Catalyst – solid sorbent – or support therefor: product or process – Catalyst or precursor therefor – Silicon containing or process of making
Patent
1984-12-14
1986-07-22
Dees, Carl F.
Catalyst, solid sorbent, or support therefor: product or process
Catalyst or precursor therefor
Silicon containing or process of making
502 80, 423131, B01J 2010, B01J 2112
Patent
active
046019979
ABSTRACT:
Clay, preferably kaolin, is calcined through its exotherm, but without substantial mullite formation (e.g., 1 hour at 1000.degree. C.). The calcined clay is leached with an alkaline aqueous solution to remove (i.e., leach) silica. The severity of leaching, i.e., amount of silica removed, determines whether the final product will comprise mullite plus excess Al.sub.2 O.sub.3. If the molar Al.sub.2 O.sub.3 /SiO.sub.2 ratio is <3/2 the final product will contain mullite plus excess SiO.sub.2 and if the Al.sub.2 O.sub.3 /SiO.sub.2 ratio is >3/2, the final product will contain excess Al.sub.2 O.sub.3. The leached clay is washed, preferably under acid conditions at about pH 3-5, to remove excess alkali ions; and then dried. The washed clay is then calcined at conditions to produce mullite (e.g., 3 hours at 1250.degree. F.). Materials made in this manner exhibit high pore volume despite the final high temperature heat treatment.
REFERENCES:
patent: 1839062 (1931-12-01), Tellier
patent: 2536122 (1951-01-01), Bertorelli et al.
patent: 2840618 (1958-06-01), Hecht
patent: 2939764 (1960-07-01), Schoenfelder et al.
patent: 2939765 (1960-07-01), Schoenfelder et al.
patent: 3235512 (1966-02-01), Koepernik
Dees Carl F.
Engelhard Corporation
Moselle I. L.
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