This page contains a searchable list of Dr. Stamires’ patents including abstracts…to go to his Patents page click here…
Patent number: 10457873
Abstract: A process is disclosed for converting a particulate solid biomass material to a high quality bio-oil in high yield. The process comprises a pretreatment step and a pyrolysis step. The pretreatment comprises a step of at least partially demineralizing the solid biomass, and improving the accessibility of the solid biomass by opening the texture of the particles of the solid biomass. In a preferred embodiment the liquid pyrolysis product is separated into the bio-oil and an aqueous phase, and the aqueous phase is used as a solvent in the demineralization step and/or in the step of improving the accessibility of the solid biomass by opening the texture of the particles of the solid biomass.
Type: Grant
Filed: March 24, 2010
Date of Patent: October 29, 2019
Assignee: Inaeris Technologies, LLC
Inventors: Dennis Stamires, Michael Brady, Paul O’Connor, Jacobus Cornelis Rasser
Patent number: 10286391
Abstract: Processes for making a catalytic system and catalytic systems for converting solid biomass into fuel or specialty chemical products, or for upgrading bio-oils are described. The catalyst system may comprise a non-zeolitic matrix with a hierarchical pore structure ranging from 300 to about 104 Angstrom pore size, a zeolite, such as MFI-type or IM-5 zeolite, and a binder.
Type: Grant
Filed: February 15, 2013
Date of Patent: May 14, 2019
Assignee: Inaeris Technologies, LLC
Inventors: Dennis Stamires, Michael Brady
Patent number: 9738833
Abstract: A two-stage reactor is disclosed for the conversion of solid particulate biomass material. The reactor is designed to maximize conversion of the solid biomass material, while limiting excess cracking of primary reaction products. The two-stage reactor comprises a first stage rector, in which solid biomass material is thermally pyrolyzed to primary reaction products. The primary reaction products are catalytically converted in a second stage reactor.
Type: Grant
Filed: March 27, 2015
Date of Patent: August 22, 2017
Assignee: Inaeris Technologies, LLC
Inventors: Michael Brady, Ronald Lee Cordle, Peter Loezos, Dennis Stamires
Patent number: 9700874
Abstract: A process for biomass catalytic cracking is disclosed herein. More specifically, the process is in presence of is a mixed metal oxide catalyst represented by the formula (X1O).(X2O)a.(X3YbO4) wherein X1, X2 and X3 are alkaline earth elements selected from the group of Mg, Ca, Be, Ba, and mixture thereof, and Y is a metal selected from the group of Al, Mn, Fe, Co, Ni, Cr, Ga, B, La, P and mixture thereof, wherein the catalyst is formed by calcining at least one compound comprising at least one alkaline earth element and a metal element.
Type: Grant
Filed: December 4, 2014
Date of Patent: July 11, 2017
Assignee: Inaeris Technologies, LLC
Inventors: Robert Bartek, Michael Brady, Dennis Stamires
Patent number: 9649624
Abstract: Catalyst compositions comprising a phosphorous-promoted ZSM-5 component and a silica-containing binder, and methods for making and using same, are disclosed. More, specifically, processes for making a catalyst for biomass conversion are provided. The process includes: treating a ZSM-5 zeolite with a phosphorous-containing compound to form a phosphorous-promoted ZSM-5 component; preparing a slurry comprising the phosphorous-promoted ZSM-5 component and a silica-containing binder; and shaping the slurry into shaped bodes. Such catalysts can be used for the Thermocatalytic conversion of particulate biomass to liquid products such as bio-oil, resulting in higher bio-oil yields and lower coke than conventional catalysts.
Type: Grant
Filed: May 6, 2015
Date of Patent: May 16, 2017
Assignee: Inaeris Technologies, LLC
Inventors: Bruce Adkins, Dennis Stamires, Robert Bartek, Michael Brady, John Hacskaylo
Patent number: 9643166
Abstract: A process for preparing a catalyst is disclosed. The process generally comprises the steps of: (a) preparing a slurry comprising clay, zeolite, a sodium-free silica source, quasi-crystalline boehmite, and micro-crystalline boehmite, provided that the slurry does not comprise peptized quasi-crystalline boehmite; (b) adding a monovalent acid to the slurry; (c) adjusting the pH of the slurry to a value above about 3, and (d) shaping the slurry to form particles. This process results in attrition resistant catalysts with a good accessibility.
Type: Grant
Filed: December 20, 2005
Date of Patent: May 9, 2017
Assignee: Albemarle Netherlands B.V.
Inventors: Dennis Stamires, Paul O’Connor, Erik Jeroen Laheij, Charles Vadovic
Patent number: 9381502
Abstract: Process for the preparation of a catalyst comprising the steps of (a) preparing a slurry comprising clay, zeolite, a sodium-free silica source, quasi-crystalline boehmite, and micro-crystalline boehmite, provided that the slurry does not comprise peptized quasi-crystalline boehmite, (b) adding a monovalent acid to the slurry, (c) adjusting the pH of the slurry to a value above 3, and (d) shaping the slurry to form particles. This process results in attrition resistant catalysts with a good accessibility.
Type: Grant
Filed: September 4, 2015
Date of Patent: July 5, 2016
Assignee: Albemarle Netherlands, B.V.
Inventors: Dennis Stamires, Paul O’Connor, Erik Jeroen LaHeij, Charles Vadovic
Patent number: 9333494
Abstract: A process for producing catalyst for biomass catalytic cracking is disclosed herein. The process includes modifying a phyllosilicate to produce a modified phyllosilicate having an improved yield of a pyrolysis reaction. The modification of the phyllosilicate includes leaching the clay with an acid or basic solution to form a leached clay preparation, calcining the leached clay and contacting the treated clay with a suspension comprising metal ions for ion-exchange. The modified clay catalyst can then be mixed with inorganic materials such as zeolites and dried to form fluidizable microspheres.
Type: Grant
Filed: March 7, 2012
Date of Patent: May 10, 2016
Assignee: Inaeris Technologies, LLC
Inventors: Robert Bartek, Michael Brady, Dennis Stamires
Publication number: 20160017238
Abstract: Processes for making a catalytic system and catalytic systems for converting solid biomass into fuel of specialty chemical products are described. The catalyst system may comprise a non-zeolitic matrix and an in situ grown zeolite, such as MFI-type zeolite, with a meso-micro hierarchical pore structure. In some embodiments, the non-zeolitic matrix has a meso-macro hierarchical pore structure.
Type: Application
Filed: February 15, 2013
Publication date: January 21, 2016
Inventors: Dennis Stamires, Michael Brady
Publication number: 20150375216
Abstract: Process for the preparation of a catalyst comprising the steps of (a) preparing a slurry comprising clay, zeolite, a sodium-free silica source, quasi-crystalline boehmite, and micro-crystalline boehmite, provided that the slurry does not comprise peptised quasi-crystalline boehmite, (b) adding a monovalent acid to the slurry, (c) adjusting the pH of the slurry to a value above 3, and (d) shaping the slurry to form particles. This process results in attrition resistant catalysts with a good accessibility.
Type: Application
Filed: September 4, 2015
Publication date: December 31, 2015
Inventors: Dennis Stamires, Paul O’Connor, Erik Jeroen LaHeij, Charles Vadovic
Publication number: 20150352541
Abstract: Processes for making a catalytic system and catalytic systems for converting solid biomass into fuel or specialty chemical products, or for upgrading bio-oils are described. The catalyst system may comprise a non-zeolitic matrix with a hierarchical pore structure ranging from 300 to about 104 Angstrom pore size, a zeolite, such as MFI-type or IM-5 zeolite, and a binder.
Type: Application
Filed: February 15, 2013
Publication date: December 10, 2015
Inventors: Dennis Stamires, Michael Brady
Publication number: 20150231613
Abstract: Catalyst compositions comprising a phosphorous-promoted ZSM-5 component and a silica-containing binder, and methods for making and using same, are disclosed. More, specifically, processes for making a catalyst for biomass conversion are provided. The process includes: treating a ZSM-5 zeolite with a phosphorous-containing compound to form a phosphorous-promoted ZSM-5 component; preparing a slurry comprising the phosphorous-promoted ZSM-5 component and a silica-containing binder; and shaping the slurry into shaped bodes. Such catalysts can be used for the Thermocatalytic conversion of particulate biomass to liquid products such as bio-oil, resulting in higher bio-oil yields and lower coke than conventional catalysts.
Type: Application
Filed: May 6, 2015
Publication date: August 20, 2015
Inventors: Bruce Adkins, Dennis Stamires, Robert Bartek, Michael Brady, John Hackskaylo
Publication number: 20150203763
Abstract: A two-stage reactor is disclosed for the conversion of solid particulate biomass material. The reactor is designed to maximize conversion of the solid biomass material, while limiting excess cracking of primary reaction products. The two-stage reactor comprises a first stage rector, in which solid biomass material is thermally pyrolyzed to primary reaction products. The primary reaction products are catalytically converted in a second stage reactor.
Type: Application
Filed: March 27, 2015
Publication date: July 23, 2015
Inventors: Michael Brady, Ronald Lee Cordle, Peter Loezos, Dennis Stamires
Patent number: 9044741
Abstract: Catalyst compositions comprising a phosphorous-promoted ZSM-5 component and a silica-containing binder, and methods for making and using same, are disclosed. More specifically, processes for making a catalyst for biomass conversion are provided. The process includes: treating a ZSM-5 zeolite with a phosphorous-containing compound to form a phosphorous-promoted ZSM-5 component; preparing a slurry comprising the phosphorous-promoted ZSM-5 component and a silica-containing binder; and shaping the slurry into shaped bodies. Such catalysts can be used for the thermocatalytic conversion of particulate biomass to liquid products such as bio-oil, resulting in higher bio-oil yields and lower coke than conventional catalysts.
Type: Grant
Filed: April 13, 2012
Date of Patent: June 2, 2015
Assignee: KiOR, Inc.
Inventors: Bruce Adkins, Dennis Stamires, Robert Bartek, Michael Brady, John Hackskaylo
Patent number: 9017428
Abstract: A two-stage reactor is disclosed for the conversion of solid particulate biomass material. The reactor is designed to maximize conversion of the solid biomass material, while limiting excess cracking of primary reaction products. The two-stage reactor comprises a first stage reactor, in which solid biomass material is thermally pyrolyzed to primary reaction products. The primary reaction products are catalytically converted in a second stage reactor.
Type: Grant
Filed: November 16, 2010
Date of Patent: April 28, 2015
Assignee: KiOR, Inc.
Inventors: Michael Brady, Ronald Lee Cordle, Peter Loezos, Dennis Stamires
Publication number: 20150111723
Abstract: A process for biomass catalytic cracking is disclosed herein. More specifically, the process is in presence of is a mixed metal oxide catalyst represented by the formula (X1O).(X2O)a.(X3YbO4) wherein X1, X2 and X3 are alkaline earth elements selected from the group of Mg, Ca, Be, Ba, and mixture thereof, and Y is a metal selected from the group of Al, Mn, Fe, Co, Ni, Cr, Ga, B, La, P and mixture thereof, wherein the catalyst is formed by calcining at least one compound comprising at least one alkaline earth element and a metal element.
Type: Application
Filed: December 4, 2014
Publication date: April 23, 2015
Inventors: Robert Bartek, Michael Brady, Dennis Stamires
Patent number: 9000245
Abstract: A process is disclosed for converting biomass to fuels and/or valuable chemicals. The process comprises the steps of a) activating biomass to make it more susceptible to conversion; c) partially converting the biomass to a solubilized material; and d) subjecting the unconverted biomass to a second conversion step. The process optionally comprises a step b) of adding a solvent to the activated biomass. In a preferred embodiment the solubilized biomass obtained in step c) is removed before the unconverted biomass is subjected to step d).
Type: Grant
Filed: August 1, 2011
Date of Patent: April 7, 2015
Assignee: KiOR, Inc.
Inventors: Paul O’Connor, Dennis Stamires, Sjoerd Daamen
Publication number: 20150027871
Abstract: A process for making a catalytic system for converting solid biomass into fuel of specialty chemical products is disclosed. The process includes preparing a slurry precursor mixture by mixing an aluminosilicate clay material with a pore regulating agent and optionally a binder, shaping the mixture into shaped bodies; removing the pore regulating agent to form porous shaped bodies, preparing an aqueous reaction mixture comprising the porous shaped bodies in presence of a zeolite seeding material, and thermally treating the aqueous reaction mixture to form the catalyst system. The catalyst system can comprise, for example, a MFI-type zeolite.
Type: Application
Filed: February 15, 2013
Publication date: January 29, 2015
Inventors: Dennis Stamires, Michael Brady
Patent number: 8932371
Abstract: A process is disclosed for preparing fluidizable particles of a biomass/catalyst composite material. The process comprises the steps of (i) providing a particulate, solid biomass material; (ii) forming a composite of the biomass material and a catalytic material; (iii) subjecting the biomass material to a thermal treatment at a torrefaction temperature at or above 200° C., and low enough to avoid significant conversion of the biomass material to liquid conversion products; and (iv) forming fluidizable particles from the biomass material. Step (ii) may be carried out before or after step (iii).
Type: Grant
Filed: December 10, 2009
Date of Patent: January 13, 2015
Assignee: KiOR, Inc.
Inventors: Robert Bartek, Dennis Stamires, Michael Brady
Patent number: 8921628
Abstract: A process for biomass catalytic cracking is described herein. More specifically, the process comprises heating the cellulosic biomass to a conversion temperature in presence of a mixed metal oxide catalyst represented by the formula (X1O).(X2O)a.(X3YbO4), wherein X1, X2 and X3 are alkaline earth elements selected from the group of Mg, Ca, Be, Ba , and mixture thereof, and Y is a metal selected from the group of Al, Mn, Fe, Co, Ni, Cr, Ga, B, La, P and mixture thereof.
Type: Grant
Filed: March 10, 2011
Date of Patent: December 30, 2014
Assignee: KiOR, Inc.
Inventors: Robert Bartek, Michael Brady, Dennis Stamires
Patent number: 8876925
Abstract: A process is disclosed for converting a biomass material to a stabilized bio-oil. The process comprises converting the biomass to a pyrolytic oil having suspended therein particles of metal compounds, and removing at least part of the suspended metal compounds to obtain a stabilized bio-oil.
Type: Grant
Filed: December 22, 2009
Date of Patent: November 4, 2014
Assignee: KiOR, Inc.
Inventors: Michael Brady, Dennis Stamires, Paul O’Connor
Patent number: 8709239
Abstract: A process is disclosed process for converting a solid or highly viscous carbon-based energy carrier material to liquid and gaseous reaction products, said process comprising the steps of: a) contacting the carbon-based energy carrier material with a particulate catalyst material b) converting the carbon-based energy carrier material at a reaction temperature between 200° C. and 450° C., preferably between 250° C. and 350° C., thereby forming reaction products in the vapor phase. In a preferred embodiment the process comprises the additional step of: c) separating the vapor phase reaction products from the particulate catalyst material within 10 seconds after said reaction products are formed. In a further preferred embodiment step c) is followed by: d) quenching the reaction products to a temperature below 200° C.
