Catalyst, a process for its preparation, and its use

Abstract

Process for the preparation of a catalyst comprising the steps of (a) preparing a slurry comprising clay, zeolite, and quasi-crystalline boehmite, provided that the slurry does not comprise peptised quasi-crystalline boehmite, (b) adding a monovalent acid to the slurry, (c) adding a silicon source to the slurry, and (d) shaping the slurry to form particles. This process leads to a catalyst with high accessibility and high attrition resistance.

1 : A process for the preparation of a catalyst comprising the steps of:
 a) preparing a slurry comprising clay, zeolite, and quasi-crystallinc boehmite, provided that the slurry does not comprise peptised quasi-crystalline boehmite,   b) adding a monovalent acid to the slurry,   c) adding a silicon source to the slurry, and   d) shaping the slurry to form particles.   
   
   
       2 : The process according to  claim 1  wherein the slurry obtained in step a) does not comprise a silicon source. 
   
   
       3 : The process according to  claim 1  wherein the silicon source added in step c) is selected from the group consisting of sodium silicate, potassium silicate, lithium silicate, calcium silicate, magnesium silicate, barium silicate, strontium silicate, zinc silicate, phosphorus silicate, barium silicate, polyorganosiloxanes, methyl chlorosilane, dimethyl chlorosiline, trimethyl chlorosilane, and mixtures thereof. 
   
   
       4 : The process according to  claim 3  wherein the silicon source is added in step c) in an amount of 1-35 wt %, based on dry solids content and calculated as SiO 2 . 
   
   
       5 : A catalyst composition comprising clay, zeolite, and quasi-crystalline boehmite, wherein the composition is prepared by a) preparing a slurry comprising clay, zeolite, and quasi-crystalline boehmite, provided that the slurry does not comprise peptised quasi-crystalline boehmite; b) adding a monovalent acid to the slurry; c) adding a silicon source to the slurry, and d) shaping the slurry to form particles. 
   
   
       6 : A catalyst comprising micro-crystalline boehmite, quasi-crystalline boehmite, zeolite, and silica. 
   
   
       7 : (canceled)