Zeolite fluid cracking catalysts and preparation thereof...

Details Zeolite fluid cracking catalysts and preparation thereof... Zeolite fluid cracking catalysts and preparation thereof...

B - Operations, Transporting

01

J

196/100, 252/2.A

B01J 23/10 (2006.01) B01J 29/08 (2006.01) B01J 37/08 (2006.01) C10G 11/05 (2006.01)

Patent

CA 2000329

ABSTRACT OF THE DISCLOSURE A novel improved process for manufacturing fluid cracking catalysts 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 sometimes 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.

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