Type: Grant
Filed: May 13, 2013
Date of Patent: April 29, 2014
Assignee: KiOR, Inc.
Inventors: Paul O’Connor, Dennis Stamires, Jacob Adriaan Moulijn
Publication number: 20140007493
Abstract: The invention relates to catalyst compositions and components thereof for use in a catalytic process, and more particularly in a catalytic pyrolysis process or gasification of solid biomass material. In one aspect, a catalyst component is provided. The catalyst component includes a hybrid silica-alumina having a controlled Lewis acidity, and having a controlled porosity providing optimized accessibility for reactants.
Type: Application
Filed: July 2, 2013
Publication date: January 9, 2014
Applicant: KiOR, Inc.
Inventors: Christine M. Henry, Stephen Schuylen, Jerry J. Springs, Dennis Stamires, Zongchao Zhang, Ling Zhou
Publication number: 20140007499
Abstract: A composition of matter is disclosed comprising an intimate mixture of a particulate solid biomass material and a carbonaceous material. The composition is suitable for conversion to a bio-oil in a pyrolysis reaction. The carbonaceous material acts as a reducing agent during the pyrolysis reaction. The composition of matter produces bio-oil in a greater yield than prior art processes. The bio-oil is of improved quality, as evidenced by its low TAN value.
Type: Application
Filed: September 6, 2013
Publication date: January 9, 2014
Applicant: KiOR, Inc.
Inventors: Dennis Stamires, Paul O’Connor
Patent number: 8552233
Abstract: A composition of matter is described herein that can be subjected to pyrolysis and converted into a bio-oil. The composition comprises an intimate mixture of a particulate solid biomass material and a carbonaceous material. The carbonaceous material acts as a reducing agent during the pyrolysis reaction. The composition of matter produces bio-oil in a greater yield than prior art processes. The bio-oil is of improved quality, as evidenced by its low TAN value.
Type: Grant
Filed: December 16, 2009
Date of Patent: October 8, 2013
Assignee: KiOR Inc.
Inventors: Dennis Stamires, Paul O’Connor
Publication number: 20130261355
Abstract: Aspects of the invention relate to a catalyst system for the conversion of biomass material. In an exemplary embodiment, the catalyst system has a specific combined mesoporous and macroporous surface area in the range of from about 1 m2/g to about 100 m2/g. The catalyst system can be used in a two-stage reactor assembly unit for the catalytic thermoconversion of biomass material wherein the thermolysis process and the catalytic conversion process are optimally conducted separately.
Type: Application
Filed: March 7, 2013
Publication date: October 3, 2013
Applicant: KIOR, INC.
Inventor: Dennis Stamires
Publication number: 20130245346
Abstract: A process is disclosed process for converting a solid or highly viscous carbon-based energy carrier material to liquid and gaseous reaction products, said process comprising the steps of: a) contacting the carbon-based energy carrier material with a particulate catalyst material b) converting the carbon-based energy carrier material at a reaction temperature between 200° C. and 450° C., preferably between 250° C. and 350° C., thereby forming reaction products in the vapor phase. In a preferred embodiment the process comprises the additional step of: c) separating the vapor phase reaction products from the particulate catalyst material within 10 seconds after said reaction products are formed. In a further preferred embodiment step c) is followed by: d) quenching the reaction products to a temperature below 200° C.
Type: Application
Filed: May 13, 2013
Publication date: September 19, 2013
Applicant: KiOR, Inc.
Inventors: Paul O’Connor, Dennis Stamires, Jacob Adriaan Moulijn
Patent number: 8500910
Abstract: A process is disclosed for preparing biomass particles for thermolytic or enzymatic conversion whereby the biomass particles baying a moisture content of at least 20% are subjected to flash heating. The flash heating may be preceded by one or more adsorption/desorption cycles with water or steam. A swelling aid may be added during the adsorption part of an adsorption/desorption cycle.
Type: Grant
Filed: December 22, 2009
Date of Patent: August 6, 2013
Assignee: KiOR, Inc.
Inventors: Michael Brady, Dennis Stamires, Paul O’Connor
Patent number: 8465627
Abstract: A method for reducing the mechanical strength of solid biomass material, in particular lignocellulosic biomass, comprises mixing the solid biomass material with an inorganic material and heating the solid biomass material mixture to a toasting temperature in the range of 105° C. to 140° C. during an exposure time of from 1 minute to 12 hours. Before or after the heat treatment, which is referred to as “toasting”, the biomass material mixture is subject to flash heating. The treatment significantly reduces the mechanical energy required for reducing the particle size of the solid biomass material and is suitable as a pretreatment prior to a conversion reaction of the solid biomass material.
Type: Grant
Filed: November 30, 2009
Date of Patent: June 18, 2013
Assignee: KiOR, Inc.
Inventors: Michael Brady, Robert Bartek, Dennis Stamires, Paul O’Connor
Patent number: 8460541
Abstract: A process is disclosed process for converting a solid or highly viscous carbon-based energy carrier material to liquid and gaseous reaction products, said process comprising the steps of: a) contacting the carbon-based energy carrier material with a particulate catalyst material b) converting the carbon-based energy carrier material at a reaction temperature between 200° C. and 450° C., preferably between 250° C. and 350° C., thereby forming reaction products in the vapor phase. In a preferred embodiment the process comprises the additional step of: c) separating the vapor phase reaction products from the particulate catalyst material within 10 seconds after said reaction products are formed. In a further preferred embodiment step c) is followed by: d) quenching the reaction products to a temperature below 200° C.
Type: Grant
Filed: January 18, 2011
Date of Patent: June 11, 2013
Assignee: KiOR, Inc.
Inventors: Paul O’Connor, Dennis Stamires, Jacob Adriaan Moulijn
Patent number: 8425766
Abstract: Aspects of the present invention relate to methods, systems, and compositions for preparing a solid biomass for fast pyrolysis. The method includes contacting the solid biomass with an inorganic material present in an effective amount for increasing fast pyrolysis yield of an organic liquid product (e.g., bio-oil). In various embodiments, the inorganic material is selected from the group consisting of aluminum sulfate, aluminum nitrate, aluminum chloride, aluminum hydroxide, ammonium hydroxide, magnesium hydroxide, potassium hydroxide, and combinations thereof.
Type: Grant
Filed: July 11, 2012
Date of Patent: April 23, 2013
Assignee: KiOR, Inc.
Inventors: Robert Bartek, Michael Brady, Dennis Stamires
Publication number: 20130012376
Abstract: A process for producing catalyst for biomass catalytic cracking is disclosed herein. The process includes modifying a phyllosilicate to produce a modified phyllosilicate having an improved yield of a pyrolysis reaction. The modification of the phyllosilicate includes leaching the clay with an acid or basic solution to form a leached clay preparation, calcining the leached clay and contacting the treated clay with a suspension comprising metal ions for ion-exchange. The modified clay catalyst can then be mixed with inorganic materials such as zeolites and dried to form fluidizable microspheres.
Type: Application
Filed: March 7, 2012
Publication date: January 10, 2013
Applicant: KiOR, Inc.
Inventors: Robert Bartek, Michael Brady, Dennis Stamires
Publication number: 20130000183
Abstract: Catalyst compositions comprising a phosphorous-promoted ZSM-5 component and a silica-containing binder, and methods for making and using same, are disclosed. More specifically, processes for making a catalyst for biomass conversion are provided. The process includes: treating a ZSM-5 zeolite with a phosphorous-containing compound to form a phosphorous-promoted ZSM-5 component; preparing a slurry comprising the phosphorous-promoted ZSM-5 component and a silica-containing binder; and shaping the slurry into shaped bodies. Such catalysts can be used for the thermocatalytic conversion of particulate biomass to liquid products such as bio-oil, resulting in higher bio-oil yields and lower coke than conventional catalysts.
Type: Application
Filed: April 13, 2012
Publication date: January 3, 2013
Applicant: KiOR, Inc.
Inventors: Bruce Adkins, Dennis Stamires, Robert Bartek, Michael Brady, John Hackskaylo
Patent number: 8323458
Abstract: A process is disclosed for making a biomass susceptible to depolymerization or liquefaction under mild conditions. The process comprises introducing into the biomass a material susceptible to the absorption of electro-magnetic radiation to form a radiation absorbent biomass. The radiation absorbent biomass is subjected to electro-magnetic radiation to form an activated biomass.
Type: Grant
Filed: July 13, 2007
Date of Patent: December 4, 2012
Assignee: KiOR, Inc.
Inventors: Paul O’Connor, Dennis Stamires
Publication number: 20120272565
Abstract: Aspects of the present invention relate to methods, systems, and compositions for preparing a solid biomass for fast pyrolysis. The method includes contacting the solid biomass with an inorganic material present in an effective amount for increasing fast pyrolysis yield of an organic liquid product (e.g., bio-oil). In various embodiments, the inorganic material is selected from the group consisting of aluminum sulfate, aluminum nitrate, aluminum chloride, aluminum hydroxide, ammonium hydroxide, magnesium hydroxide, potassium hydroxide, and combinations thereof.
Type: Application
Filed: July 11, 2012
Publication date: November 1, 2012
Applicant: KiOR, Inc.
Inventors: Robert Bartek, Michael Brady, Dennis Stamires
Patent number: 8288600
Abstract: A process for producing fuel from biomass is disclosed herein. The process includes torrefying biomass material at a temperature between 80° C. to 400° C. to form particulated biomass having a mean average particle size between 1 ?m and 1000 ?m. The particulated biomass is mixed with a liquid hydrocarbon to form a suspension, wherein the suspension includes from 1 weight percent to 40 weight percent particulated biomass. The suspension is fed into a unit selected from the group consisting of a pyrolysis reactor, a fluid catalytic cracking unit, a delayed coker, a fluid coker, a hydroprocessing unit, and a hydrocracking unit, and then at least a portion of the particulated biomass of the suspension is converted into fuel.
Type: Grant
Filed: November 2, 2010
Date of Patent: October 16, 2012
Assignee: KiOR Inc.
Inventors: Robert Bartek, Michael Brady, Dennis Stamires, Steve Yanik, Paul O’Connor, Jacobus Cornelius Rasser
Publication number: 20120232299
Abstract: A process for biomass catalytic cracking is disclosed herein. More specifically, the process is in presence of is a mixed metal oxide catalyst represented by the formula (X1O).(X2O)a.(X3YbO4) wherein X1, X2 and X3 are alkaline earth elements selected from the group of Mg, Ca, Be, Ba, and mixture thereof, and Y is a metal selected from the group of Al, Mn, Fe, Co, Ni, Cr, Ga, B, La, P and mixture thereof, wherein the catalyst is formed by calcining at least one compound comprising at least one alkaline earth element and a metal element.
Type: Application
Filed: March 10, 2011
Publication date: September 13, 2012
Applicant: KIOR, Inc.
Inventors: Robert Bartek, Michael Brady, Dennis Stamires
Publication number: 20120214216
Abstract: A process is described for pretreating lignocellulosic biomass. The process comprises swelling the lignocellulosic biomass with an aqueous liquid. The pretreated lignocellulosic biomass may be used as a feedstock for the enzymatic conversion to ethanol, or in a thermal conversion. process to produce bio-oil. The pretreatment results in a greater yield and, in the case of a thermal conversion process, a better quality of the bio-oil. The pretreatment process may be used to adjust the composition and amount of inorganic material present in the lignocellulosic biomass material.
Type: Application
Filed: April 27, 2012
Publication date: August 23, 2012
Applicant: KiOR, Inc.
Inventors: Michael Brady, Paul O’Connor, Dennis Stamires
Patent number: 8236173
Abstract: Aspects of the present invention relate to methods, systems, and compositions for preparing a solid biomass for fast pyrolysis. The method includes contacting the solid biomass with an inorganic material present in an effective amount for increasing fast pyrolysis yield of an organic liquid product (e.g., bio-oil). In various embodiments, the inorganic material is selected from the group consisting of aluminum sulfate, aluminum nitrate, aluminum chloride, aluminum hydroxide, ammonium hydroxide, magnesium hydroxide, potassium hydroxide, and combinations thereof.
Type: Grant
Filed: March 10, 2011
Date of Patent: August 7, 2012
Assignee: KiOR, Inc.
Inventors: Robert Bartek, Michael Brady, Dennis Stamires
Publication number: 20120190062
Abstract: A process is disclosed for converting biomass to fuels and/or valuable chemicals. The process comprises the steps of a) activating biomass to make it more susceptible to conversion; c) partially converting the biomass to a solubilized material; and d) subjecting the unconverted biomass to a second conversion step. The process optionally comprises a step b) of adding a solvent to the activated biomass. In a preferred embodiment the solubilized biomass obtained in step c) is removed before the unconverted biomass is subjected to step d).
Type: Application
Filed: August 1, 2011
Publication date: July 26, 2012
Applicant: KIOR INC.
Inventors: Paul O’Connor, Dennis Stamires, Sjoerd Daamen
Publication number: 20120144730
Abstract: A process is disclosed for converting a particulate solid biomass material to a high quality bio-oil in high yield. The process comprises a pretreatment step and a pyrolysis step. The pretreatment comprises a step of at least partially demineralizing the solid biomass, and improving the accessibility of the solid biomass by opening the texture of the particles of the solid biomass. In a preferred embodiment the liquid pyrolysis product is separated into the bio-oil and an aqueous phase, and the aqueous phase is used as a solvent in the demineralization step and/or in the step of improving the accessibility of the solid biomass by opening the texture of the particles of the solid biomass.
Type: Application
Filed: March 24, 2010
Publication date: June 14, 2012
Applicant: KIOR INC.
Inventors: Dennis Stamires, Michael Brady, Paul O’Connor, Jacobus Cornelis Rasser
Publication number: 20120137571
Abstract: A process is disclosed for converting a biomass material to a stabilized bio-oil. The process comprises converting the biomass to a pyrolytic oil having suspended therein particles of metal compounds, and removing at least part of the suspended metal compounds to obtain a stabilized bio-oil.
Type: Application
Filed: December 22, 2009
Publication date: June 7, 2012
Applicant: KIOR INC.
Inventors: Michael Brady, Dennis Stamires, Paul O’connor
Publication number: 20120142520
Abstract: A catalyst system is disclosed for catalytic pyrolysis of a solid biomass material. The system comprises an oxide, silicate or carbonate of a metal or a metalloid. The specific combined meso and macro surface area of the system is in the range of from 1 m2/g to 100 m2/g. When used in a catalytic process the system provides a high oil yield and a low coke yield. The liquid has a relatively low oxygen content.
