub.2 O/M.sub.2 O=12 to 40 (M=alkali metal),and is prepared by mixing together an aqueous alkali metal silicate solution, an aqueous alkali metal aluminate solution and an aqueous alkali metal hydroxide solution to prepare a liquid phase substance having a composition defined by the following oxide molar ratios:SiO.sub.2 /Al.sub.2 O.sub.3 =8 to 14,M.sub.2 O/Al.sub.2 O.sub.

Abstract: Catalyst of aluminosilicate type for isomerization of a C.sub.8 aromatic cut, characterized by the following composition, expressed by weight:(a) 0.01 to 1.5% of at least one metal selected from platinum and palladium,(b) 0 to 99.49% of a matrix,(c) 0.5 to 99.99% of a zeolite corresponding to the following approximate formula:M.sub.2/n O, Al.sub.2 O.sub.3, X SiO.sub.2,whereinM is a proton and/or a metal cation,n is the valence of said cation,x is a number from 12 to 1000, the zeolite, of MFI structure, synthesized in fluoride medium, containing a fluorine proportion, incorporated therewith during the synthesis, in the range from 0.02 to 1.5% by weight.

Abstract: Catalytic cracking catalysts which contain a basic alkaline earth metal component in amounts greater than 5 percent by weight (expressed as the oxides) are used to crack hydrocarbon feedstocks that contain substantial quantities of metals such as vanadium, nickel, copper and iron. In a particularly preferred embodiment natural or synthetic particulate magnesium oxide (MgO) containing composites such as dolomite or a formed particulate coprecipitated magnesia-silica cogel (MgO.SiO.sub.2) having a substantial intra-particle pore volume in pores ranging from about 200-10,000 .ANG. in diameter and an average pore diameter greater than about 400 .ANG. in the 200-10,000 .ANG. diameter range is mixed with a zeolite containing fluid cracking catalyst (FCC) either as an integral component of the catalyst particle or as a separate additive.

Abstract: Sulfur oxide gettering agents which comprise a metal sulfate, such as magnesium sulfate, are described. These getterin agents are used to reduce sulfur oxide emissions from a variety of processes and units, including fluid catalytic cracking (FCC) units.

Abstract: There is provided an improvement for making large crystallite ZSM-5 zeolites by a method comprising forming the zeolite in a medium containing a combination of tetramethylammonium and tetrapropylammonium cations. The improvement involves the addition of sodium chloride to the aqueous reaction medium to increase the uniformity of crystallite size and to increase the mean crystallite size. Also provided are catalysts comprising these ZSM-5 crystallites and processes for converting organic compounds with these catalysts.

Abstract: ZSM-5 crystallites are produced with very low levels of blocking tetrapropyl ammonium ions (Q). The reaction mixture contains sources of silica, soda, alumina and trace amounts of Q ions as nucleation agents. Because the crystallites as synthesized from the aqueous medium exhibit only a very small fraction of blocking cations, there is always a diffusion path for the hydrated sodium ions to be exchanged without the need of prior removal of the blocking cations by calcination or otherwise. The small size crystallites can be exchanged, blended with other materials, and formed into catalyst particles. The silica to alumina ratio can be varied and when no aluminum is added, silicalite may be formed. The systhesis can be done in 24 hours or less.

Abstract: Cracking catalysts which yield higher octane gasoline than conventional cracking catalysts are made with large pore size zeolites such as zeolite Beta and zeolite ZSM-20 in the low sodium, H.sup.+ form. These zeolites are mixed with a matrix which contains at least a binder and formed into catalyst particles. These catalysts are especially suitable to be used in fluid catalytic cracking.

Abstract: A method for making a catalyst containing a vanadium passivating agent in the form of anatase crystalline TiO.sub.2 including a method for processing hydrocarbon feeds containing vanadium.

Abstract: Catalytic compositions which comprise alumina bound spinel and/or spinel-mullite mixtures having an alkali metal content of below about 0.50 weight percent, preferably below about 0.10. The compositions are obtained by calcining and caustic leaching preformed particulate composites of clay and alumina sol, preferably chlorhydrol. The catalysts are particularly useful for the catalytic cracking of heavy hydrocarbon feedstocks to obtain gasoline and light cycle oil. When used for cracking feedstocks high in vanadium content these compositions may contain added alkaline earth oxide in order to passivate the vanadium.

