Fine particle clay catalysts for coal liquefaction. Quarterly technical progress report, February 9, 1992--May 8, 1992

An investigation of new methods for the production of iron-pillared clay catalysts and clay-supported iron hydroxyoxide catalysts and the determination of their catalytic activities was continued in this quarter. Previous work in this project showed that a catalyst prepared by adding ferric nitrate and ammonia to an acid-washed clay gave an active catalyst following sulfidation. Further testing of this catalyst with a model compound showed that its hydrocracking activity was considerably lower when used in 10% concentration rather than 50%. In contrast, the mixed iron/alumina pillared clay catalysts were still highly effective at 10% concentration and gave good conversions at one and two hour reaction times. An investigation of preparation methods demonstrated that calcination of both the iron hydroxyoxide-impregnated clay and the mixed iron/alumina pillared clays is essential for activity. High activity was obtained for these catalysts only when they were removed from the aqueous media rapidly, dried, and calcined. The use of ferric sulfate to prepare a clay-supported sulfated iron catalyst was attempted, the resulting catalyst was relatively inactive for hydrocracking. Several new catalysts were synthesized with the idea of decreasing the pillar density and thereby increasing the micropore volume. A zirconia-pillared clay with low pillar density was prepared and intercalated with triiron complex. The hydrocracking activity of this catalyst was somewhat lower than that of the mixed alumina/iron-pillared catalyst. Other new catalysts, that were prepared by first pillaring with an organic ammonium pillaring agent, then introducing a lower number of silica or alumina pillars, and finally the iron component, were also tested. The mixed alumina/iron-pillared catalysts was further tested at low concentration for pyrene hydrogenating and hydrocracking activities