Type: Application
Filed: April 22, 2010
Publication date: June 7, 2012
Applicant: KIOR INC.
Inventors: Robert Bartek, Michael Brady, Dennis Stamires
Publication number: 20120117860
Abstract: A two-stage reactor is disclosed for the conversion of solid particulate biomass material. The reactor is designed to maximize conversion of the solid biomass material, while limiting excess cracking of primary reaction products. The two-stage reactor comprises a first stage reactor, in which solid biomass material is thermally pyrolyzed to primary reaction products. The primary reaction products are catalytically converted in a second stage reactor.
Type: Application
Filed: November 16, 2010
Publication date: May 17, 2012
Applicant: KiOR, Inc.
Inventors: Michael Brady, Ronald Lee Cordle, Peter Loezos, Dennis Stamires
Patent number: 8168840
Abstract: A process is described for pretreating lignocellulosic biomass. The process comprises swelling the lignocellulosic biomass with an aqueous liquid. The pretreated lignocellulosic biomass may be used as a feedstock for the enzymatic conversion to ethanol, or in a thermal conversion. process to produce bio-oil. The pretreatment results in a greater yield and, in the case of a thermal conversion process, a better quality of the bio-oil. The pretreatment process may be used to adjust the composition and amount of inorganic material present in the lignocellulosic biomass material.
Type: Grant
Filed: June 25, 2009
Date of Patent: May 1, 2012
Assignee: KiOR Inc.
Inventors: Michael Brady, Paul O’Connor, Dennis Stamires
Publication number: 20120060408
Abstract: A process is disclosed for preparing fluidizable particles of a biomass/catalyst composite material. The process comprises the steps of (i) providing a particulate, solid biomass material; (ii) forming a composite of the biomass material and a catalytic material; (iii) subjecting the biomass material to a thermal treatment at a torrefaction temperature at or above 200° C., and low enough to avoid significant conversion of the biomass material to liquid conversion products; and (iv) forming fluidizable particles from the biomass material. Step (ii) may be carried out before or after step (iii).
Type: Application
Filed: December 10, 2009
Publication date: March 15, 2012
Applicant: KIOR INC.
Inventors: Robert Bartek, Dennis Stamires, Michael Brady
Publication number: 20120047794
Abstract: Aspects of the present invention relate to methods, systems, and compositions for preparing a solid biomass for fast pyrolysis. The method includes contacting the solid biomass with an inorganic material present in an effective amount for increasing fast pyrolysis yield of an organic liquid product (e.g., bio-oil). In various embodiments, the inorganic material is selected from the group consisting of aluminum sulfate, aluminum nitrate, aluminum chloride, aluminum hydroxide, ammonium hydroxide, magnesium hydroxide, potassium hydroxide, and combinations thereof.
Type: Application
Filed: March 10, 2011
Publication date: March 1, 2012
Applicant: KIOR, INC.
Inventors: Robert Bartek, Michael Brady, Dennis Stamires
Patent number: 8088354
Abstract: Process for the preparation of quasi-crystalline boehmite comprising the steps of: (a) preparing an aqueous precursor mixture comprising a water-insoluble aluminum source; (b) decreasing the pH of the precursor mixture of step (a) by at least 2 units; (c) increasing the pH of the mixture of step (b) by at least 2 units, and (d) aging the mixture of step (c) under hydrothermal conditions to form a quasi-crystalline boehmite. This process provides for the hydrothermal preparation of quasi-crystalline boehmites with high peptizability. The invention therefore further relates to quasi-crystalline boehmites with a high peptizability, measured as the Z-average submicron particle size. This Z-average submicron particle size preferably is less than 500 nm, more preferably less than 300 nm, even more preferably less than 200 nm, and most preferably less than 100 nm.
Type: Grant
Filed: November 19, 2004
Date of Patent: January 3, 2012
Assignee: Albemarle Netherlands B.V.
Inventors: Erik Jeroen Laheij, Paul O’Connor, Dennis Stamires, Edisson Morgado, Jr., Marco Antonio Santos de Abreu, Márcio Fernandes, Michael Brady
Patent number: 8063258
Abstract: A process for producing fuel from biomass is disclosed herein. The process includes torrefying biomass material at a temperature between 80° C. and 300° C. to form particulated biomass having a mean average particle size from about 1 ?m to about 1000 ?m. The particulated biomass is mixed with a liquid to form a suspension, wherein the liquid comprises bio-oil, wherein the suspension includes between 1 weight percent to 40 weight percent particulated biomass. The suspension is fed into a hydropyrolysis reactor; and at least a portion of the particulated biomass of the suspension is converted into fuel.
Type: Grant
Filed: November 2, 2010
Date of Patent: November 22, 2011
Assignee: Kior Inc.
Inventors: Robert Bartek, Michael Brady, Dennis Stamires
Publication number: 20110258913
Abstract: A composition of matter is disclosed comprising an intimate mixture of a particulate solid biomass material and a carbonaceous material. The composition is suitable for conversion to a bio-oil in a pyrolysis reaction. The carbonaceous material acts as a reducing agent during the pyrolysis reaction. The composition of matter produces bio-oil in a greater yield than prior art processes. The bio-oil is of improved quality, as evidenced by its low TAN value.
Type: Application
Filed: December 16, 2009
Publication date: October 27, 2011
Applicant: KIOR INC.
Inventors: Dennis Stamires, Paul O’connor
Publication number: 20110256615
Abstract: A process is disclosed for preparing biomass particles for thermolytic or enzymatic conversion whereby the biomass particles baying a moisture content of at least 20% are subjected to flash heating. The flash heating may be preceded by one or more adsorption/desorption cycles with water or steam. A swelling aid may be added during the adsorption part of an adsorption/desorption cycle.
Type: Application
Filed: December 22, 2009
Publication date: October 20, 2011
Applicant: KIOR, INC.
Inventors: Michael Brady, Dennis Stamires, Paul O’Connor
Patent number: 8022260
Abstract: The present invention relates to the conversion of solid biomass to liquid fuels and specialty chemicals. The process utilizes an activating step to make the biomass more susceptible to conversion, that is the biomass is broken down such that the components of the biomass are dissociated. Subsequently, the activated biomass undergoes a reaction to convert it to a bio-oil.
Type: Grant
Filed: May 4, 2007
Date of Patent: September 20, 2011
Assignee: Kior Inc.
Inventors: Paul O’Connor, Dennis Stamires, Sjoerd Daamen
Patent number: 8003835
Abstract: A method for converting solid biomass into hydrocarbons includes contacting the solid biomass with a catalyst in a first riser operated at a temperature in the range of from about 50° C. to about 200° C. to thereby produce a first biomass-catalyst mixture and a first product comprising hydrocarbons; a) separating the first product from the first biomass-catalyst mixture; c) charging the first biomass-catalyst mixture to a second riser operated at a temperature in the range of from about 200° C. to about 400° C. to thereby produce a second biomass-catalyst mixture and a second product comprising hydrocarbons; d) separating the second product from the second biomass-catalyst mixture; e) charging the second biomass-catalyst mixture to a third riser operated at a temperature greater than about 450° C. to thereby produce a spent catalyst and a third product comprising hydrocarbons; and f) separating the third effluent from the spent catalyst.
Type: Grant
Filed: October 27, 2009
Date of Patent: August 23, 2011
Assignee: Kior Inc.
Inventors: Steve Yanik, Robert Bartek, Paul O’Connor, Dennis Stamires, Michael Brady
Publication number: 20110197511
Abstract: A process is disclosed process for converting a solid or highly viscous carbon-based energy carrier material to liquid and gaseous reaction products, said process comprising the steps of: a) contacting the carbon-based energy carrier material with a particulate catalyst material b) converting the carbon-based energy carrier material at a reaction temperature between 200° C. and 450° C., preferably between 250° C. and 350° C., thereby forming reaction products in the vapor phase. In a preferred embodiment the process comprises the additional step of: c) separating the vapor phase reaction products from the particulate catalyst material within 10 seconds after said reaction products are formed. In a further preferred embodiment step c) is followed by: d) quenching the reaction products to a temperature below 200° C.
Type: Application
Filed: January 18, 2011
Publication date: August 18, 2011
Applicant: KIOR INC.
Inventors: Paul O’Connor, Dennis Stamires, Jacob Adriaan Moulijn
Publication number: 20110154720
Abstract: A process for producing fuel from biomass is disclosed herein. The process includes torrefying biomass material at a temperature between 80° C. to 400° C. to form particulated biomass having a mean average particle size between 1 ?m and 1000 ?m. The particulated biomass is mixed with a liquid hydrocarbon to form a suspension, wherein the suspension includes from 1 weight percent to 40 weight percent particulated biomass. The suspension is fed into a unit selected from the group consisting of a pyrolysis reactor, a fluid catalytic cracking unit, a delayed coker, a fluid coker, a hydroprocessing unit, and a hydrocracking unit, and then at least a portion of the particulated biomass of the suspension is converted into fuel.
Type: Application
Filed: November 2, 2010
Publication date: June 30, 2011
Applicant: KiOR, Inc.
Inventors: Robert Bartek, Michael Brady, Dennis Stamires, Steve Yanik, Paul O’Connor, Jacobus C. Rasser
Publication number: 20110114876
Abstract: A process is disclosed for pretreating lignocellulosic biomass. The process comprises swelling the lignocellulosic biomass with an aqueous liquid. The pretreated lignocellulosic biomass may be used as a feedstock for the enzymatic conversion to ethanol, or in a thermal conversion process to produce bio-oil. The pretreatment results in a greater yield and, in the case of a thermal conversion process, a better quality of the bio-oil. The pretreatment process may be used to adjust the composition and amount of inorganic material present in the lignocellulosic biomass material.
Type: Application
Filed: June 25, 2009
Publication date: May 19, 2011
Applicant: KIOR, INC.
Inventors: Michael Brady, Paul O’Connor, Dennis Stamires
Publication number: 20110114765
Abstract: A method is disclosed for reducing the mechanical strength of solid biomass material, in particular ligno-cellulosic biomass. The method comprises heating the solid biomass material to a temperature in the range of 105° C. to 200° C. The heat treatment, which is referred to as “toasting”, significantly reduces the mechanical energy required for reducing the particle size of the solid biomass material. The method is particularly suitable as a pretreatment step to a conversion reaction of the solid biomass material.
Type: Application
Filed: November 30, 2009
Publication date: May 19, 2011
Applicant: KiOR, INC.
Inventors: Michael Brady, Robert Bartek, Dennis Stamires, Paul O’Connor
Publication number: 20110099888
Abstract: A process for producing fuel from biomass is disclosed herein. The process includes torrefying biomass material at a temperature between 80° C. and 300° C. to form particulated biomass having a mean average particle size from about 1 ?m to about 1000 ?m. The particulated biomass is mixed with a liquid to form a suspension, wherein the liquid comprises bio-oil, wherein the suspension includes between 1 weight percent to 40 weight percent particulated biomass. The suspension is fed into a hydropyrolysis reactor; and at least a portion of the particulated biomass of the suspension is converted into fuel.
Type: Application
Filed: November 2, 2010
Publication date: May 5, 2011
Applicant: KiOR, Inc.
Inventors: Robert Bartek, Michael Brady, Dennis Stamires
Patent number: 7901568
Abstract: A process is disclosed process for converting a solid or highly viscous carbon-based energy carrier material to liquid and gaseous reaction products, said process comprising the steps of: a) contacting the carbon-based energy carrier material with a particulate catalyst material b) converting the carbon-based energy carrier material at a reaction temperature between 200° C. and 450° C., preferably between 250° C. and 350° C., thereby forming reaction products in the vapor phase. In a preferred embodiment the process comprises the additional step of: c) separating the vapor phase reaction products from the particulate catalyst material within 10 seconds after said reaction products are formed; In a further preferred embodiment step c) is followed by: d) quenching the reaction products to a temperature below 200° C.
Type: Grant
Filed: May 4, 2007
Date of Patent: March 8, 2011
Assignee: Kior Inc.
Inventors: Paul O’Connor, Dennis Stamires, Jacob Adriaan Moulijn
Patent number: 7824540
Abstract: Process for upgrading a liquid hydrocarbon feed comprising the steps of (a) preparing a slurry comprising the hydrocarbon feed having a boiling range above 350° C. and solid particles comprising a rehydratable material, (b) thermally treating said slurry at a temperature in the range of 250 to 550° C., (c) optionally separating the thermally treated slurry into (I) a lower boiling fraction and (ii) a higher boiling fraction containing the solid particles and formed coke, if any, and (d) separating the solid particles and formed coke, if any, from the thermally treated slurry resulting from step b) or the higher boiling fraction of step c).
Type: Grant
Filed: June 16, 2005
Date of Patent: November 2, 2010
Assignee: Albemarle Corporation
Inventors: Paul O’Connor, Erik Jeroen Laheij, Dennis Stamires, Michael F. Brady, Francisco René Mas Cabre, Oscar René Chamberlain Pravia, Henrique Soares Cerqueira, Fabió Lopes De Azevedo
Publication number: 20100228068
Abstract: A process is disclosed for mild hydro-conversion of oxygenated hydrocarbon compounds. The oxygenated hydrocarbon compounds are contacted with a hydro-conversion catalyst material at a reaction pressure below 100 bar. Preferred oxygenated hydrocarbon compounds are those obtained by the liquefaction of biomass. In a specific embodiment the process is used for production of normal alkanes by hydrotreating mixtures of triglycerides (or compounds derived-from triglycerides, including free fatty acids) and vacuum gasoil.
Type: Application
Filed: August 15, 2007
Publication date: September 9, 2010
Applicant: BIOECON INTERNATIONAL HOLDING N.V.
Inventors: Paul O’Connor, Avelino Corma Camos, Dennis Stamires
Publication number: 20100209965
Abstract: A process is disclosed for converting a particulate biomass material to a bioliquid. In the process the biomass material is mixed with a heat transfer medium and a catalytic material, and heated to a temperature in the range of from 150 to 600° C. The particle size of the solid biomass may be reduced by abrasion in admixture with inorganic particles under agitation by a gas. The biomass particles of reduced size obtained in the abrasion process may be converted to bioliquid in any of a number of conversion processes.
Type: Application
Filed: July 13, 2007
Publication date: August 19, 2010
Applicants: BIOECON INTERNATIONAL HOLDING N.V.
Inventors: Paul O’Connor, Dennis Stamires
Publication number: 20100152024
Abstract: Process for the preparation of a catalyst comprising the steps of (a) preparing a slurry comprising clay, zeolite, a sodium-free silica source, quasi-crystalline boehmite, and micro-crystalline boehmite, provided that the slurry does not comprise peptised quasi-crystalline boehmite, (b) adding a monovalent acid to the slurry, (c) adjusting the pH of the slurry to a value above 3, and (d) shaping the slurry to form particles. This process results in attrition resistant catalysts with a good accessibility.