Abstract: Commercial catalysts are prepared combining the various ingredients into a catalytic binder system which has been freed of sodium so that the catalyst ingredients can be preferably spray dried and used in Fluid Catalytic Cracking or Reduced Crude Conversion hydrocarbon conversion operations without subsequent washing or drying. Catalysts can even be prepared on site, e.g., in spray drier operations performed in the FCC/RCC refenerator. Low-sodium slurries of any or all of the following ingredients can be employed in the manufacture: zeolites, clays, sols, carbon blacks, sacrificial sieves, acid matrix substances, and getters.

Abstract: Disclosed are hydrocarbon conversion catalyst compositions, such as fluidizable cracking catalyst compositions, containing an anionic clay, e.g. a clay having a hydrotalcite, an ettringite or a hydrocalumite structure, for the conversion of sulphur-containing feedstocks, the anionic clay serving as sulphur oxides binding material. Also disclosed are absorbents containing the anionic clay embedded in a matrix. The absorbents may be used to purify sulphur oxides-containing gases.

Abstract: The invention involves composite structures of multiple phases, at least two of which are inorganic crystalline compositions that are contiguous and have a common crystal framework and structure, and at least one of them contains phosphorus and aluminum atoms as part of its crystalline framework structure; and to processes for making the same. It is desired that each phase has a microporous molecular sieve structure. The process involves the growth of a crystalline structure constituting such a phase in the presence of crystals of another of such a phase. Preferably, the process involves a hydrothermal crystallization treatment of the precursors to such phase.

Abstract: Catalytic compositions which comprise alumina bound spinel and/or spinel-mullite mixtures having an alkali metal content of below about 0.50 weight percent, preferably below about 0.10. The compositions are obtained by calcining a caustic leaching preformed particulate composites of clay and alumina sol, preferably chlorhydrol. The catalysts are particularly useful for the catalytic cracking of heavy hydrocarbon feedstocks to obtain gasoline and light cycle oil. When used for cracking feedstocks high in vanadium content these compositions may contain added alkaline earth oxide in order to passivate the vanadium.

Abstract: Acid reacted metakaolin useful for the preparation of catalyst and catalyst support compositions. The compositions may include solid inorganic oxides, such as zeolities, clay and/or inorganic gels. The compositions are spray dried and calcined to obtain highly active, dense, attrition resistant fluid cracking catalysts, or used in the preparation of formed catalyst supports.

Abstract: There is disclosed a process for cracking a hydrocarbon feed in the presence of a fluidizable cracking catalyst composition containing a sepiolite, an ultrastable Y-zeolite and a matrix material, characterized in that the hydrocarbon feed is metal-free.

Abstract: Hydrocarbon conversion catalysts containing zeolite beta as a catalytically active component, either on its own or with other zeolites, especially faujasites such as ultrastable zeolite Y (USY) are produced by including a metal cationic complex compound such as aluminum hydroxychloride or aluminum zirconium hydroxychloride as a stabilizing component to improve the hydrothermal stability and physical strength of the catalyst. The zeolites may be formulated into catalysts for catalytic cracking, hydrocracking, dewaxing, alkylation, isomerization, hydration and other hydrocarbon conversion processes using porous matrix materials such as silica, silica alumina or clays.

Abstract: Catalysts which comprise or contain caustic leached spinel/mullite are found to possess a particularly high activity and stability for the catalytic conversion of hydrocarbons.

Abstract: High concentrations of small (<4 microns) crystalline catalyst ingredients such as ZSM-5, low-soda exchanged Y-zeolite, ultra-stable Y-zeolite etc., can be incorporated into a durable matrix by use of binder formulations prepared from amorphous silica, alumina and zirconia, particularly those of colloidal dimensions. The binder formulations are slurried and associated with at least one active catalyst ingredient, which preferably is up to 60% ZSM-5. The resulting material is then spray-dryed and calcined to form binder matrices which are particularly resistant to attrition and particle density change.

Abstract: Octane and improvement in catalytic cracking processes can be attained by the addition to conventional cracking catalysts of small amounts of additive catalyst comprising a class of zeolites characterized by a silica to alumina mole ratio greater than about 12 and a Constraint Index of about 1 to 12 bound in a matrix chosen such that the matrix component forms a thermodynamically favored compound with selected cations. Sustained catalytic activity is achieved by pre-exchanging the catalyst to a high level of selected cation loading. By extending the active life of the additive catalyst, markedly lower makeup catalyst addition rates are required.

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: A cracking catalyst composition comprising a zeolitic, crystalline aluminosilicate, a matrix material and a barium titanium oxide. The catalyst composition is particularly suitable for cracking metal-containing hydrocarbon feedstocks.

