Preparation of Amorphous Silica-Alumina Using the Sol–Gel Method and its Reactivity for a Matrix in Catalytic Cracking

Amorphous silica-aluminas were prepared by the sol–gel method using organic templates such as carboxylic acid and the gel skeletal reinforcement method. Their reactivities as a matrix for the catalytic cracking were investigated. Malic acid (MA) was used as a catalyst for the sol–gel method, an organic template and a reagent for the dispersion of Al. When the ratio of MA/TEOS (tetraethoxysilane) increased from 0.22 to 1.22, surface area, pore volume and pore diameter increased and the mesopore was formed at 1.22. Their average BET pore diameters for 0.22 and 1.22 of MA/TEOS were 2.0 to 5.1 nm, respectively. Although conversions of n-dodecane were around 20% or less with single amorphous silica-aluminas, both single beta-zeolite and the mixed catalysts of zeolite and amorphous silica-aluminas showed much higher activity. Further, the mixed catalyst using silica-alumina with mesopore (MAT(MA122-5)) exhibited the higher ratio of multi-branched paraffin to single branched paraffin in the gasoline franction of products (C5–C11) than the mixed catalysts using silica-alumina with only micropore and silica with mesopore or single zeolite. In the gel skeletal reinforcement method, tetraethoxy orthosilicate (TEOS) was used as not only a precursor of silica but also an agent which reinforces the skeleton of silica-gel to prepare an aerogel and extremely large mesopores were formed for resultant silicas and silica-aluminas. When silica aerogel was reinforced by TEOS solution, the pore diameter and pore volume reached 30 nm and 3.1 cm3/g, respectively, in the N2 adsorption measurement by the BJH method, indicating that most of pores for this silica consisted of mesopores. In catalytic clacking reaction of n-dodecane, the mixed catalyst prepared by beta-zeolite and silica-alumina with large mesopore exhibited not only the comparable activity to that for single zeolite but also the unique selectivity where large amounts of branched products were formed. When the catalyst beds of silica-alumina and zeolite were separated, the reference silica-alumina (ref.SA) → zeolite system exhibited the higher activity and the product selectivity close to those for MAT(ref.SA). It is likely that the primary cracking of n-dodecane on silica-alumina would occur to produce the primary cracked product which effectively reacted with zeolite and inhibited the coke formation by overcracking.