Type: Application
Filed: December 20, 2005
Publication date: June 17, 2010
Inventors: Dennis Stamires, Paul O’connor, Erik jeroen Laheij, Charles Vadovic
Publication number: 20100133149
Abstract: A process is disclosed for converting Tar Sand to fuels and/or valuable chemicais. The process comprises the steps of a) activating Tar Sand to make it more susceptible to conversion; c) partially converting the Tar Sand to a solubilized material; and d) subjecting the unconverted Tar Sand to a second conversion step. The process optionally comprises a step b) of adding a solvent to the activated Tar Sand. In a preferred embodiment the solubilized Tar Sand obtained in step c) is removed before the unconverted Tar Sand is subjected to step d).
Type: Application
Filed: October 10, 2007
Publication date: June 3, 2010
Applicant: BIOECON INTERNATIONAL HOLDING
Inventors: Paul O’connor, Dennis Stamires
Publication number: 20100105970
Abstract: A method for converting solid biomass into hydrocarbons includes contacting the solid biomass with a catalyst in a first riser operated at a temperature in the range of from about 50° C. to about 200° C. to thereby produce a first biomass-catalyst mixture and a first product comprising hydrocarbons; a) separating the first product from the first biomass-catalyst mixture; c) charging the first biomass-catalyst mixture to a second riser operated at a temperature in the range of from about 200° C. to about 400° C. to thereby produce a second biomass-catalyst mixture and a second product comprising hydrocarbons; d) separating the second product from the second biomass-catalyst mixture; e) charging the second biomass-catalyst mixture to a third riser operated at a temperature greater than about 450° C. to thereby produce a spent catalyst and a third product comprising hydrocarbons; and f) separating the third effluent from the spent catalyst.
Type: Application
Filed: October 27, 2009
Publication date: April 29, 2010
Applicant: KiOR INC.
Inventors: STEVE YANIK, ROBERT BARTEK, PAUL O’CONNOR, DENNIS STAMIRES, MICHAEL BRADY
Publication number: 20090314627
Abstract: A process is disclosed for making a biomass susceptible to depolymerization or liquefaction under mild conditions. The process comprises introducing into the biomass a material susceptible to the absorption of electro-magnetic radiation to form a radiation absorbent biomass. The radiation absorbent biomass is subjected to electro-magnetic radiation to form an activated biomass.
Type: Application
Filed: July 13, 2007
Publication date: December 24, 2009
Applicant: BIOECON INTERNATIONAL HOLDING N.V.
Inventors: Paul O’Connor, Dennis Stamires
Publication number: 20090308787
Abstract: A process is disclosed process for converting a solid or highly viscous carbon-based energy carrier material to liquid and gaseous reaction products, said process comprising the steps of: a) contacting the carbon-based energy carrier material with a particulate catalyst material b) converting the carbon-based energy carrier material at a reaction temperature between 200° C. and 450° C., preferably between 250° C. and 350° C., thereby forming reaction products in the vapor phase. In a preferred embodiment the process comprises the additional step of: c) separating the vapor phase reaction products from the particulate catalyst material within 10 seconds after said reaction products are formed; In a further preferred embodiment step c) is followed by: d) quenching the reaction products to a temperature below 200° C.
Type: Application
Filed: May 4, 2007
Publication date: December 17, 2009
Applicant: BIOeCon INTERNATIONAL HOLDING B.V.
Inventors: Paul O’Connor, Dennis Stamires, Jacob Adriaan Moulijn
Publication number: 20090305872
Abstract: Fluid catalytic cracking process comprising the steps of (a) preparing a physical 5 mixture comprising (i) aluminium trihydrate and/or flash-calcined aluminium trihydrate and (ii) a divalent metal oxide, hydroxide, carbonate, or hydroxycarbonate, (b) shaping the physical mixture of step a) to form fluidisable particles, and (c) adding the fluidisable particles obtained from step b) or step c) to a fluid catalytic cracking unit. In this FCC process, active sites of the catalyst composition are formed in-situ, i.e. in the FCC unit, without requiring peptisation, aging, or calcination steps prior to the addition of the composition to the hydrocarbon conversion unit.
Type: Application
Filed: November 19, 2005
Publication date: December 10, 2009
Applicant: ALBEMARLE NETHERLANDS BV
Inventors: Dennis Stamires, Paul O’Connor
Publication number: 20090269266
Abstract: Oxidic composition consisting essentially of oxidic forms of a first metal, a second metal, and optionally a third metal, the first metal being either Ca or Ba and being present in the composition in an amount of from about 5 to about 80 wt %, the second metal being Al and being present in the composition in an amount of from about 5 to about 80 wt %, the third metal being selected from the group consisting of La, Ti, and Zr, and being present in an amount of from 0 to about 17 wt %—all weight percentages calculated as oxides and based on the weight of the oxidic composition, the oxidic composition being obtainable by (a) preparing a physical mixture comprising solid compounds of the first, the second, and the optional third metal, (b) optionally aging the physical mixture, without anionic clay being formed, and (c) calcining the mixture. This composition is suitable for use in FCC processes for the passivation of metals with only minimal influence on the zeolite’s hydrothermal stability.
Type: Application
Filed: June 2, 2006
Publication date: October 29, 2009
Applicant: ALBEMARLE NETHERLANDS B.V.
Inventors: Dennis Stamires, Paul O’connor, William Jones, Erik Jeroen Laheij
Patent number: 7598202
Abstract: Novel compositions of matter comprising a cationic layered material and a second compound. The second compound has a reflection in its XRD pattern at 18.5 degrees two-theta, and s second reflection at 29 degrees two-theta. The composition of matter may be used in hydrocarbon conversion, purification, and synthesis processes, such as fluid catalytic cracking and hydroprocessing. The materials are especially suitable for the reduction of SOx and NOx emissions and the reduction of the sulfur and nitrogen content in fuels like gasoline and diesel.
Type: Grant
Filed: December 20, 2005
Date of Patent: October 6, 2009
Assignee: Albemarle Netherlands B.V.
Inventors: Paul O’Connor, William Jones, Dennis Stamires
Patent number: 7582202
Abstract: A Composition comprising one or more metal hydroxy salts and a matrix, binder or carrier material, wherein the metal hydroxy salt is a compound comprising (a) as metal either (i) one or more divalent metals, at least one of them being selected from the group consisting of Ni, Co, Ca, Zn, Mg, Fe, and Mn, or (ii) one or more trivalent metal(s), (b) framework hydroxide, and (c) a replaceable anion. This composition has various catalytic applications.
Type: Grant
Filed: February 10, 2004
Date of Patent: September 1, 2009
Assignees: Akzo Nobel N.V., Albemarle Netherlands B.V.
Inventors: William Jones, Paul O’Connor, Dennis Stamires
Publication number: 20090211944
Abstract: Oxidic composition consisting essentially of oxidic forms of a first metal, a second metal, and optionally a third metal, the first metal being either Ca or Ba and being present in the composition in an amount of from about 5 to about 80 wt %, the second metal being Al and being present in the composition in an amount of from about 5 to about 80 wt %, the third metal being selected from the group consisting of La, Ti, and Zr, and being present in an amount of from 0 to about 17 wt %—all weight percentages calculated as oxides and based on the weight of the oxidic composition, the oxidic composition being obtainable by (a) preparing a physical mixture comprising solid compounds of the first, the second, and the optional third metal, (b) optionally aging the physical mixture, without anionic clay being formed, and (c) calcining the mixture. This composition is suitable for use in FCC processes for the passivation of metals with only minimal influence on the zeolite’s hydrothermal stability.
Type: Application
Filed: June 2, 2006
Publication date: August 27, 2009
Applicant: Albemarle Netherlands B.V.
Inventors: Dennis Stamires, Paul O’Connor, William Jones
Patent number: 7576024
Abstract: The invention relates to a composition comprising anionic clay and rare earth metal hydroxy carbonate. This composition can suitably be used in FCC for the reduction of NOx and/or SOx emissions, the reduction of the S and/or N-content in fuels, and as a metal trap. The composition can be prepared by precipitating a divalent metal salt, a trivalent metal salt, and a rare earth metal salt to form a precipitate, calcining the precipitate at 200-800° C., and rehydrating the precipitate in the presence of a carbonate source to form a composition comprising anionic clay and a rare earth metal hydroxy carbonate.
Type: Grant
Filed: December 6, 2004
Date of Patent: August 18, 2009
Assignee: Albemarle Netherlands B.V.
Inventors: William Jones, Dennis Stamires, Paul O’Connor, Michael F. Brady
Patent number: 7576025
Abstract: A composition comprising FCC catalyst particles and additive particles suitable for the reduction of NOx emissions from a FCC regenerator, said additive particles comprising a Mg and Al-containing anionic clay or solid solution, a rare earth metal oxide, alumina and/or silica-alumina, and Y-type zeolite. The invention further relates to a process for preparing such a composition and its use for reducing NOx emissions.
Type: Grant
Filed: October 12, 2004
Date of Patent: August 18, 2009
Assignee: Albemarle Netherlands B.V.
Inventors: Christopher W. Kuehler, Paul O’Connor, Dennis Stamires
Publication number: 20090149317
Abstract: Process for the preparation of an aluminium phosphate-containing composition wherein an aluminium source is converted partly to aluminium phosphate using a phosphorus-containing compound and partly to (i) an anionic clay and/or a Al-MII mixed metal (hydr)oxide using a divalent metal (MII) source, (ii) an aluminosilicate using a silicon source, and/or (iii) a MII- aluminosilicate using both a divalent metal source and a silicon source.
Type: Application
Filed: November 7, 2006
Publication date: June 11, 2009
Applicant: ALBEMARLE NETHERLANDS B.V.
Inventors: Dennis Stamires, Paul O’Connor
Publication number: 20090118559
Abstract: Oxidic composition consisting essentially of oxidic forms of a first metal, a second metal, and optionally a third metal, the first metal being either Fe or Zn and being present in the composition in an amount of from about 5 to about 80 wt %, the second metal being Al and being present in the composition in an amount of from about 5 to about 80 wt %, the third metal being selected from the group consisting of Mo, W, Ce, and V, and being present in an amount of from 0 to about 17 wt %—all weight percentages calculated as oxides and based on the weight of the oxidic composition, the oxidic composition being obtainable by (a) preparing a physical mixture comprising solid compounds of the first, the second, and the optional third metal, (b) optionally aging the physical mixture, without anionic clay being formed, and (c) calcining the mixture.
Type: Application
Filed: June 2, 2006
Publication date: May 7, 2009
Applicant: ALBEMARLE NETHERLANDS B.V.
Inventors: Dennis Stamires, Paul O’Connor, William Jones
Publication number: 20090090046
Abstract: Disclosed is a hydrothermal treatment process for conversion of a carbon-based energy carrier material. The process comprises a step for sensitizing or activating the carbon based energy carrier material to increase its susceptibility to hydrothermal conversion. As a result of the sensitization step, the hydrothermal conversion step itself may be carried out under relatively mild conditions. The process comprises the steps of sensitizing the carbon-based energy carrier material to increase its susceptibility to hydrothermal conversion; and subjecting the sensitized carbon-based energy carrier material to hydrothermal conversion at a temperature of less than 300 degrees centigrade in a hydrothermal treatment reactor.
Type: Application
Filed: May 4, 2007
Publication date: April 9, 2009
Applicant: BIOECON INTERNATIONAL HOLDING B.V.
Inventors: Paul O’Connor, Dennis Stamires, Sjoerd Daamen
Publication number: 20090048097
Abstract: Process for the preparation of an oxidic catalyst composition consisting of one or more trivalent metals preferably aluminum, one or more divalent metals preferably magnesium and more than 18 wt % of one or more compounds selected from the group consisting of rare earth metal compounds, phosphorus compounds, and transition metal compounds, which process comprises the steps of preparing a precursor mixture consisting of (i) or more trivalent metal compounds, (ii) one or more divalent metal compounds, (iii) one or more compounds selected from the group consisting of rare earth metal compounds, and transition metal compounds, and (iv) optionally water, which precursor mixture is not a solution. The resulting oxidic catalyst composition is suitable as a metal trap and SOx sorbent FCC processes.
Type: Application
Filed: December 6, 2004
Publication date: February 19, 2009
Applicant: AKZO NOBEL N.V.
Inventors: William Jones, Dennis Stamires, Paul O’Connor, Michael Brady
Patent number: 7473663
Abstract: Process for the preparation of an additive-containing anionic clay comprising the steps of (a) preparing a physical mixture of a divalent and a trivalent metal compound, (b) calcining the physical mixture at a temperature in the range 200-800° C. without performing a prior aging or shaping step, thereby forming a product containing at least 5 wt % of a rehydratable compound, and (c) rehydrating the calcined mixture in aqueous suspension containing an additive to form the additive-containing anionic clay. This process provides a simple and cost-effective way of preparing additive-containing anionic clays. The process does neither require aging or reaction steps before calcination, nor does it require precipitation of metal salts or the handling of inhomogeneous slurries.
Type: Grant
Filed: April 26, 2005
Date of Patent: January 6, 2009
Assignee: Albemarle Netherlands B.V.
Inventors: William Jones, Dennis Stamires, Paul O’Connor, Michael F. Brady
Publication number: 20080308456
Abstract: Oxidic composition consisting essentially of oxidic forms of a first metal, a second metal, and optionally a third metal, the first metal being either Ca or Ba and being present in the composition in an amount of from about 5 to about 80 wt %, the second metal being Al and being present in the composition in an amount of from about 5 to about 80 wt %, the third metal being selected from the group consisting of La, Ti, and Zr, and being present in an amount of from 0 to about 17 wt %—all weight percentages calculated as oxides and based on the weight of the oxidic composition, the oxidic composition being obtainable by (a) preparing a physical mixture comprising solid compounds of the first, the second, and the optional third metal, (b) optionally aging the physical mixture, without anionic clay being formed, and (c) calcining the mixture. This composition is suitable for use in FCC processes for the passivation of metals with only minimal influence on the zeolite’s hydrothermal stability.
Type: Application
Filed: June 2, 2006
Publication date: December 18, 2008
Applicant: ALBEMARLE NETHERLANDS B.V.
Inventors: Dennis Stamires, Paul O’Connor, William Jones
Publication number: 20080296203
Abstract: Hydrocarbon conversion process comprising the steps of (a) suspending catalyst particles comprising a layered material in a first, polar hydrocarbon, employing conditions such as will cause delamination of the layered material to form a suspension comprising particles with a size of less than 1 micron, (b) optionally adding the suspension to a second hydrocarbon, (c) converting the first and/or the optional second hydrocarbon in the presence of said delaminated layered material, and (d) separating the delaminated material from the first and the optional second hydrocarbon. This process provides an economically desired way of converting hydrocarbons using small catalyst particles.