Abstract: Hydrocarbon feedstocks containing relatively high levels of nitrogen contaminants are converted by catalytic cracking to products of lower average molecular weight by contacting the feedstock under cracking conditions with a cracking catalyst having a surface area of at least 150 m.sup.2 /gm and comprising greater than about 25 weight percent of a rare earth exchanged Y zeolite dispersed in a matrix containing a synthetic silica-alumina component in which the weight ratio of silica-to-alumina is equal to or greater than about 0.5.

Abstract: A method is provided of crystallizing strong-bound zeolites on the surfaces of a monolithic ceramic substrate by hydrothermally treating the substrate, in the presence of active silica, with a caustic bath to zeolitize the silica. According to various embodiments of the invention, the active silica can be present as a component of the caustic bath, in the form of a dried coating pre-deposited on the substrate, or as a separate phase of the monolithic substrate, homogeneous dispersed within the ceramic material.

Abstract: A cracking catalyst composition comprising a zeolitic, crystalline aluminosilicate, a matrix material and a barium titanium oxide. The catalyst composition is particularly suitable for cracking metal-containing hydrocarbon feedstocks.

Abstract: A process for catalytic cracking using a catalyst obtained by preparing pillared interlayered clay materials comprises the steps of contacting a smectite containing material, preferably bentonite, with a solution comprising at least one of ammonium and alkali metal carboxylates and alkali metal carbonates and bicarbonates, plus preferably also alkali metal dithionite; separating the thus-contacted material from the solution; treating the separated material with a solution comprising a polymeric cationic hydroxy metal complex, preferably of aluminum (more preferably, polymeric hydroxy aluminum chloride); separating and finally heating the thus-treated smectite material. The pillared interlayered clay material of this invention can be intimately admixed with zeolite. The pillared interlayered clay material of this invention, with or without zeolite, can be used as catalyst for cracking hydrocarbon-containing oils.

Abstract: A catalyst composition that is prepared by adding phosphorus to a hydrogel slurry of fibrous pseudoboehmite having a diameter of 0.05-0.3 .mu. and a length of 0.5 .mu. or more, mixing a crystalline aluminosilicate zeolite and a clay mineral therewith, spray drying this mixture and calcining, and has a total pore volume (PV) of 0.3-0.7 cc/g, a volume (PVa) occupied by pores whose diameter is 600 .ANG. or less of 0.3-0.7 cc/g and a PVb/PVa ratio where PV-PVa=PVb of 0.5-2.0, displays superior activity, selectivity and metals tolerance when used in the fluid cat-cracking of heavy hydrocarbon oils, in particular residual oils.

Abstract: A crystalline swellable sheet silicate of the saponite type, of the formula[Mg.sub.6 (Si.sub.8-x Al.sub.x)O.sub.20 (OH).sub.4 ].sup.x-.(x/z)M.sup.z+ n H.sub.2 Oin whichx is a number which is less than 1.5 but at least 0.2,z is an integer from 1 to 3,M denotes a cation having the valency of z andn is a number less than 20, is prepared. For this purpose, an aqueous solution or suspension containing magnesium ions, a silica source, an alumina source and a sodium oxide source are combined. The atomic ratio of Mg/Si and Mg/Al used in this procedure correspond to the composition of the desired saponite. The atomic ration (Na-Al):(Mg+Si+3/2.Al) should be between x/5 and 1, Na denoting the amount of sodium atoms present in alkaline compounds. The pH of the reaction mixture should be at least 9.0. The crystals of the resulting synthetic saponite in the sodium form are separated off from the mother liquor and, if appropriate, treated with an aqueous solution or suspension of a salt having the cation M.sup.

Abstract: Catalysts which comprise or contain caustic leached spinel/mullite are found to possess a particularly high activity and stability for the catalytic conversion of hydrocarbons.

Abstract: A process for preparing pillared interlayered clay materials comprises the steps of contacting a smectite containing material, preferably bentonite, with a solution comprising at least one of ammonium and alkali metal carboxylates and alkali metal carbonates and bicarbonates, plus preferably also alkali metal dithionite; separating the thus-contacted material from the solution; treating the separated material with a solution comprising a polymeric cationic hydroxy metal complex, preferably of aluminum (more preferable, polymeric hydroxy aluminum chloride); separating and finally heating the thus-treated smectite material. The pillared interlayered clay material of this invention can be intimately admixed with zeolite. The pillared interlayered clay material of this invention, with or without zeolite, can be used as catalyst for cracking hydrocarbon-containing oils.

