Catalysts silica alumina production

It is necessary, however, to maximize the intermediate olefin product at the expense of the aromatic/paraffin product which makes up the gasoline ( ). The olefin yield increases with increasing temperature and decreasing pressure and contact time. Judicious selection of process conditions result in high olefin selectivity and complete methanol conversion. The detailed effect of temperature, pressure, space velocity and catalyst silica/alumina ratio on conversion and selectivity has been reported earlier ( ). The distribution of products from a typical MTO experiment is compared to MTG in Figure 4. Propylene is the most abundant species produced at MTO conditions and greatly exceeds its equilibrium value as seen in the table below for 482 C. It is apparently the product of autocatalytic reaction (7) between ethylene and methanol (8). 

Catalytic pyrolysis 370-550 PE, PS, PP Nitrogen Product spectrum strongly depends on the catalyst. Silica-alumina produces high yield of liquids from PE and PP. FCC promotes high gas yield even for PS and PE (waxes fraction decrease from 90 to 1%) [18, 25]... 

The preferred catalyst is one which contains 5% of chromium oxides, mainly Cr03, on a finely divided silica-alumina catalyst (75-90% silica) which has been activated by heating to about 250°C. After reaction the mixture is passed to a gas-liquid separator where the ethylene is flashed off, catalyst is then removed from the liquid product of the separator and the polymer separated from the solvent by either flashing off the solvent or precipitating the polymer by cooling. 

The product distrihution is influenced hy the catalyst properties as well as the various reaction parameters. The catalyst activity and selectivity are functions of acidity, crystalline size, silica/alumina ratio, and even the synthetic procedure. Since the discovery of the MTG process. 

Compared to amorphous silica-alumina catalysts, the zeolite catalysts are more active and more selective. The higher activity and selectivity translate to more profitable liquid product yields and additional cracking capacity. To take full advantage of the zeolite catalyst, refiners have revamped older units to crack more of the heavier, lower-value feedstocks. 

The breakthrough in FCC catalyst was the use of X and Y zeolites during the early 1960s. The addition of these zeolites substantially increased catalyst activity and selectivity. Product distribution with a zeolite-containing catalyst is different from the distribution with an amorphous silica-alumina catalyst (Table 4-3). In addition, zeolites are 1,000 times more active than the amorphous silica alumina catalysts. 

The catalytic degradation of HDPE and PP was carried out in a powder-particle fluidised bed with an inside diameter of 25 mm. Two catalysts were used as the medium fluidisation particles. These were F9 (with a composition of silica alumina sodium oxide of 32 48 20 wt.percent) and silica/alumina (SA, with a composition of silica alumina of 71 29 wt.percent). Liquid fuel was produced in high yield. SA produced a higher yield of liquid fuel nd a more valuable gas product between temperatures of400-550C. Over 86 wt.percent conversion... 

As an example of the selective removal of products, Foley et al. [36] anticipated a selective formation of dimethylamine over a catalyst coated with a carbon molecular sieve layer. Nishiyama et al. [37] demonstrated the concept of the selective removal of products. A silica-alumina catalyst coated with a silicalite membrane was used for disproportionation and alkylation of toluene to produce p-xylene. The product fraction of p-xylene in xylene isomers (para-selectivity) for the silicalite-coated catalyst largely exceeded the equilibrium value of about 22%. 

As described in the previous section, the silica-alumina catalyst covered with the silicalite membrane showed exceUent p-xylene selectivity in disproportionation of toluene [37] at the expense of activity, because the thickness of the sihcahte-1 membrane was large (40 pm), limiting the diffusion of the products. In addition, the catalytic activity of silica-alumina was not so high. To solve these problems, Miyamoto et al. [41 -43] have developed a novel composite zeohte catalyst consisting of a zeolite crystal with an inactive thin layer. In Miyamoto s study [41], a sihcahte-1 layer was grown on proton-exchanged ZSM-5 crystals (silicalite/H-ZSM-5) [42]. The silicalite/H-ZSM-5 catalysts showed excellent para-selectivity of >99.9%, compared to the 63.1% for the uncoated sample, and independent of the toluene conversion. 

Table 9.5. Approximate product distributions of fluid catalytic cracking for amorphous silica-alumina and zeolite catalysts.

This reaction takes place on silica-alumina catalysts in the temperature range from 300 to 600 °C. It is a clean reaction with negligible production of by-products. 

As already mentioned, the acidity of the HY zeolite precludes its use as a support for Fe3(C0)- 29 then iron particles. The same behaviour is observed for Fe3(C0) 2 silica alumina system. This material, when decomposed at 200°C is not an efficient catalyst for F-T synthesis and only C-j-C products are... 

As catalysis proceeds at the surface, a catalyst should preferably consist of small particles with a high fraction of surface atoms. This is often achieved by dispersing particles on porous supports such as silica, alumina, titania or carbon (see Fig. 1.2). Unsupported catalysts are also in use. The iron catalysts for ammonia synthesis and CO hydrogenation (the Fischer-Tropsch synthesis) or the mixed metal oxide catalysts for production of acrylonitrile from propylene and ammonia form examples. 

The production of toluene from benzene and xylenes was studied by Johanson Watson (National Petroleum News, 7 Aug 1946) in a standard 1-inch pipe reactor with a silica-alumina catalyst. At the reaction temperature of 932 F (773 K) the reaction mixture was vapor phase, but the feeds were measured as liquids. The feed consisted of an equimolal mixture of reactants. The stated LHSV is (ml feed at 60 F/h)/(ml reactor). The reactor contained 85 g catalyst packed in a volume of 135 ml. The densities of benzene and xylenes at 60 F are 0.879 and 0.870, respectively. 

Although beyond the scope of this book, a vast amount of work has been directed to supporting homogeneous catalysts on solid supports including silica, alumina and zeolites, and functionalized dendrimers and polymers [19]. These give rise to so-called solid-liquid biphasic catalysis and in cases where the substrate and product are both liquids or gases then co-solvents are not always required. In many ways solvent-free synthesis represents the ideal method but currently solvent-free methods can only be applied to a limited number of reactions [20],... 

Full catalyst formulations consist of zeolite, metal and a binder, which provides a matrix to contain the metal and zeolite, as well as allowing the composite to be shaped and have strength for handling. The catalyst particle shape, size and porosity can impact the diffusion properties. These can be important in facile reactions such as xylene isomerization, where diffusion of reactants and products may become rate-limiting. The binder properties and chemistry are also key features, as the binder may supply sites for metal clusters and affect coke formation during the process. The binders often used for these catalysts include alumina, silica and mixtures of other refractory oxides. 

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