Type: Application
Filed: August 25, 2005
Publication date: December 4, 2008
Inventors: Dennis Stamires, Paul O’Connor, Elbert Jan De Graaf
Patent number: 7448561
Abstract: A combined process for the conversion of solid starting particles into solid intermediate particles and reducing the median diameter of the intermediate particles to obtain product particles. This process involves flowing a suspension of starting particles through a series of at least two conversion vessels, thereby converting at least part of the starting particles into intermediate particles, adding a supercritical fluid to one or more of the conversion vessels, thereby forming a supercritical suspension, and releasing pressure from the supercritical suspension, thereby expanding the suspension and converting the intermediate particles into product particles.
Type: Grant
Filed: December 2, 2003
Date of Patent: November 11, 2008
Assignee: Albemarle Netherlands B.V.
Inventors: Paul O’Connor, Erik Jeroen Laheij, Dennis Stamires, Edwin Mark Berends
Publication number: 20080210600
Abstract: Process for upgrading a liquid hydrocarbon feed comprising the steps of (a) preparing a slurry comprising the hydrocarbon feed having a boiling range above 350° C. and solid particles comprising a rehydratable material, (b) thermally treating said slurry at a temperature in the range of 250 to 550° C., (c) optionally separating the thermally treated slurry into (I) a lower boiling fraction and (ii) a higher boiling fraction containing the solid particles and formed coke, if any, and (d) separating the solid particles and formed coke, if any, from the thermally treated slurry resulting from step b) or the higher boiling fraction of step c).
Type: Application
Filed: June 16, 2005
Publication date: September 4, 2008
Inventors: Paul O’Connor, Erik Jeroen Laheij, Dennis Stamires, Michael F. Brady, Francisco Rene Mas Cabre, Oscar Rene Chamberlain Pravia, Henrique Soares Cerqueira, Fabio Lopes De Azevedo
Publication number: 20080210599
Abstract: “FCC equilibrium catalysts, even when highly contaminated with vanadium, can be upgraded to make them suitable again for use in catalytic processes, for instance, as catalyst additives in FCC, by employing a process comprising the steps of (a) treating an FCC equilibrium catalyst that contains alumina and zeolite with an acidic solution to obtain an acid-treated equilibrium catalyst, and (b) contacting the acid-treated equilibrium catalyst with an aqueous solution or suspension of a divalent metal compound.
Type: Application
Filed: January 6, 2006
Publication date: September 4, 2008
Inventors: Paul O’Connor, Erik Jeroen Laheij, Dennis Stamires, Oscar Rene Chamberlain Pravia, Rodolfo Eugenio Roncolatto, Yiu Lau Lam
Publication number: 20080039314
Abstract: The invention relates to a catalyst composition comprising anionic clay, lanthanum (hydr)oxide carbonate, and cerium oxide. This composition can suitably be used in FCC for the reduction of NOx and/or SOx emissions, the reduction of the S and/or N-content in fuels, and as a metal trap. The composition can be prepared by forming a precipitate from a solution comprising a divalent metal salt, a trivalent metal salt, a lanthanum salt, and a cerium salt, calcining the precipitate at 200-800° C., and rehydrating the calcined precipitate in the presence of a carbonate source to form a composition comprising anionic clay, lanthanum (hydr)oxide carbonate, and cerium oxide.
Type: Application
Filed: December 6, 2004
Publication date: February 14, 2008
Inventors: William Jones, Dennis Stamires, Paul O’Connor, Michael F. Brady
Publication number: 20080039313
Abstract: Process for the preparation of a metal-containing composition, which process comprises the steps of (a) calcining a physical mixture of an anionic clay and a metal additive at a temperature between 200 and 800° C., and (b) rehydrating the calcined product of step a). This process allows the use of insoluble metal additives. It does not require the use of soluble metal additives, which has economic and environmental advantages.
Type: Application
Filed: April 26, 2005
Publication date: February 14, 2008
Inventors: William Jones, Dennis Stamires, Paul O’Connor, Michael Brady
Publication number: 20080032884
Abstract: Process for the preparation of an additive-containing anionic clay comprising the steps of (a) milling a physical mixture of a divalent metal compound and a trivalent metal compound, (b) calcining the physical mixture at a temperature in the range 200-800° C., and (c) rehydrating the calcined mixture in aqueous suspension, wherein an additive is present in the physical mixture and/or the aqueous suspension of step (c). With this process additive-containing anionic clays with a homogeneous additive distribution can be prepared.
Type: Application
Filed: April 26, 2005
Publication date: February 7, 2008
Inventors: William Jones, Dennis Stamires, Paul O’Connor, Michael Brady
Publication number: 20070287626
Abstract: Process for the preparation of an oxidic composition comprising a trivalent metal, a divalent metal and—calculated as oxide and based on the total composition—more than 18 wt % of one or more compounds selected from the group consisting of rare earth metal compounds, phosphorus compounds, and transition metal compounds, which process comprises the following steps: (a) preparing a precursor mixture comprising (i) a compound 1 being a trivalent metal compound, (ii) a compound 2 being a divalent metal compound, and (iii) a compound 3 being different from compounds 1 and 2 and being selected from the group consisting of rare earth metal compounds, phosphorus compounds, and transition metal compounds, (b) optionally aging the mixture, without anionic clay being formed, (c) drying the mixture, and (d) calcining the product of step c). The resulting oxidic composition is suitable as a metal trap and SOx sorbent FCC processes.
Type: Application
Filed: December 6, 2004
Publication date: December 13, 2007
Inventors: William Jones, Dennis Stamires, Paul O’Connor, Michael Brady
Publication number: 20070272594
Abstract: The invention relates to an oxidic catalyst composition comprising 5-60 wt % of a divalent metal, 5-60 wt % of a trivalent metal, and 35-60 wt % of a rare earth metal, calculated as oxide and based on the total weight of the oxidic catalyst composition. The invention also relates to a process for preparing such an oxidic catalyst composition. This composition is suitable as metal trap in FCC processes.
Type: Application
Filed: December 6, 2004
Publication date: November 29, 2007
Inventors: William Jones, Dennis Stamires, Paul O’Connor, Michael Brady
Publication number: 20070274903
Abstract: Process for the preparation of quasi-crystalline boehmite comprising the steps of: (a) preparing an aqueous precursor mixture comprising a water-insoluble aluminium source; (b) decreasing the pH of the precursor mixture of step (a) by at least 2 units; (c) increasing the pH of the mixture of step (b) by at least 2 units, and (d) aging the mixture of step (c) under hydrothermal conditions to form a quasi-crystalline boehmite. This process provides for the hydrothermal preparation of quasi-crystalline boehmites with high peptizability. The invention therefore further relates to quasi-crystalline boehmites with a high peptizability, measured as the Z-average submicron particle size. This Z-average submicron particle size preferably is less than 500 nm, more preferably less than 300 nm, even more preferably less than 200 nm, and most preferably less than 100 nm.
Type: Application
Filed: November 11, 2004
Publication date: November 29, 2007
Inventors: Eric Laheij, Paul O’Connor, Dennis Stamires, Edisson Morgado, Marco Santos De Abreu, Marcio Fernandes, Michael Brady
Publication number: 20070275847
Abstract: A composition comprising FCC catalyst particles and additive particles suitable for the reduction of NOx emissions from a FCC regenerator, said additive particles comprising a Mg and Al-containing anionic clay or solid solution, a rare earth metal oxide, alumina and/or silica-alumina, and Y-type zeolite. The invention further relates to a process for preparing such a composition and its use for reducing NOx emissions.
Type: Application
Filed: October 12, 2004
Publication date: November 29, 2007
Inventors: Christopher Kuehler, Paul O’Connor, Dennis Stamires
Publication number: 20070189937
Abstract: A continuous process for the hydrothermal conversion of a solid starting iron compound selected from the group of iron oxides, iron hydroxides, iron oxyhydroxides, and mixtures thereof into a solid product iron compound with different physical, chemical, and/or structural properties. The process comprises the steps of a) dispersing the solid starting iron compound in a liquid thus forming a suspension, and b) feeding the suspension continuously though one or more agitated conversion vessel(s), in which vessel(s) the solid starting iron compound is converted into the solid product iron compound under hydrothermal conditions.
Type: Application
Filed: March 27, 2007
Publication date: August 16, 2007
Inventors: Edgar Steenwinkel, Johannes Verlaan, Marieke Spee, Erik Laheij, Paul O’Connor, Dennis Stamires
Publication number: 20070191213
Abstract: Metal-containing composition and use thereof in catalytic reactions, which metal-containing composition is obtainable by contacting a metal hydroxy salt with a solution comprising one or more pH-dependent anions selected from the group consisting of pH-dependent boron-containing anions, vanadium-containing anions, tungsten-containing anions, molybdenum-containing anions, iron-containing anions, niobium-containing anions, tantalum-containing anions, aluminium-containing anions, and gallium-containing anions.
Type: Application
Filed: May 19, 2004
Publication date: August 16, 2007
Applicant: ALBEMARLE NETHERLANDS B.V.
Inventors: William Jones, Paul O’Connor, Dennis Stamires
Patent number: 7217400
Abstract: An apparatus and continuous process for the conversion of one solid iron compound to another solid iron compound in a heterogeneous suspension wherein the suspension is formed by dispersing a solid starting iron compound in a liquid that is continuously fed through one or more agitated conversion vessels under hydrothermal conditions and converted to a solid product iron compound having different physical, chemical, or structural properties from the solid starting iron compound.
Type: Grant
Filed: August 18, 2003
Date of Patent: May 15, 2007
Assignee: Albemarle Netherlands B.V.
Inventors: Edgar Evert Steenwinkel, Johannes Petrus Jozef Verlaan, Marieke Paulyne Renate Spee, Erik Jeroen Laheij, Paul O’Connor, Dennis Stamires
Patent number: 7208446
Abstract: The present invention pertains to a quasi-crystalline boehmite containing additive in a homogeneously dispersed state. Suitable additives are compounds containing elements selected from the group of alkaline earth metals, alkaline metals, rare earth metals, transition metals, actinides, silicon, gallium, boron, titanium, and phosphorus. Said QCBs according to the invention may be prepared in several ways. In general, a quasi-crystalline boehmite precursor and an additive are converted to a quasi-crystalline boehmite containing the additive in a homogeneously dispersed state.
Type: Grant
Filed: November 18, 2002
Date of Patent: April 24, 2007
Assignee: Albemarle Netherlands B. V.
Inventors: Dennis Stamires, Paul O’Connor, Gregory Pearson, William Jones
Publication number: 20070060780
Abstract: The invention comprises a catalyst composition comprising a pentasil type of zeolite, one or more solid acidic promoters, an additional material selected from the group consisting of an anionic clay, smectite clay, and thermally or chemically modified clay, and optionally a filler and/or binder, methods for making the catalyst composition and a process for using the catalyst in the manufacture of olefins.
Type: Application
Filed: June 21, 2006
Publication date: March 15, 2007
Inventors: Dennis Stamires, Paul O’Connor, Arja Hakuli-Pieterse, Rajeev Rao, Erik Laheij
Publication number: 20060216229
Abstract: A Ccomposition comprising one or more metal hydroxy salts and a matrix, binder or carrier material, wherein the metal hydroxy salt is a compound comprising (a) as metal either (i) one or more divalent metals, at least one of them being selected from the group consisting of Ni, Co, Ca, Zn, Mg, Fe, and Mn, or (ii) one or more trivalent metal(s), (b) framework hydroxide, and (c) a replaceable anion. This composition has various catalytic applications.
Type: Application
Filed: February 10, 2004
Publication date: September 28, 2006
Applicant: AKZO NOBEL N.V.
Inventors: William Jones, Paul O’Connor, Dennis Stamires
Publication number: 20060194692
Abstract: Novel compositions of matter comprising a cationic layered material and a second compound. The second compound has a reflection in its XRD pattern at 18.5 degrees two-theta, and s second reflection at 29 degrees two-theta. The composition of matter may be used in hydrocarbon conversion, purification, and synthesis processes, such as fluid catalytic cracking and hydroprocessing. The materials are especially suitable for the reduction of SOx and NOx emissions and the reduction of the sulfur and nitrogen content in fuels like gasoline and diesel.
Type: Application
Filed: December 20, 2005
Publication date: August 31, 2006
Inventors: Paul O’Connor, William Jones, Dennis Stamires
Publication number: 20060124783
Abstract: A combined process for the conversion of solid starting particles into solid intermediate particles and reducing the median diameter of the intermediate particles to obtain product particles. This process involves flowing a suspension of starting particles through a series of at least two conversion vessels, thereby converting at least part of the starting particles into intermediate particles, adding a supercritical fluid to one or more of the conversion vessels, thereby forming a supercritical suspension, and releasing pressure from the supercritical suspension, thereby expanding the suspension and converting the intermediate particles into product particles.
Type: Application
Filed: December 2, 2003
Publication date: June 15, 2006
Inventors: Paul O’Connor, Erik Laheij, Dennis Stamires, Edwin Berends
Publication number: 20060096891
Abstract: The present invention pertains to a quasi-crystalline boehmite containing additive in a homogeneously dispersed state. Suitable additives are compounds containing elements selected from the group of alkaline earth metals, alkaline metals, rare earth metals, transition metals, actinides, silicon, gallium, boron, titanium, and phosphorus. Said QCBs according to the invention may be prepared in several ways. In general, a quasi-crystalline boehmite precursor and an additive are converted to a quasi-crystalline boehmite containing the additive in a homogeneously dispersed state.
Type: Application
Filed: November 18, 2002
Publication date: May 11, 2006
Inventors: Dennis Stamires, Paul O’Connor, Gregory Pearson, William Jones
Patent number: 7033487
Abstract: A catalyst composition comprising about 5–55 wt % metal-doped anionic clay, about 10–50 wt % zeolite, about 5–40 wt % matrix alumina, about 0–10 wt % silica, about 0–10 wt % of other ingredients, and balance kaolin. In metal-doped anionic clays, the additive, i.e. the metal dopant, is distributed more homogeneously within the anionic clay than in impregnated anionic clays, without separate phases of additive being present. Hence, abrasion of this catalyst composition will result in microfines poorer in additive than the prior art composition. Furthermore, the catalyst composition according to the invention results in a higher reduction of sulfur in fuels such as gasoline and diesel than is the case in compositions comprising impregnated anionic clay.
Type: Grant
Filed: June 25, 2003
Date of Patent: April 25, 2006
Assignee: Albemarle Netherlands B.V.
Inventors: Paul O’Connor, Gregory A. Pearson, Jerry J. Springs, Dennis Stamires
Patent number: 7025873
Abstract: Cationic layered materials, a process for their preparation and their use in hydrocarbon conversion, purification, and synthesis processes, such as fluid catalytic cracking. Cationic layered materials are especially suitable for the reduction of SOx and NOx emissions and the reduction of the sulfur and nitrogen content in fuels like gasoline and diesel. The new preparation process avoids the use of metal salts and does not require the formation of anionic clay as an intermediate.