Abstract: Macrostructural units of various shapes and forms having a catalytically-active zeolite surface particularly useful in catalyzing hydrocarbon conversion reactions are prepared by:(a) mixing a slurry containing one or more of finely divided silicon, silica gel, alumina, aluminum hydroxide and kaolin, and having the desired ratio of silicon atoms to aluminum atoms, with plasticizer to form a plastic mass;(b) shaping the plastic mass to a desired configuration;(c) calcining the shaped plastic mass at 500.degree. to 800.degree. C. for 1 to 10 hours to form a rigid macrostructural unit having the same configuration as the shaped plastic mass;(d) crystallizing 5 to 80% of the rigid macrostructural unit obtained by calcination to crystalline aluminosilicate zeolite; and,(e) activating the crystalline aluminosilicate zeolite to catalytically-active zeolite.

Abstract: An improved process for ion-exchanging sodium ions in particles containing sodium form zeolite crystals and sodium silicate. The process involves an initial ion-exchange at pH about 4.5 to 5.0 with an ammonium salt followed by exchange with an ammonium salt at about pH 2.0 to 3.5. Cracking catalysts having improved cracking activity are produced.

Abstract: The invention relates to a process for the dry incorporation of manganese ions on the external reactive sites of Zn-ZSM-5 or Zn-ZSM-11 pentasil which comprises mixing a Zn-ZSM-5 or Zn-ZSM-11 zeolite with bentonite, impregnating the dry mixture with a minimum amount of a solution of a manganese salt thereby to form a malleable paste and extruding said paste under pressure whereby the manganese ions are affixed to the surface reactive sites of the treated zeolite and to the zeolite catalyst thus obtained.

Abstract: Pillared, interlayered clay products suitable as gas separation agents or as substrates for catalyst compositions are prepared by methods that provide an increase in surface area and pore volume as compared to similar products made by prior art methods.

Abstract: According to the present invention, a catalyst composition for use in cracking hydrocarbon can be prepared by spray drying an aqueous slurry containing a flash calcined alumina obtained by contacting an aluminum hydroxide with a hot air of 350.degree.-700.degree. C. in a short time within 5 seconds, kaolin, a precursor substance of a silica-system matrix and a crystalline aluminosilicate. Since this catalyst composition contains the flash calcined alumina and kaolin in addition to the siliceous matrix and the crystalline aluminosilicate, it can exhibit an excellent selectivity for production of intermediate fractions such as kerosene, gas oil and the like, when used for catalytic cracking of hydrocarbon.

Abstract: The useful storage life of a clear solution of seeds used to initiate the crystallization of zeolite in porous microspheres of calcined clay is increased by adding sodium silicate solution to a matured seed solution.

Abstract: A catalyst composition suitable for catalytic cracking of a heavy hydrocarbon oil containing large amounts of metal contaminants is prepared by the steps of spray-drying an aqueous slurry containing a flash calcined alumina obtained by contacting an aluminum hydroxide prepared Bayer's process with a hot air of 350.degree.-700.degree. C. for 5 seconds or less, clay being predominantly composed of silica and alumina, a precursor of a siliceous inorganic oxide and a crystalline aluminosilicate; washing this particle until the alkali metal content therein is reduced to 1.0 wt % or less as oxide; and thereafter incorporating a rare earth component in the particle.

Abstract: A novel catalyst composition comprising a solid cracking catalyst and a diluent containing substantially catalytically inactive crystalline aluminosilicate.

Abstract: Commercial catalysts are prepared combining the various ingredients into a catalytic binder system which has been freed of sodium so that the catalyst ingredients can be preferably spray dried and used in Fluid Catalytic Cracking or Reduced Crude Conversion hydrocarbon conversion operations without subsequent washing or drying. Catalysts can even be prepared on site, e.g., in spray drier operations performed in the FCC/RCC regenerator. Low-sodium slurries of any or all of the following ingredients can be employed in the manufacture: zeolites, clays, sols, carbon blacks, sacrificial sieves, acid matrix substances, and getters.

Abstract: Catalysts of improved strength and activity are formed by compositing a clay matrixing material with a zeolite which contains cations of a Group IB metal, preferably a monovalent metal such as silver. The presence of the cations gives the zeolite improved resistance to the high sintering temperatures necessary to confer adequate strength upon the resulting catalyst.

Abstract: The present invention is directed to a fluid catalytic cracking catalyst comprising a blend of a catalytically active first component and a second component for reducing the emissions of oxides of sulfur from the regenerator of a catalytic cracking unit and the use of that catalyst to crack sulfur containing petroleum feedstocks. The catalytically active first component contains Y-faujasite zeolite and comprises about 10-70% by weight, preferably about 25-50% by weight, of the catalyst. The second component of the catalyst comprises about 30-90% by weight, preferably about 50-75% by weight, of the catalyst. The second component comprises fluidizable particles containing at least about 70% by weight, preferably at least about 90% by weight, alumina and having an equilibrium surface area in the range of about 40-100 m.sup.2 /g., preferably in the range of about 50-90 m.sup.2 /g.

