Filtrol catalysts

A comparison of virgin, steam-treated, and used Fluid Filtrol catalysts is presented in Fig. 19 and Table I. The hysteresis isotherm for the virgin material has been discussed in some detail by Oulton (42). Virgin Filtrol has an area of 339 sq. m./g., which is considerably smaller than... 

Commercial use of a Fluid Filtrol catalyst effected more than a twofold decrease in area, 339 to 141 sq. m./g., in the case of the Equilibrium E sample and an approximately corresponding increase in average pore radius, 24.2 to 47.1 A. The isotherm for the steam-treated sample... 

The first delivery of Filtrol catalyst for use in the TCC or Thermofor Catalytic Cracking of petroleum was sold to Socony-Vacuum in the spring of... 

Figure 6 shows spectra of NO adsorbed on a similar series of catalysts having the same concentrations of metals on Filtrol 90 alumina which, as discussed, sulfides the catalyst during subsequent reduction. The effect of sulfide, as on Mo/alumlna catalysts (8,10) and as later seen on CoMo catalysts after more-usual sulfiding, was mainly a marked reduction In the Intensities of the NO bands. These were roughly a fourth as Intense as those on unsulflded catalysts on... 

Figure 9. Spectra of CO adsorbed on Co+ 8% Mo/A1.0 catalysts supported on (A.) Aero 1000 alumina and (6.) Filtrol 90 alumina. Co concentrations as indicated on spectra.

Of course, there were catalysts on the market in 1977-78 that were being targeted for processing heavier stocks, with higher levels of metals. Catalyst manufacturers such as Davison and Filtrol had already been working along these lines. 

The test at M. W. Kellogg s and the test in the ARCO pilot nnit were done with different feeds, with different catalysts and in different pilot nnits, so it was not expected that the yields should be identical. The feed to the M. W. Kellogg s pilot unit was a synthetic Statfjord atmospheric residne and the catalyst used was a Filtrol 900 catalyst containing nickel and vanadinm contaminants [1]. This pilot unit was also pressurized. In the ARCO pilot unit at Chalmers the feed was a laboratory distilled Statfjord atmospheric residue and the catalyst was an almost metal-free EKZ eqnilibrinm catalyst from Katalistiks. The ARCO nnit is working at atmospheric pressnre. 

R. Grace, Engelhard, American Cyanamid, Criterion, Arco, United Catalyst, Ashland, Filtrol, Gulf, Air Products, and Amoco. 

Catalyst-manufacturing methods can be classified into two broad categories. In one, a naturally occurring solid material is treated to alter its physical or chemical properties. The treated solids are sometimes referred to as natural catalysts. These include the Filtrol activated clays and the bauxite Cycloversion catalyst. In the other category of methods, the solid catalyst is produced synthetically by interaction of aqueous solutions of the raw materials. 

Filtrol SR catalyst is apparently made from a different raw clay. Details have not been published. 

Filtrol SR catalyst is relatively immune to sulfur poisoning (326), possibly because of the much lower iron content or because of some difference in hydration characteristics. Silica-magnesia under some conditions is poisoned by sulfur compounds, but the normal concentrations of steam that prevail in commercial units appear adequate to avoid this difficulty (100). 

The crystal structures of synthetic silica-magnesia and Filtrol SR catalyst have not been published. However, it has been reported that silica-magnesia is converted to a crystalline nonporous magnesium silicate when heated to about 1400°F. (354). 

Relatively few data have been published on commercial performance of Filtrol SR, but this catalyst apparently more nearly resembles synthetic silica-alumina than does the regular activated-clay catalyst. 

The ratio of CO2 to CO with Filtrol SR catalyst has been reported to be 1.2-1.3, closely resembling that obtained with synthetic silica-alumina (326). The ratio tends to increase with use for silica-alumina catalyst but not with silica-magnesia (355). The increase with silica-alumina is presumably due, at least in part, to accumulation of metal contaminants that promote complete combustion to CO2 total iron pick-up during commercial use was reported to be much less in the case of silica-magnesia than in a companion commercial run on silica-alumina (355). Intentional addition of a small amount of chromium to TCC bead catalyst is practiced commercially for the specific purpose of insuring complete combustion to CO2 and thereby avoiding afterburning (333). 

The first FCC catalysts, super filtrols, were produced by activating clays with acid. These materials... 

Several zeolites in the II-form, two activated clays, a silica-alumina, a sulfonic acid resin and a silica-occluded heteropoly acid were tested in the reaction of cyclohcxcne and toluene (excess) at 110 °C [64]. The ortho / meta / para ratio of the mixtures strongly depends on the structure of the catalysts involved. With zeolite H-USY and Filtrol-24 as active catalysts the meta / para ratio is found to be about 2 1, in agreement with the thermodynamic equilibrium, and the ortho-isomer is essentially absent.By contrast 11-Bcta and H-mordenite gave a meta /para ratio of 1 4.5. As H-USY appeared to be a good isomerization catalyst for the cyclohexyltoluenes, the mechanism may involve ortho / para-alkylation followed by isomerization. Researchers of UOP (Dcs Plaines, USA) found a separation method for meta / para cyclohexyltoluenc (undisclosed technique). Altogether the results open a new low-waste route to 3-methylbiphenyl. 

The efficacy of different catalysts at 50°C is given in the Fig.l. Among the catalysts used, HP A (unsupported and supported on KIO) and ion exchange resins (Amberlyst-15 and lndion-130) showed very high activities followed by sulphated zirconia, Filtrol-24 and KIO. The aluminium pillaring with SWy2 showed a little activity. Catalysts based on the zeolites such as H-ZSM-5, Y and mordenite did not show any activity. It appears that the pore sizes of these catalysts pose considerable intraparticle resistance for the reactant 2-MON to access the catalytic sites. 

Preferred bentonite clays are those whose chief constituent is mont-morillonite, a mineral of the composition corresponding to the empirical formula, 4Si02-Al203 H20. The principal sources of raw clay for the manufacture of the presently most widely used natural catalyst (Filtrol Corporation) are deposits in Arizona and Mississippi. The clay from these deposits contains appreciable amounts of impurities, principally CaO, MgO, and Fe203, which replace part of the A1203 in the ideal montmorillonite structure. The catalyst is prepared by leaching the raw clay with dilute sulfuric acid until about half of the alumina and associated impurities is removed. The resulting product is then washed, partially dried, and extruded into pellets, after which it is activated by calcination. A typical analysis of the finished catalyst is as follows (Mills, 12). 

The clay type catalysts such as TCC clay and Fluid Filtrol have a considerably wider pore size distribution which includes pores having radii much greater than those of the synthetic silica-alumina and silica-magnesia. There is appreciable adsorption in the high relative pressure region, and the hysteresis loops are broad (Oulton, 42 Ries, Johnson, Melik, and Kreger, 48 Ritter and Drake, 53). 

The significance of steam in catalyst deterioration is supported indirectly in Fig. 20. Plotted here are three equilibrium used Filtrols from three different refineries whose charging stocks differ rather widely, for example, with respect to poisonous contaminants. The three refineries have in common the use of steam and approximately the same tern-... 

Another Fluid Filtrol cracking catalyst designated Filtrol SR and claimed to be sulfur resistant has been introduced into commercial use... 

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