Type: Grant
Filed: June 24, 2003
Date of Patent: April 11, 2006
Assignees: Albemarle Netherlands BV., Akzo Nobel NV.
Inventors: Paul O’Connor, William Jones, Dennis Stamires
Patent number: 7022304
Abstract: The present invention is directed to a process for the preparation of a doped anionic clay. In said process a trivalent metal source is reacted with a divalent metal source, at least one of the metal sources being either doped boehmite, doped MgO or doped brucite, to obtain a doped anionic clay. Suitable dopants are compounds containing elements selected from the group of alkaline earth metals (for instance Ca and Ba), alkaline metals, transition metals (for example Co, Mn, Fe, Ti, Zr, Cu, Ni, Zn, Mo, W, V, Sn), actinides, rare earth metals such as La, Ce, and Nd, noble metals such as Pt and Pd, silicon, gallium, boron, titanium, and phosphorus.
Type: Grant
Filed: February 7, 2002
Date of Patent: April 4, 2006
Assignee: Akzo Nobel N.V.
Inventors: Dennis Stamires, William Jones, Paul O’Connor
Patent number: 7008896
Abstract: The present invention is directed to a process for the preparation of crystalline anionic clay-containing bodies from sources comprising a trivalent metal source and a divalent metal source comprising the steps of: a) preparing a precursor mixture containing a liquid, a divalent metal source and/or a trivalent metal source, at least one of them being insoluble in the liquid; b) shaping the precursor mixture to obtain shaped bodies; c) optionally thermally treating the shaped bodies; and d) aging the shaped bodies to obtain crystalline anionic clay-containing bodies; with the proviso that if no divalent or trivalent metal source is present in the precursor mixture of step a), such source is added to the shaped bodies after shaping step b) and before aging step d); and with the further proviso that the combined use of an aluminium source as the trivalent metal source and a magnesium source as the divalent metal source is excluded.
Type: Grant
Filed: January 31, 2002
Date of Patent: March 7, 2006
Assignee: Akzo Nobel NV
Inventors: Dennis Stamires, William Jones, Paul O’Connor
Patent number: 6969692
Abstract: A process for the preparation of a metal-doped pentasil-type zeolite comprising the steps of: a) preparing an aqueous precursor mixture comprising a silicon source and an aluminum source, at least one of these sources being doped with a rare earth metal or a transition metal of Groups Vb–VIIIb, Ib, or IIb of the Periodic System, and b) thermally treating the precursor mixture to form a metal-doped pentasil-type zeolite. With this process, metal-doped pentasil-type zeolites can be prepared while the risk of precipitation of the dopant as a separate phase is minimized.
Type: Grant
Filed: August 25, 2003
Date of Patent: November 29, 2005
Assignee: Albemarle Netherlands B.V.
Inventors: Mike Brady, Erik Jeroen Laheij, Paul O’Connor, Dennis Stamires
Patent number: 6964934
Abstract: The present invention relates to a process for the preparation of doped pentasil-type zeolite, which process comprises the steps of: a) preparing an aqueous precursor mixture from a silicon source, an aluminium source, and doped non-zeolitic seeds; and b) thermally treating the precursor mixture to form a doped pentasil-type zeolite. The term “non-zeolitic seeds” includes seeds made from materials selected from the group consisting of (i) X-ray amorphous materials, (ii) milled crystalline materials, such as milled zeolites, that have a relative crystallinity of not more than 75%, and (iii) crystalline materials other than zeolites, such as clays (e,g, bentonite and kaolin) and (low) crystalline aluminas.
Type: Grant
Filed: August 25, 2003
Date of Patent: November 15, 2005
Assignee: Albemarle Netherlands B.V.
Inventors: Mike Brady, Erik Jeroen Laheij, Paul O’Connor, Dennis Stamires
Publication number: 20050250642
Abstract: The invention pertains to a continuous process for the conversion of inorganic solid starting particles which either are amorphous or possess a degree of order into inorganic solid product particles which when the starting particles are amorphous, possess a degree of order, or when the starting particles possess a degree of order, possess a different order, a different degree of order, or no order, which product particles are suitable for use in or as a catalyst, in or as a carrier, or in or as an adsorbent, in which process the starting particles are dispersed in a liquid thus forming a suspension. The suspension flows through at least two separate conversion vessels (3) which are connected in series and the suspension is agitated in each of these vessels (3). The invention furthermore relates to an apparatus suitable for carrying out the process according to the invention. This invention allows the processing of suspension with a high Solids to Liquid Ratio.
Type: Application
Filed: June 2, 2005
Publication date: November 10, 2005
Inventors: Dennis Stamires, Paul O’Connor, Erik Laheij, Johannes Maria Sonnemans
Patent number: 6933324
Abstract: A method for performing a Fischer-Tropsch process using as a catalyst (precursor) an iron-containing layered material selected from the group consisting of layered materials in which iron is present in the layered structure as divalent and/or trivalent metal (group 1), iron-doped layered materials (group 2), calcined iron-doped layered materials (group 3), and calcined layered materials in which iron is present in the layered structure as divalent metal (group 4). The term “layered material” includes anionic clays, layered hydroxy salts, cationic clays, and cationic layered materials.
Type: Grant
Filed: August 8, 2003
Date of Patent: August 23, 2005
Assignee: Akzo Nobel N.V.
Inventors: Dennis Stamires, Marieke Paulyne Renate Spee, Erik Jeroen Laheij, Paul O’Connor
Patent number: 6903040
Abstract: The invention pertains to a continuous process for the conversion of inorganic solid starting particles which either are amorphous or possess a degree of order into inorganic solid product particles which (a) when the starting particles are amorphous, possess a degree of order, or (b) when the starting particles possess a degree of order, possess a different order, a different degree of order, or no order, which product particles are suitable for use in or as a catalyst, in or as a carrier, or in or as an adsorbent, in which process the starting particles are dispersed in a liquid thus forming a suspension. The suspension flows through at least two separate conversion vessels (3) which are connected in series and the suspension is agitated in each of these vessels (3). The invention furthermore relates to an apparatus suitable for carrying out the process according to the invention. This invention allows the processing of suspension with a high Solids to Liquid Ratio.
Type: Grant
Filed: May 8, 2002
Date of Patent: June 7, 2005
Assignee: Akzo Nobel NV
Inventors: Dennis Stamires, Paul O’Connor, Erik Jeroen Laheij, Johannes Wilhelmus Maria Sonnemans
Patent number: 6887457
Abstract: A process for the preparation of a composition comprising a pentasil-type zeolite, which process comprises the following steps: a) hydrothermally treating an aqueous slurry comprising an aluminium source, a silicon source, a seeding material, and optionally a divalent metal source, thereby forming a pentasil-type zeolite and at least one other compound, and b) shaping the product of step a). Examples of the at least one other compound are anionic clay, cationic clay, Si—Al cogel, and (pseudo)boehmite.
Type: Grant
Filed: August 25, 2003
Date of Patent: May 3, 2005
Assignee: Akzo Nobel N.V.
Inventors: Paul O’Connor, Dennis Stamires
Patent number: 6835364
Abstract: The present invention provides new compositions of matter, referred to as quasi-crystalline carboxylates (QCCs), their preparation and use. The materials comprise a quasi-crystalline hydrated magnesium-aluminium hydroxy carboxylate and are characterised by the presence of at least a strong reflection in the powder X-ray diffraction pattern at a basal spacing in the range of 5 to 15 Å. The invention further relates to a process for preparing the QCCs, Mg—Al solid solutions and anionic clays under acidic conditions. The QCC is prepared by aging an acidic mixture of a magnesium carboxylate and an aluminium source. Calcination of the QCC results in a Mg—Al solid solution; rehydration of this solid solution gives an anionic clay.
Type: Grant
Filed: January 31, 2002
Date of Patent: December 28, 2004
Assignee: Akzo Nobel N.V.
Inventors: Dennis Stamires, Thomas Joseph Pinnavaia, Michael Brady
Patent number: 6815389
Abstract: An economical and environment-friendly process for the synthesis of anionic clays with carbonate and/or hydroxide anions as the charge-balancing interlayer species is disclosed. The process involves reacting a slurry comprising an aluminum source and a magnesium source, the aluminum source comprising two types of aluminum-containing compounds, preferably aluminum trihydrate and/or thermally treated calcined aluminum trihydrate. There is no necessity to wash or filter the product. It can be spray dried directly to form microspheres or can be extruded to form shaped bodies. The product can be combined with other ingredients in the manufacture of catalysts, absorbents, pharmaceuticals, cosmetics, detergents, and other commodity products.
Type: Grant
Filed: March 15, 2002
Date of Patent: November 9, 2004
Assignee: Akzo Nobel NV
Inventors: Dennis Stamires, Michael F. Brady, William Jones, Fathi Kooli
Patent number: 6800578
Abstract: This patent describes economical and environment-friendly processes for the synthesis of anionic clays. It involves reacting a slurry comprising boehmite, which has been peptized with acid with a divalent metal source followed by addition of source of base. The slurry is then hydrothermally aged. There is no necessity to wash or filter the product and it can be spray dried directly to form microspheres, or can be extruded to form shaped bodies. The product can be combined with other ingredients in the manufacture of catalysts, absorbents, pharmaceuticals, cosmetics, detergents, polymeric nanocomposites and other commodity products that contain anionic clays.
Type: Grant
Filed: October 15, 2002
Date of Patent: October 5, 2004
Assignee: Akzo Nobel NV
Inventors: Dennis Stamires, Paul O’Connor, William Jones, Michael Brady
Patent number: 6756029
Abstract: A process for preparing molecular sieves of type Y faujasite structure is described, as well as pre-shaped bodies of faujasite structure type Y molecular sieves. The process comprises preparing a precursor gel from a source of silica-alumina or a source of alumina and a source of silica with a template agent at a SiO2/Al2O3 greater than 7 and suitable for forming a type Y zeolite, drying the precursor gel and contacting the dried precursor gel with steam, optionally followed by caustic washing, without the formation of crystalline phases other than type Y zeolite being observed. Advantageously, the pre-shaped bodies prepared with the precursor gel of Y zeolite, when subjected to the process of the invention, will have their outer surface covered by type Y zeolite crystals. The molecular sieves so obtained may be employed as catalysts or adsorbents in various processes of the chemical or oil industry.
Type: Grant
Filed: June 7, 2002
Date of Patent: June 29, 2004
Assignees: Petroleo Brasileiro S.A.-Petrobras, Akzo Nobel N.V.
Inventors: Yiu Lau Lam, Alvaro Saavedra, Alexandre de Figueiredo Costa, Anselmo da Silva Santos, Gustavo Torres Moure, Rodolfo Eugenio Roncolatto, Dennis Stamires, Paul O’Connor
Publication number: 20040121900
Abstract: A process for the preparation of a metal-doped pentasil-type zeolite comprising the steps of:
Type: Application
Filed: August 25, 2003
Publication date: June 24, 2004
Inventors: Mike Brady, Erik Jeroen Laheij, Paul O’Connor, Dennis Stamires
Publication number: 20040110629
Abstract: The invention comprises a catalyst composition comprising a pentasil type of zeolite, one or more solid acidic promoters and optionally a filler and/or binder, methods for making the catalyst composition and a process for using the catalyst in the manufacture of olefins.
Type: Application
Filed: August 28, 2003
Publication date: June 10, 2004
Inventors: Dennis Stamires, Paul O’Connor, Arja Hakuli-Pieterse, Rajeev S. Rao, Erik Jeroen Laheij
Publication number: 20040096380
Abstract: A continuous process for the hydrothermal conversion of a solid starting iron compound selected from the group of iron oxides, iron hydroxides, iron oxyhydroxides, and mixtures thereof into a solid product iron compound with different physical, chemical, and/or structural properties.
Type: Application
Filed: August 18, 2003
Publication date: May 20, 2004
Inventors: Edgar Evert Steenwinkel, Johannes Petrus Jozef Verlaan, Marieke Paulyne Renate Spee, Erik Jeroen Laheij, Paul O’Connor, Dennis Stamires
Publication number: 20040092386
Abstract: The present invention relates to a process for the preparation of doped pentasil-type zeolite, which process comprises the steps of:
Type: Application
Filed: August 25, 2003
Publication date: May 13, 2004
Inventors: Mike Brady, Erik Jeroen Laheij, Paul O’Connor, Dennis Stamires
Publication number: 20040092608
Abstract: A method for performing a Fischer-Tropsch process using as a catalyst (precursor) an iron-containing layered material selected from the group consisting of layered materials in which iron is present in the layered structure as divalent and/or trivalent metal (group 1), iron-doped layered materials (group 2), calcined iron-doped layered materials (group 3), and calcined layered materials in which iron is present in the layered structure as divalent metal (group 4). The term “layered material” includes anionic clays, layered hydroxy salts, cationic clays, and cationic layered materials.
Type: Application
Filed: August 8, 2003
Publication date: May 13, 2004
Inventors: Dennis Stamires, Marieke Paulyne Renate Spee, Erik Jeroen Laheij, Paul O’Connor
Publication number: 20040092756
Abstract: A process for the preparation of a composition comprising a pentasil-type zeolite, which process comprises the following steps:
Type: Application
Filed: August 25, 2003
Publication date: May 13, 2004
Inventors: Paul O’Connor, Dennis Stamires
Patent number: 6716785
Abstract: A process for the in-situ preparation of a composite comprising a cationic clay and binder/matrix material from sources comprising an aluminum containing source, a silicon containing source and a di-valent metal containing source comprising the steps of: a. preparing a precursor mixture by mixing the aluminum containing source, the silicon containing source and the di-valent metal containing source with seeding material, b. homogenizing the precursor mixture, and c. aging the precursor mixture to obtain the composite. One or two of the aluminum containing source, silicon containing source or di-valent metal containing source is to be in excess of the amount required for stoichiometry of the three sources with respect to the formation of the cationic clay. The excess source or sources will form the binder/matrix material of the composite. The invention also includes a body comprising a composite obtained by this process having binding/matrix material present in a discontinuous phase.
Type: Grant
Filed: September 27, 2002
Date of Patent: April 6, 2004
Assignee: Akzo Nobel NV
Inventors: Dennis Stamires, Paul O’Connor
Patent number: 6710004
Abstract: This invention relates to a process for the preparation of anionic clay and boehmite-containing compositions. These compositions may also contain unreacted trivalent metal source and/or divalent metal source. The process involves subjecting a precursor mixture comprising a divalent metal source and a trivalent metal source to at least two aging steps, wherein at least once between two aging steps an aluminum source is added. An advantage of the invention is that the crystallinity of the boehmite in the composition can be tuned.