Abstract: A zeolite agglomerated article is provided, which is formed from a zeolite composition having incorporated therein at least one additive selected from alkaline earth metal oxides and hydroxides, alkaline earth metal aluminates and silicates and double salts containing an alkaline earth metal chloride. The zeolite agglomerated article is stable against a hydrothermal reaction.

Abstract: Catalytic cracking catalysts and catalytic cracking process wherein the cracking catalysts are prepared by: (i) contacting a mixture of a large pore zeolite and an inorganic oxide matrix at effective conditions of temperature, pH and time with a fluoro salt; and (ii) ammonium exchanging the product of step (i) to provide a catalyst having less than 2.0 percent by weight Na.sub.2 O, based on the weight of the zeolite. Optionally, the product is provided with an effective amount of at least one cation selected from the class consisting of cerium, lanthanum, praseodymium, neodymium, promethium, samarium, europium, lutetium, gadolinium, terbium, dysprosium, holmium, erbium, thulium and ytterbium.

Abstract: A catalyst nominally containing zeolite, clay and silica-alumina gel. The zeolite is preferably partially exchanged with high La/Ce ratio solution in a wetting step. The catayst and processes for its manufacture and use are disclosed. The catalyst is excellent for processing heavy oils, generally produces higher LCO/slurry oil ratio and has high metals tolerance.

Abstract: Catalytic cracking catalysts and catalytic cracking process wherein the cracking catalysts are prepared by: (1) contacting a mixture of a large pore zeolite and an inorganic oxide matrix at effective conditions of temperature, pH and time with a fluoro salt; and (2) ammonium exchanging the product of step (1) to provide a catalyst having less than 0.3 percent by weight Na.sub.2 O. Optionally, the product is provided with an effective amount of at least one cation selected from the class consisting of cerium, lanthanum, praseodymium, neodymium, promethium, samarium, europium, lutetium, gadolinium, terbium, dysprosium, holmium, erbium, thulium and ytterbium.

Abstract: Co-product fines from the manufacture of zeolitic cracking catalysts from microspheres of calcined clay have heretofore been discarded as a waste stream. These fines, recovered as a moist cake, are slurried in a sodium silicate solution, spray dried to form microspheres and ion-exchanged initially at high pH and then at lower pH to produce attrition-resistant cracking catalysts which produce low levels of coke during use.

Abstract: An improved process for preparing a fluid cracking catalyst is disclosed. A slurry of microspheres of kaolin clay calcined to undergo the characteristic exotherm, microspheres of kaolin clay calcined to metakaolin condition and sodium hydroxide solution is formed. The weight ratio of microspheres of kaolin calcined to undergo the exotherm to microspheres of kaolin calcined to metakaolin condition is in the range of about 9/1 to 4/1; the sodium hydroxide solution is of about 16% to 20% concentration and is present in amount such that the molar ratio of Na.sub.2 O/Al.sub.2 O.sub.3 in said slurry is in the range of about 0.6 to 0.7. The slurry is aged and an additional quantity of microspheres of kaolin clay calcined to undergo the characteristic exotherm is added. The quantity of microspheres of clay calcined to undergo the exotherm added is such that the total weight ratio of such microspheres to microspheres of metakaolin is in excess of 9/1.

Abstract: A single catalyst system capable of demetalizing, hydrotreating and hydrodewaxing petroleum residue in a single stage process is described. The catalyst system utilized includes one or more metal oxides or sulfides of Group VIA and Group VIII of the periodic Table impregnated on a base of refractory oxide material and Zeolite Beta. The catalyst also has about 75% of its pore volume in pores no greater than 100 Angstrom units in diameter and about 20% of its pore volume in pore greater than about 300 Angstrom units in diameter.

Abstract: A new catalyst which can be prepared from certain aluminosilicates and certain clay minerals, a process for its preparation and a process for the skeletal isomerization of n-alkenes to iso-alkenes which is carried out in the presence of this catalyst.

Abstract: Catalytic compositions comprising up to about 50 weight percent ZSM-5 zeolite dispersed in an attrition resistant, porous inorganic oxide matrix selected from silica-alumina cogels, silica, alumina and silica alumina sol bound clay. The compositions are combined with zeolitic containing catalytic cracking catalysts and used to convert residual and/or gas oil hydrocarbon feedstocks into lower molecular weight products that include high octane gasoline fractions.