Physically mixed catalyst components

Two or more soHd catalyst components can be mixed to produce a composite that functions as a supported catalyst. The ingredients may be mixed as wet or dry powders and pressed into tablets, roUed into spheres, or pelletized, and then activated. The promoted potassium ferrite catalysts used to dehydrogenate ethylbenzene in the manufacture of styrene or to dehydrogenate butanes in the manufacture of butenes are examples of catalysts manufactured by pelletization and calcination of physically mixed soHd components. In this case a potassium salt, iron oxide, and other ingredients are mixed, extmded, and calcined to produce the iron oxide-supported potassium ferrite catalyst. 

Product distribution data (Table V) obtained in the hydrocracking of coal, coal oil, anthracene and phenanthrene over a physically mixed NIS-H-zeolon catalyst indicated similarities and differences between the products of coal and coal oil on the one hand and anthracene and phenanthrene on the other hand. There were differences in the conversions which varied in the order coal> anthracene>phenanthrene coal oil. The yield of alkylbenzenes also varied in the order anthracene >phenanthrene>coal oil >coal under the conditions used. The alkylbenzenes and C -C hydrocarbon products from anthracene were similar to the products of phenanthrene. The most predominant component of alkylbenzenes was toluene and xylenes were produced in very small quantities. Methane was the most and butanes the least predominant components of the gaseous product. The products of coal and coal oil were also found to be similar. The most predominant components of alkylbenzenes and gaseous product were benzene and propane respectively. The data also indicated distinct differences between products of coal origin and pure aromatic hydrocarbons. The alkyl-benzene products of coal and coal oil contained more benzene and xylenes and less toluene, ethylbenzene and higher benzenes when compared to the products from anthracene and phenanthrene. The gaseous products of coal and coal oil contained more propane and butanes and less methane and ethane when compared to the products of anthracene and phenanthrene. The differences in the hydrocracked products were obviously due to the differences in the nature of reactants. Coal and coal oil contain hydroaromatic, naphthenic, heterocyclic and aliphatic structures, in addition to polynuclear aromatic structures. Hydrocracking under severe conditions yielded more BTX as shown in Table VI. The yields of BTX obtained from coal, coal oil, anthracene and phenanthrene were respectively 18.5, 25.5, 36.0, and 32.5 percent. Benzene was the most... 

Magnesia. Magnesia is not a particularly useful support in itself since it hydrates and dehydrates too readily leading to a loss in physical integrity of the catalyst granule. It is, however, a not infrequent component of mixed catalyst where because of its greater basicity it can confer a useful anionic exchange capacity. 

In the search for stable catalysts, the influence of the support has been one of the issues most investigated. The need to support the active metal is evident when supported catalysts are compared with physical mixtures of components.76 Merely by mixing NiO and very low activity is... 

Another type of the encapsulated catalyst with the H-P zeolite shell over Co/Al Oj pellets was described in [106]. The core-shell structure without defects was produced by the hydrothermal synthesis. The molar ratio of C /C in the products increased by 64% for the encapsulated catalyst compared with the physically mixed components... 

As another variation, the production of alkanes can be accomplished by modifying the support with a mineral acid (such as HCl) that is co-fed with the aqueous sorbitol reactant. In general, the selectivities to heavier alkanes increase as more acid sites are added to a non-acidic Pt/alumina catalyst by making physical mixtures of Pt/alumina and silica-alumina. The alkane selectivities are similar for an acidic Pt/silica-alumina catalyst and a physical mixture of Pt/alumina and silica-alumina components, both having the same ratio of Pt to acid sites, indicating that the acid and metal sites need not be mixed at the atomic level. The alkane distribution also shifts to heavier alkanes for the non-addic Pt/alumina catalyst when the pH of the aqueous sorbitol feed is lowered by addition of HCl. The advantages of using a solid acid are... 

Where two or more components are co-precipitated, special steps must be taken to ensure homogeneity of the final catalyst. This can be achieved by adding a solution of both components to an excess of the precipitating agent, rather than the other way round. The physical properties of precipitated catalysts will often depend on the conditions of precipitation e,g. concentration of solutions, order and rate of mixing, temperature of precipitation, washing, drying and calcination) all of which must be carefully studied. 

Experimental methods and techniques for catalyst manufacture are particularly important because chemical composition is not enough by itself to determine activity. The physical properties of surface area, pore size, particle size, and particle structure also have an influence. These properties are determined to a large extent by the preparation procedure. To begin with, a distinction should be drawn between preparations in which the entire material constitutes the catalyst and those in which the active ingredient is dispersed on a support or carrier having a large surface area. The first kind of catalyst is usually made by precipitation, gel formation, or simple mixing of the components. 

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