Type: Grant
Filed: February 7, 2002
Date of Patent: March 23, 2004
Assignee: Akzo Nobel nv
Inventors: Dennis Stamires, William Jones, Paul O’Connor
Publication number: 20040031727
Abstract: Cationic layered materials, a process for their preparation and their use in hydrocarbon conversion, purification, and synthesis processes, such as fluid catalytic cracking. Cationic layered materials are especially suitable for the reduction of SOx and NOx emissions and the reduction of the sulfur and nitrogen content in fuels like gasoline and diesel. The new preparation process avoids the use of metal salts and does not require the formation of anionic clay as an intermediate.
Type: Application
Filed: June 24, 2003
Publication date: February 19, 2004
Inventors: Paul O’Conner, William Jones, Dennis Stamires
Publication number: 20040029717
Abstract: A catalyst composition comprising about 5-55 wt % metal-doped anionic clay, about 10-50 wt % zeolite, about 5-40 wt % matrix alumina, about 0-10 wt % silica, about 0-10 wt % of other ingredients, and balance kaolin. In metal-doped anionic clays, the additive, i.e. the metal dopant, is distributed more homogeneously within the anionic clay than in impregnated anionic clays, without separate phases of additive being present. Hence, abrasion of this catalyst composition will result in microfines poorer in additive than the prior art composition. Furthermore, the catalyst composition according to the invention results in a higher reduction of sulfur in fuels such as gasoline and diesel than is the case in compositions comprising impregnated anionic clay.
Type: Application
Filed: June 25, 2003
Publication date: February 12, 2004
Inventors: Paul O’Connor, Gregory A. Pearson, Jerry J. Springs, Dennis Stamires
Patent number: 6689333
Abstract: The present invention pertains to cheaper process for the preparation of quasi-crystalline boehmite containing additive in a homogeneously dispersed state. In this cheaper process an inexpensive quasi-crystalline boehmite precursor is and additive are combined and aged to form a quasi-crystalline boehmite containing additive in a homogeneously dispersed state. Suitable inexpensive quasi-crystalline boehmite precursors are aluminum trihydrate and thermally treated forms thereof and inorganic aluminum salts. Suitable additives are compounds containing elements selected from the group of rare earth metals alkaline earth metals, transition metals, actinides, silicon, gallium, boron, and phosphorus.
Type: Grant
Filed: August 11, 2000
Date of Patent: February 10, 2004
Assignee: Akzo Nobel N.V.
Inventors: Dennis Stamires, Paul O’Connor, Gregory Pearson, William Jones
Patent number: 6652828
Abstract: This patent describes economical and environment-friendly processes for the synthesis of Mg-containing non-Al anionic clays. It involves a one-step process wherein a suspension comprising a trivalent metal source and at least a magnesium containing source as a divalent metal source is reacted to obtain a magnesium-containing non-Al anionic clay. The anionic clay has interlayers containing anions comprising hydroxycarbonate, carbonate, bicarbonate, acetate, hydroxyacetate, oxalate, nitrate, hydroxyl, and/or formate or mixtures thereof. There is no necessity to wash or filter the product. It can be spray dried directly to form microspheres or can be extruded to form shaped bodies. The product can be combined with other ingredients in the manufacture of catalysts, absorbents, pharmaceuticals, cosmetics, detergents, and other commodity products that contain anionic clays.
Type: Grant
Filed: August 30, 2002
Date of Patent: November 25, 2003
Assignee: Akzo Nobel N.V.
Inventors: Dennis Stamires, William Jones
Publication number: 20030180214
Abstract: The present invention pertains to an improved process for the preparation of quasi-crystalline boehmite. In this improved process a quasi-crystalline boehmite precursor is aged at a pH below 7, prefereably under hydrothermal conditions. It was found that when conducting the preparation processes for quasi-crystalline aluminas described in the prior art at a pH below 7 and under hydrothermal conditions instead of the high pH and thermal aging used in the prior art, QCBs with higher crystallinity are obtained. In the process according to the invention additives may be added to the quasi-crystalline boehmite precursor. This results in a high quality QCB with additives in a homogeneously dispersed state. Suitable additives are compounds containing elements selected from the group of rare earth metals alkaline earth metals, transition metals, actinides, silicon, gallium, boron, and phosphorus.
Type: Application
Filed: January 15, 2003
Publication date: September 25, 2003
Inventors: Dennis Stamires, Paul O’Connor, Gregory Pearson, William Jones
Patent number: 6593265
Abstract: A process for preparing a 3R1-type crystalline anionic clay comprising the steps of: a) preparing an aqueous precursor mixture comprising aluminum trihydrate or a thermally treated form thereof and a magnesium source, the magnesium source is milled before use or when present in the precursor mixture, b) aging the precursor mixture at temperatures in the range 30°-100° C. to obtain the crystalline clay product, and c) optionally shaping the product of step b). Milling of the magnesium source, either alone or in combination with the (thermally treated) aluminum trihydrate, results in a faster reaction and higher conversion to anionic clay. The resulting anionic clay can be obtained by simply drying the slurry retrieved from the reactor. There is no need for washing or filtering, and a wide range of ratios of Mg/Al in the reaction product is possible.
Type: Grant
Filed: February 7, 2002
Date of Patent: July 15, 2003
Assignee: Akzo Nobel N.V.
Inventors: Dennis Stamires, William Jones, Sjoerd Daamen
Patent number: 6589902
Abstract: The present invention is directed to a process for the preparation of crystalline anionic clay-containing bodies from sources comprising an aluminum source and a magnesium source comprising the steps of: a) preparing a precursor mixture, b) shaping the precursor mixture to obtain shaped- bodies, c) optionally thermally treating the shaped bodies, and d) aging to obtain crystalline anionic clay-containing bodies. The quintessence of the present invention is that the bodies are shaped prior to the forming of the crystalline anionic clay in said bodies. This results in very attrition resistant bodies, without the need to add a binder material.
Type: Grant
Filed: August 11, 2000
Date of Patent: July 8, 2003
Assignee: Akzo Nobel N.V.
Inventors: Dennis Stamires, Paul O’Connor
Publication number: 20030087750
Abstract: This patent describes economical and environment-friendly processes for the synthesis of anionic clays. It involves reacting a slurry comprising boehmite, which has been peptized with acid with a divalent metal source followed by addition of source of base. The slurry is then hydrothermally aged. There is no necessity to wash or filter the product and it can be spray dried directly to form microspheres, or can be extruded to form shaped bodies. The product can be combined with other ingredients in the manufacture of catalysts, absorbents, pharmaceuticals, cosmetics, detergents, polymeric nanocomposites and other commodity products that contain anionic clays.
Type: Application
Filed: October 15, 2002
Publication date: May 8, 2003
Inventors: Dennis Stamires, Paul O’Connor, William Jones, Michael Brady
Patent number: 6555496
Abstract: A microcrystalline boehmite containing additive in a homogeneously dispersed state. Suitable additives are compounds containing elements selected from the group consisting of alkaline earth metals, alkaline metals, rare earth metals, transition metals, actinides, silicon, gallium, boron, titanium, and phosphorus. The microcrystalline boehmite according to the invention may be prepared in several ways. In general, a microcrystalline boehmite precursor and an additive are converted to a microcrystalline boehmite containing the additive in a homogeneously dispersed state. The additive does not contain zirconia or magnesia.
Type: Grant
Filed: August 11, 2000
Date of Patent: April 29, 2003
Assignee: Akzo Nobel N.V.
Inventors: Dennis Stamires, Paul O’Connor, Gregory Pearson, William Jones
Publication number: 20030073567
Abstract: The present invention is directed to a process for the in-situ preparation of a composite comprising a cationic clay and binder/matrix material from sources comprising an aluminum containing source, a silicon containing source and a di-valent metal containing source comprising the steps of:
Type: Application
Filed: September 27, 2002
Publication date: April 17, 2003
Inventors: Dennis Stamires, Paul O’Connor
Patent number: 6541409
Abstract: An economical and environment-friendly processes for the synthesis of anionic clays and the products made therefrom. It involves reacting a slurry comprising non-peptized boehmite with a magnesium source. There is no necessity to wash or filter the product. It can be spray dried directly to form microspheres or can be extruded to form shaped bodies. The product can be combined with other ingredients in the manufacture of catalysts, absorbents, pharmaceuticals, cosmetics, detergents, and other commodity products that contain anionic clays.
Type: Grant
Filed: January 26, 2000
Date of Patent: April 1, 2003
Assignee: Akzo Nobel N.V.
Inventors: William Jones, Dennis Stamires, Michael Brady
Publication number: 20030049189
Abstract: This patent describes economical and environment-friendly processes for the synthesis of Mg-containing non-Al anionic clays. It involves a one-step process wherein a suspension comprising a trivalent metal source and at least a magnesium containing source as a divalent metal source is reacted to obtain a magnesium-containing non-Al anionic clay. The anionic clay has interlayers containing anions comprising hydroxycarbonate, carbonate, bicarbonate, acetate, hydroxyacetate, oxalate, nitrate, hydroxyl, and/or formate or mixtures thereof. There is no necessity to wash or filter the product. It can be spray dried directly to form microspheres or can be extruded to form shaped bodies. The product can be combined with other ingredients in the manufacture of catalysts, absorbents, pharmaceuticals, cosmetics, detergents, and other commodity products that contain anionic clays.
Type: Application
Filed: August 30, 2002
Publication date: March 13, 2003
Inventors: Dennis Stamires, William Jones
Publication number: 20030044350
Abstract: A process for preparing molecular sieves of type Y faujasite structure is described, as well as pre-shaped bodies of faujasite structure type Y molecular sieves. The process comprises preparing a precursor gel from a source of silica-alumina or a source of alumina and a source of silica with a template agent at a SiO2/Al2O3 greater than 7 and suitable for forming a type Y zeolite, drying the precursor gel and contacting the dried precursor gel with steam, optionally followed by caustic washing, without the formation of crystalline phases other than type Y zeolite being observed. Advantageously, the pre-shaped bodies prepared with the precursor gel of Y zeolite, when subjected to the process of the invention, will have their outer surface covered by type Y zeolite crystals. The molecular sieves so obtained may be employed as catalysts or adsorbents in various processes of the chemical or oil industry.
Type: Application
Filed: June 7, 2002
Publication date: March 6, 2003
Inventors: Yiu Lau Lam, Alvaro Saavedra, Alexandre de Figueiredo Costa, Anselmo da Silva Santos, Gustavo Torres Moure, Rodolfo Eugenio Roncolatto, Dennis Stamires, Paul O’Connor
Publication number: 20030031623
Abstract: This patent describes an economical and environment-friendly process for the synthesis of anionic clays with carbonate and/or hydroxide anions as the charge-balancing interlayer species. It involves reacting a slurry comprising an aluminium source and a magnesium source, the aluminium source comprising two types of aluminium-containing compounds, preferably aluminium trihydrate and/or thermally treated calcined aluminium trihydrate. There is no necessity to wash or filter the product. It can be spray dried directly to form microspheres or can be extruded to form shaped bodies. The product can be combined with other ingredients in the manufacture of catalysts, absorbents, pharmaceuticals, cosmetics, detergents, and other commodity products.
Type: Application
Filed: March 15, 2002
Publication date: February 13, 2003
Applicant: AKZO NOBEL NV
Inventors: Dennis Stamires, Michael F. Brady, William Jones, Fathi Kooli
Patent number: 6506358
Abstract: The present invention pertains to an improved process for the preparation of quasi-crystalline boehmite. In this improved process a quasi-crystalline boehmite precursor is aged at a pH below 7, prefereably under hydrothermal conditions. It was found that when conducting the preparation processes for quasi-crystalline aluminas described in the prior art at a pH below 7 and under hydrothermal conditions instead of the high pH and thermal aging used in the prior art, QCBs with higher crystallinity are obtained. In the process according to the invention additives may be added to the quasi-crystalline boehmite precursor. This results in a high quality QCB with additives in a homogeneously dispersed state. Suitable additives are compounds containing elements selected from the group of rare earth metals alkaline earth metals, transition metals, actinides, silicon, gallium, boron, and phosphorus.
Type: Grant
Filed: August 11, 2000
Date of Patent: January 14, 2003
Assignee: Akzo Nobel B.V.
Inventors: Dennis Stamires, Paul O’Connor, Gregory Pearson, William Jones
Patent number: 6503867
Abstract: The present invention pertains to a quasi-crystalline boehmite containing additive in a homogeneously dispersed state. Suitable additives are compounds containing elements selected from the group of alkaline earth metals, alkaline metals, transition metals, actinides, silicon, gallium, boron, titanium, and phosphorus. Said QCBs according to the invention may be prepared in several ways. In general, a quasi-crystalline boehmite precursor and an additive are converted to a quasi-crystalline boehmite containing the additive in a homogeneously dispersed state.
Type: Grant
Filed: August 11, 2000
Date of Patent: January 7, 2003
Assignee: Akzo Nobel N.V.
Inventors: Dennis Stamires, Paul O’Connor, Gregory Pearson, William Jones
Publication number: 20030003035
Abstract: The invention pertains to a continuous process for the conversion of inorganic solid starting particles which either are amorphous or possess a degree of order into inorganic solid product particles which
Type: Application
Filed: May 8, 2002
Publication date: January 2, 2003
Inventors: Dennis Stamires, Paul O’Connor, Erik Jeroen Laheij, Johannes Wilhelmus Maria Sonnemans
Publication number: 20020168313
Abstract: The present invention provides new compositions of matter, referred to as quasi-crystalline carboxylates (QCCs), their preparation and use. The materials comprise a quasi-crystalline hydrated magnesium-aluminium hydroxy carboxylate and are characterised by the presence of at least a strong reflection in the powder X-ray diffraction pattern at a basal spacing in the range of 5 to 15 Å. The invention further relates to a process for preparing the QCCs, Mg—Al solid solutions and anionic clays under acidic conditions. The QCC is prepared by aging an acidic mixture of a magnesium carboxylate and an aluminium source. Calcination of the QCC results in a Mg—Al solid solution; rehydration of this solid solution gives an anionic clay.
Type: Application
Filed: January 31, 2002
Publication date: November 14, 2002
Inventors: Dennis Stamires, Thomas Joseph Pinnavaia, Michael Brady
Publication number: 20020159940
Abstract: The present invention is directed to a process for the preparation of a doped anionic clay. In said process a trivalent metal source is reacted with a divalent metal source, at least one of the metal sources being either doped boehmite, doped MgO or doped brucite, to obtain a doped anionic clay. Suitable dopants are compounds containing elements selected from the group of alkaline earth metals (for instance Ca and Ba), alkaline metals, transition metals (for example Co, Mn, Fe, Ti, Zr, Cu, Ni, Zn, Mo, W, V, Sn), actinides, rare earth metals such as La, Ce, and Nd, noble metals such as Pt and Pd, silicon, gallium, boron, titanium, and phosphorus.
