A modified Y-type molecular sieve has a rare earth content of about 4% to about 11% by weight on the basis of the oxide, a phosphorus content of about 0.05% to about 10% by weight on the basis of P.sub.2O.sub.5, a sodium content of no more than about 0.5% by weight on the basis of sodium oxide, and an active element content of about 0.1% to about 5% by weight on the basis of the oxide, with the active element being gallium and/or boron. The modified Y-type molecular sieve has a total pore volume of about 0.36 mL/g to about 0.48 mL/g, a percentage of the pore volume of secondary pores having a pore size of 2-100 nm of about 20% to about 40%; a lattice constant of about 2.440 nm to about 2.455 nm, and a lattice collapse temperature of not lower than about 1060° C.

A method of producing a catalyst comprises generating an aerosolized flow of catalyst support particles, heating a catalytically active compound precursor to produce a catalytically active compound precursor vapor, contacting the aerosolized flow of catalyst support particles with the catalytically active compound precursor vapor, and condensing the catalytically active compound precursor onto the catalyst support particles to produce the catalyst comprising catalytically active compound deposited on surfaces of the catalyst support particles. The method may further comprise aerosolizing a catalyst support precursor mixture, drying the aerosolized catalyst support precursor mixture in a first heating zone to form an aerosolized flow of catalyst support particles, and contacting the catalyst support particles with a catalytically active compound precursor vapor in a second heating zone to form the catalyst comprising the layer of the catalytically active compound deposited on surfaces of the catalyst of catalyst support particles.

Disclosed herein is a process and an apparatus for producing coated catalysts. A process of the present disclosure includes providing a composition containing a liquid and a catalytically active material and/or a precursor thereof in a stock vessel, providing a support material in a vessel which is rotatable about a longitudinal axis, transporting the composition from the stock vessel through a first conduit to a spray nozzle, transporting a propellant fluid through a second conduit to the spray nozzle, atomizing the composition and propellant fluid in the nozzle to produce an aerosol that flows into the vessel and impregnates the support material present therein, heating the vessel so the liquid present in the aerosol evaporates from the support material and the finely divided support material which has been treated with catalytically active material and/or a precursor thereof is dried, and discharging the vaporized liquid from the vessel.

A multi-functional composite catalyst includes a catalyst support material, a preformed catalyst material at least partially secured in the catalyst support, and at least one catalytically active compound supported by the catalyst support, the preformed catalyst material, or both. The catalyst support material may include fumed silica, alumina, fumed alumina, fumed titania, or combinations of these. A catalytic activity of the catalytically active compound may be different than a catalytic activity of the preformed catalyst material. The composite catalyst may be catalyst for producing propene from 2-butene and may include a zeolite as the preformed catalyst material and a metal oxide, such as tungsten oxide, as the catalytically active material. A method of making the composite catalyst may include aerosolizing a catalyst precursor mixture that includes a preformed catalyst material, catalyst support precursor, and catalytically active compound precursor, and drying the aerosolized catalyst precursor mixture.

One or more embodiments presently disclosed is directed to a method for reacting a chemical stream which may include contacting the chemical stream with a catalyst to produce a product stream. The catalyst may include alumina, silica, and a catalytically active compound such as tungsten.

A preparation method for a propylene epoxidation catalyst: pre-hydrolyzing a silicon source, adding a titanium source and reacting to form a sol, atomizing the sol and then spraying it into liquid ammonia for molding, implementing pore broadening, and performing drying, calcination, and silanization treatment to obtain a Ti—SiO.sub.2 composite oxide catalyst. The present catalyst can be used in the chemical process of preparing propylene oxide by epoxidation of propylene, the average propylene oxide selectivity being up to 97.5%, having prospects for industrial application.

A modified Y-type molecular sieve has a rare earth content of about 4-11% by weight on the basis of rare earth oxide, a sodium content of no more than about 0.7% by weight on the basis of sodium oxide, a zinc content of about 0.5-5% by weight on the basis of zinc oxide, a phosphorus content of about 0.05-10% by weight on the basis of phosphorus pentoxide, a framework silica-alumina ratio of about 7-14 calculated on the basis of SiO.sub.2/Al.sub.2O.sub.3 molar ratio, a percentage of non-framework aluminum content to the total aluminum content of no more than about 20%, and a percentage of the pore volume of secondary pores having a pore size of 2-100 nm to the total pore volume of about 15-30%. The modified Y-type molecular sieve has a high crystallinity, a structure comprising secondary pores, and a high thermal and hydrothermal stability.

One or more embodiments presently disclosed is directed to a method for reacting a chemical stream which may include contacting the chemical stream with a catalyst to produce a product stream. The catalyst may include alumina, silica, and a catalytically active compound such as tungsten.

A modified Y-type molecular sieve has a rare earth content of about 4% to about 11% by weight on the basis of the oxide, a phosphorus content of about 0.05% to about 10% by weight on the basis of P.sub.2O.sub.5, a sodium content of no more than about 0.5% by weight on the basis of sodium oxide, and an active element content of about 0.1% to about 5% by weight on the basis of the oxide, with the active element being gallium and/or boron. The modified Y-type molecular sieve has a total pore volume of about 0.36 mL/g to about 0.48 mL/g, a percentage of the pore volume of secondary pores having a pore size of 2-100 nm of about 20% to about 40%; a lattice constant of about 2.440 nm to about 2.455 nm, and a lattice collapse temperature of not lower than about 1060° C.

One or more embodiments presently disclosed is directed to a method for reacting a chemical stream which may include contacting the chemical stream with a catalyst to produce a product stream. The catalyst may include alumina, silica, and a catalytically active compound such as tungsten.