Claims
- 1. A catalyst composite comprised of an alumina-on-silica material which is comprised of silica particles with surface bound aluminum groups chemically bonded to the silica surface through surface oxygen atoms, which material is dispersed in a matrix comprised of a refractory oxide, wherein said material is prepared by: (i) coating silica particles with an aluminum compound capable of being thermally converted to an alumina surface phase under the conditions of (ii) and (iii) hereof; (ii) treating the coated silica material of (i) to a heat soak at a temperature from about 90.degree. C. to about 300.degree. C., for an effective amount of time; and (iii) calcining the alumina coated silica material at a temperature from about 300.degree. C. to about 1000.degree. C.
- 2. The catalyst composite of claim 1 wherein the silica of the alumina-on-silica material has a primary particle size within the range from about 10 Angstroms to about 1000 Angstroms, a maximum aggregate dimension in any direction within the range of about 0.01 microns to about 100 microns and a surface area within the range from about 1 m.sup.2 /g to about 2000 m.sup.2 /g.
- 3. The catalyst composite of claim 2 wherein the silica of the alumina-on-silica material is selected from the group consisting of fumed silica, a precipitated silica, a silica gel, and colloidal silica.
- 4. The catalyst composite of claim 3 wherein the silica is a fumed silica or a silica gel.
- 5. The catalyst composite of claim 1 wherein the matrix is selected from alumina, silica and a silica-alumina.
- 6. The catalyst composite of claim 3 wherein the matrix is selected from alumina, silica and silica-alumina.
- 7. The catalyst composite of claim 1 wherein said alumina is coated onto said silica such that said alumina-on-silica material is comprised of about 0.01 to about 20 wt. % aluminum.
- 8. The catalyst composite of claim 6 wherein said alumina is coated onto said silica such that said alumina-on-silica material is comprised of about 0.01 to about 20 wt. % aluminum.
- 9. The catalyst composite of claim 1 wherein the weight percent of the alumina-on-silica component is about 10 to 90 based on the total weight of the composite.
- 10. The catalyst composite of claim 8 wherein the weight percent of the alumina-on-silica component to matrix component is about 10 to 90.
- 11. The catalyst composite of claim 1 wherein a zeolite material is also present.
- 12. The catalyst composite of claim 10 wherein a zeolite material is also present.
- 13. The catalyst composite of claim 11 wherein the zeolite material is a faujasite.
- 14. The catalyst composite of claim 12 wherein the zeolite material is a faujasite.
- 15. The catalyst composite of claim 14 wherein the faujasite material is a Y-type zeolite selected from rare earth Y and ultrastable Y.
- 16. A method for preparing a catalyst composite for use in fluid catalytic cracking, which method comprises:
- (i) coating silica particles with an aluminum compound capable of being thermally converted to an alumina surface phase under the conditions of (ii) and (iii) hereof;
- (ii) treating the coated silica material of (i) to a heat soak at a temperature from about 90.degree. C. to about 300.degree. C., for an effective amount of time; and
- (iii) calcining the alumina coated silica material at a temperature from about 300.degree. C. to about 1000.degree. C.
- 17. The method of claim 16 wherein the calcining is accomplished at a temperature of about 300.degree. C. to about 1000.degree. C.
- 18. The method of claim 17 wherein the aluminum compound is an organoaluminum compound.
- 19. The method of claim 18 wherein the organoaluminum compound is an aluminum alkoxide.
- 20. The method of claim 19 wherein the aluminum alkoxide is aluminum isopropoxide.
- 21. The method of claim 16 wherein the aluminum compound is an inorganic aluminum compound.
- 22. The method of claim 21 wherein the inorganic aluminum compound is selected from the group consisting of aluminum sulfate, aluminum chlorhydrate, and aluminum nitrate.
- 23. The method of claim 22 wherein the silica and inorganic aluminum compound are reacted under hydrothermal conditions in an aqueous slurry prior to calcining.
- 24. The method of claim 21 wherein the inorganic aluminum compound is selected from the group consisting of aluminum chloride, aluminum bromide, and aluminum iodine.
- 25. The method of claim 24 wherein the silica and inorganic aluminum compound are reacted in solid admixture by heating within the temperature range of about 100.degree. C. to about 800.degree. C. prior to calcining.
- 26. The method of claim 22 wherein the inorganic refractory matrix material is selected from alumina, silica, and silica-alumina.
- 27. The method of claim 24 wherein the inorganic refractory matrix material is selected from alumina, silica, and silica-alumina.
- 28. The method of claim 16 wherein the inorganic refractory matrix material is selected from alumina, silica, and silica-alumina.
- 29. The method of claim 16 wherein a zeolite material is added to the mixture of step (d).
- 30. The method of claim 18 wherein the inorganic refractory matrix material is selected from alumina, silica, and silica-alumina; and a zeolite material is also added to the mixture of step (d).
- 31. The method of claim 21 wherein the inorganic refractory matrix material is selected from alumina, silica, and silica-alumina; and a zeolite material is also added to the mixture of step (d).
- 32. The method of claim 29 wherein the zeolite is a Y-type faujasite.
- 33. The method of claim 30 wherein the zeolite is a Y-type faujasite.
- 34. The method of claim 29 wherein the zeolite is a Calcined Rare Earth Y-type zeolite.
- 35. The method of claim 34 wherein the silica is a fumed silica having a primary particle size within the range of about 10 to about 10000 Angstroms, a maximum aggregate dimension in any direction within the range of about 0.01 microns to about 100 microns and a surface area of about 1 m.sup.2 /g to about 2000 m.sup.2 /g.
CROSS REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part application of U.S. Ser. No. 288,829, filed Dec. 23, 1988 which is a continuation-in-part application of U.S. Ser. No. 114,835, filed Oct. 30, 1987 (both now abandoned).
US Referenced Citations (8)
Foreign Referenced Citations (1)
Number |
Date |
Country |
2151596A |
Jul 1985 |
GBX |
Continuation in Parts (2)
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Number |
Date |
Country |
Parent |
288829 |
Dec 1988 |
|
Parent |
114835 |
Oct 1987 |
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