Type: Application
Filed: February 7, 2002
Publication date: October 31, 2002
Inventors: Dennis Stamires, William Jones, Paul O’Connor
Patent number: 6468488
Abstract: The present invention pertains to Mg—Al anionic clay having 3R2 stacking. This new polytype of anionic clay has a three-layer repeat, but it has a different interlayer arrangement than the conventional 3R1 hydrotalcite. Said new polytype can be applied in all applications described before for the conventional 3R1 polytype anionic clay such as in catalyst compositions, catalyst additive compositions, catalyst supports, absorbent compositions, stabilizer compositions and in medicaments.
Type: Grant
Filed: August 11, 2000
Date of Patent: October 22, 2002
Assignee: Akzo Nobel N.V.
Inventors: Dennis Stamires, Paul O’Connor, William Jones
Patent number: 6444188
Abstract: This patent describes economical and environment-friendly processes for the synthesis of Mg-containing non-Al anionic clays. It involves (hydro)thermally reacting a slurry comprising a Mg metals source with a trivalent metals source to directly obtain Mg-containing non-Al anionic clay, the Mg sources being an oxide, hydroxide or a carbonate. There is no necessity to wash or filter the product. It can be spray dried directly to form microspheres or can be extruded to form shaped bodies. The product can be combined with other ingredients in the manufacture of catalysts, absorbents, pharmaceuticals, cosmetics, detergents, and other commodity products that contain anionic clays.
Type: Grant
Filed: August 11, 2000
Date of Patent: September 3, 2002
Assignee: Akzo Nobel N.V.
Inventors: Dennis Stamires, William Jones
Patent number: 6440887
Abstract: A continuous process for the synthesis of anionic clays with carbonate and/or hydroxide anions as the charge-balancing interlayer species is disclosed. The process involves reacting a slurry comprising aluminum trihydrate and/or its calcined form, with a magnesium source. There is no necessity to wash or filter the product. It can be spray dried directly to form microspheres or it can be extruded to form shaped bodies. The product can be combined with other ingredients in the manufacture of catalysts, absorbents, pharmaceuticals, cosmetics, detergents, and other commodity products.
Type: Grant
Filed: January 28, 1999
Date of Patent: August 27, 2002
Assignee: Akzo Nobel NV
Inventors: Dennis Stamires, Michael F. Brady, William Jones, Fathi Kooli
Patent number: 6440888
Abstract: This patent describes economical and environment-friendly processes for the synthesis of Al-containing non-Mg anionic clays. It involves hydrothermally reacting a slurry comprising a divalent metals source with a trivalent metals source to directly obtain Al-containing non-Mg anionic clay, at least one of the metal sources being an oxide, hydroxide or a carbonate. There is no necessity to wash or filter the product. It can be spray dried directly to form microspheres or can be extruded to form shaped bodies. The product can be combined with other ingredients in the manufacture of catalysts, absorbents, pharmaceuticals, cosmetics, detergents, and other commodity products that contain anionic clays.
Type: Grant
Filed: August 11, 2000
Date of Patent: August 27, 2002
Assignee: Akzo Nobel N.V.
Inventors: Dennis Stamires, William Jones
Publication number: 20020111263
Abstract: This invention relates to a process for the preparation of anionic clay and boehmite-containing compositions. These compositions may also contain unreacted trivalent metal source and/or divalent metal source. The process involves subjecting a precursor mixture comprising a divalent metal source and a trivalent metal source to at least two aging steps, wherein at least once between two aging steps an aluminum source is added. An advantage of the invention is that the crystallinity of the boehmite in the composition can be tuned.
Type: Application
Filed: February 7, 2002
Publication date: August 15, 2002
Inventors: Dennis Stamires, William Jones, Paul O’Connor
Publication number: 20020110520
Abstract: This invention relates to a process for preparing a 3R1-type crystalline anionic clay comprising the steps of:
Type: Application
Filed: February 7, 2002
Publication date: August 15, 2002
Inventors: Dennis Stamires, William Jones, Sjoerd Daamen
Publication number: 20020092812
Abstract: The present invention is directed to a process for the preparation of crystalline anionic clay-containing bodies from sources comprising a trivalent metal source and a divalent metal source comprising the steps of:
Type: Application
Filed: January 31, 2002
Publication date: July 18, 2002
Inventors: Dennis Stamires, William Jones, Paul O’Connor
Patent number: 6376405
Abstract: An economical and environment-friendly process for the synthesis of anionic clays with carbonate and/or hydroxide anions as the charge-balancing interlayer species is disclosed. The process involves reacting a slurry including an aluminum source and a magnesium source, the aluminum source including two types of aluminum-containing compounds, preferably aluminum trihydrate and/or thermally treated calcined aluminum trihydrate. There is no necessity to wash or filter the product. It can be spray dried directly to form microspheres or it can be extruded to form shaped bodies. The product can be combined with other ingredients in the manufacture of catalysts, absorbents, pharmaceuticals, cosmetics, detergents, and other commodity products.
Type: Grant
Filed: February 9, 1999
Date of Patent: April 23, 2002
Assignee: Akzo Nobel N.V.
Inventors: Dennis Stamires, Michael F. Brady, William Jones, Fathi Kooli
Patent number: 6171991
Abstract: This patent describes an economical and environment-friendly continuous process for the synthesis of anionic clay-containing compositions. It involves reacting a slurry comprising aluminium trihydrate and/or its calcined form, with a magnesium source. There is no necessity to wash or filter the product. It can be spray dried directly to form microspheres or can be extruded to form shaped bodies. The product can be combined with other ingredients in the manufacture of catalysts, absorbents, pharmaceuticals, cosmetics, detergents, and other commodity products.
Type: Grant
Filed: February 9, 1999
Date of Patent: January 9, 2001
Assignee: Akzo Nobel NV
Inventors: Dennis Stamires, Michael F. Brady, William Jones, Fathi Kooli
Patent number: 4362652
Abstract: This invention relates to the production of a cracking catalyst derived from hydrothermal treatment of an ammoniated silica-alumina gel, the alumina component of which is formulated from a mixture of anionic and cationic aluminum containing salts.
Type: Grant
Filed: July 8, 1981
Date of Patent: December 7, 1982
Assignee: Filtrol Corporation
Inventors: Dennis Stamires, Hamid Alafandi
Patent number: 4333857
Abstract: An improvement in abrasion resistance is obtained in zeolite compositions containing alumina and clay in a matrix by employing comminuted zeolites.
Type: Grant
Filed: March 17, 1980
Date of Patent: June 8, 1982
Assignee: Filtrol Corporation
Inventors: John Lim, Michael Brady, Dennis Stamires
Patent number: 4310441
Abstract: A silica-alumina gel derived from a cationic aluminum source and also an anionic aluminum source and processes for producing such gel.
Type: Grant
Filed: October 4, 1979
Date of Patent: January 12, 1982
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
Patent number: 4264474
Abstract: This invention relates to hydrothermal treatment of silica-alumina cogels resulting in a reduction in the NH.sub.4 content of the gel and the generation of a beta crystal phase and the employent of such gels as cracking catalysts.
Type: Grant
Filed: June 1, 1979
Date of Patent: April 28, 1981
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
Patent number: 4259210
Abstract: This invention relates to catalysts containing crystalline alumino-silicate zeolite and hydrothermally treated silica-alumina cogels and the employment of the same as cracking catalysts.
Type: Grant
Filed: June 1, 1979
Date of Patent: March 31, 1981
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
Patent number: 4252684
Abstract: This invention relates to alpha (Si, Al)O.sub.4 crystalline complex, and to silica-alumina gel and crystalline alumino silicate host containing said alpha (Si, Al)O.sub.4 complex; both gels and crystalline alumina silicates containing a novel crystalline phase resulting from the hydrothermal treatment of the host (Si, Al)O.sub.4 complexes, both amorphous gel and crystalline alumino silicates, in the presence of rare earth cations.
Type: Grant
Filed: June 1, 1979
Date of Patent: February 24, 1981
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
Patent number: 4246138
Abstract: This invention relates to catalysts containing crystalline alumino-silicate zeolite, hydrothermally treated silica-alumina cogels and the employment of the same as cracking catalysts.
Type: Grant
Filed: January 16, 1979
Date of Patent: January 20, 1981
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
Patent number: 4240932
Abstract: This invention relates to exchanged mordenite and catalysts employing the same.
Type: Grant
Filed: January 18, 1979
Date of Patent: December 23, 1980
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
Patent number: 4239651
Abstract: This invention relates to exchanged ammoniated cogels having improved catalytic activity and process for producing the same.
Type: Grant
Filed: August 21, 1978
Date of Patent: December 16, 1980
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
Patent number: 4238360
Abstract: This invention relates to hydrothermally treated silica-alumina cogels resulting in a reduction in the NH.sub.4 content of the gel and the employment of such gels as cracking catalysts.
Type: Grant
Filed: January 16, 1979
Date of Patent: December 9, 1980
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
Patent number: 4238361
Abstract: This invention relates to hydrothermal treatment of silica-alumina cogels resulting in a reduction in the NH.sub.4 content of the gel and the generation of a gamma crystal phase and the employment of such gels as cracking catalysts.
Type: Grant
Filed: June 1, 1979
Date of Patent: December 9, 1980
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
Patent number: 4237031
Abstract: This invention relates silica-alumina cogels containing a crystalline phase and to hydrothermally treatment of silica-alumina cogels resulting in generation of a crystalline phase in the gel and the employment of such crystallized gels as hydrocarbon conversion catalysts.
Type: Grant
Filed: February 5, 1979
Date of Patent: December 2, 1980
Assignee: Filtrol Corporation
Inventors: Hamid Alifandi, Dennis Stamires
Patent number: 4234457
Abstract: This invention relates to alpha (Si, Al)O.sub.4 crystalline complex, and to silica-alumina gel and crystalline alumino silicate host containing said alpha (Si, Al)O.sub.4 complex; both gels and crystalline alumina silicates containing a novel crystalline phase resulting from the hydrothermal treatment of the host (Si, Al)O.sub.4 complexes, both amorphous gel and crystalline alumino silicates, in the presence of rare earth cations.
Type: Grant
Filed: June 1, 1979
Date of Patent: November 18, 1980
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
Patent number: 4224188
Abstract: This invention relates to zeolites of the faujasite type generally referred to as X or Y zeolites which contain both aluminum and NH.sub.4 in exchange position and catalysts employing the same.The zeolite of our invention is derived from the sodium form of the zeolite by first exchanging the sodium form with an aluminum ion to replace a substantial portion of the sodium and further reducing the sodium content of the zeolite by exchange with an ammonium ion.
Type: Grant
Filed: March 13, 1978
Date of Patent: September 23, 1980
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
Patent number: 4215016
Abstract: Exchanged zeolite of the faujasite type is produced by exchanging the sodium zeolite at super atmospheric pressures at temperatures below about 500.degree. F. with salt solutions in ratios of cations in excess of an equivalent of the cation per equivalent of the sodium in the zeolite.
Type: Grant
Filed: February 3, 1978
Date of Patent: July 29, 1980
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
Patent number: 4206085
Abstract: This invention relates to an improvement in the abrasion resistance of catalysts formulated from a mixture of an exchanged zeolite of the faujasite type, hydrated alumina and ammonium polysilicate or silica sol.
Type: Grant
Filed: January 15, 1979
Date of Patent: June 3, 1980
Assignee: Filtrol Corporation
Inventors: John Lim, Dennis Stamires, Michael Brady
Patent number: 4198319
Abstract: This invention relates to zeolitic catalysts composed of an exchanged zeolite of the faujasite type and a matrix composed of clay and an alumina-silica component.
Type: Grant
Filed: February 3, 1978
Date of Patent: April 15, 1980
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
Patent number: 4198321
Abstract: This invention relates to a hydroprocessing catalyst particularly useful in hydrocracking comprising a low sodium faujasite zeolite produced by a high pressure exchange of Na cations with a solution of an ammonium salt as a substrate for incorporation of a hydrogenating metal compound.
Type: Grant
Filed: December 5, 1977
Date of Patent: April 15, 1980
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
Patent number: 4192778
Abstract: A rare earth exchanged zeolite of the faujasite type in which the equivalent of Na is less than 0.1 and the rare earth is at least 0.9 equivalents per gram atom of aluminum and catalysts including the same.
Type: Grant
Filed: January 16, 1978
Date of Patent: March 11, 1980
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
Patent number: 4164483
Abstract: This invention relates to the preparation of rare earth exchanged X type faujasite zeolites in which the Na content is reduced by exchange with rare earth cations to introduce in excess of about 0.9 equivalents of rare earth cations per gram atom of aluminum and catalysts employing the same.
Type: Grant
Filed: June 20, 1977
Date of Patent: August 14, 1979
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
Patent number: 4142995
Abstract: This invention relates to zeolitic catalysts composed of an exchanged zeolite of the faujasite type and a matrix composed of alumina and an alumina-silica component.
Type: Grant
Filed: February 16, 1977
Date of Patent: March 6, 1979
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
Patent number: 4100108
Abstract: This invention relates to production of improved zeolitic catalysts produced from mixtures of cation exchanged zeolites of the faujasite type incorporated into a matrix such as alumina, silica-alumina gels and clay or mixtures thereof.
Type: Grant
Filed: March 30, 1977
Date of Patent: July 11, 1978
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
Patent number: 4086187
Abstract: Attrition resistant zeolitic catalysts containing silica, alumina and clay components.
Type: Grant
Filed: June 17, 1976
Date of Patent: April 25, 1978
Assignee: Filtrol Corporation
Inventors: John Lim, Dennis Stamires
Patent number: 4085069
Abstract: Catalysts containing a matrix and an ammonium zeolite of the faujasite type produced by exchanging the zeolite whose exchange sites are substantially entirely occupied by Na cations, with an ammonium salt solution to exchange substantially all of the Na cations with NH.sub.4 cations with substantially no impairment of crystallinity by a control of the relation of the equivalents of NH.sub.4 in the solution to equivalents of Na in the zeolite.
Type: Grant
Filed: August 27, 1976
Date of Patent: April 18, 1978
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
Patent number: 4058484
Abstract: A process of producing an ammonium zeolite of the faujasite type in which a zeolite of the faujasite type whose exchange sites are substantially entirely occupied by Na cations, is treated with an ammonium salt solution to exchange substantially all of the Na cations with NH.sub.4 cations with substantially no impairment of crystallinity by a control of the relation of the equivalents of NH.sub.4 in the solution to equivalents of Na in the zeolite.
Type: Grant
Filed: September 9, 1976
Date of Patent: November 15, 1977
Assignee: Filtrol Corporation
Inventors: Hamid Alafandi, Dennis Stamires
