Method of producing an aromatization catalyst

Patent metadata

Field	Value
Publication number	US-11278873-B2
Application number	US-202016930462-A
Country	US
Kind code	B2
Filing date	Jul 16, 2020
Priority date	Jul 16, 2020
Publication date	Mar 22, 2022
Grant date	Mar 22, 2022

Abstract

According to the subject matter of the present disclosure, a method of producing an aromatization catalyst may comprise producing a plurality of uncalcined ZSM-5 nanoparticles via a dry-gel method, directly mixing the plurality of uncalcined ZSM-5 nanoparticles with large pore alumina and a binder to form a ZSM-5/alumina mixture, and calcining the ZSM-5/alumina mixture to form the aromatization catalyst. The plurality of uncalcined ZSM-5 nanoparticles may have an average diameter of less than 80 nm.

First claim

What is claimed is:

1. A method of producing an aromatization catalyst, the method comprising:
producing a plurality of uncalcined ZSM-5 nanoparticles via a dry-gel method, wherein the plurality of ZSM-5 nanoparticles has an average diameter of less than 80 nm;
directly mixing the plurality of uncalcined ZSM-5 nanoparticles with large pore alumina and a binder to form a ZSM-5/alumina mixture; and
calcining the ZSM-5/alumina mixture to form the aromatization catalyst; wherein the large pore alumina has a pore size of from 18 nm to 26 nm.

2. The method of producing an aromatization catalyst of claim 1 , wherein the plurality of uncalcined ZSM-5 nanoparticles has not been subjected to centrifugation above 3,000 rpm, before being mixed with the large pore alumina and binder.

3. The method of producing an aromatization catalyst of claim 1 , wherein the plurality of uncalcined ZSM-5 nanoparticles has not been subjected to calcination above 200° C. for more than 30 minutes, before being mixed with the large pore alumina and binder.

4. The method of producing an aromatization catalyst of claim 1 , wherein the ZSM-5/alumina mixture is calcined at a temperature of from 400° C. to 700° C. for from 1 hour to 10 hours.

5. The method of producing an aromatization catalyst of claim 1 , wherein the aromatization catalyst is impregnated with gallium atoms to form a Ga-ZSM-5 catalyst.

6. The method of producing an aromatization catalyst of claim 5 , wherein the Ga-ZSM-5 catalyst is calcined.

7. The method of producing an aromatization catalyst of claim 1 , wherein the aromatization catalyst is impregnated with a catalytic metal to form a metal-ZSM-5 catalyst, the metal-ZSM-5 catalyst comprises from 50 wt. % to 90 wt. % ZSM-5, 5 wt. % to 30 wt. % large pore alumina, 10 wt. % to 20 wt. % binder, and 0.2 wt. % to 6 wt. % catalytic metal.

8. The method of producing an aromatization catalyst of claim 7 , wherein the catalytic metal comprises gallium.

9. The method of producing a catalyst of claim 1 , wherein the directly mixing is extrusion.

10. The method of producing an aromatization catalyst of claim 1 , wherein the plurality of uncalcined ZSM-5 nanoparticles has an average diameter 30 nm to 80 nm.

11. The method of producing an aromatization catalyst of claim 1 , wherein at least 90% of the individual uncalcined ZSM-5 nanoparticles have diameters from 20 nm to 50 nm.

12. The method of producing an aromatization catalyst of claim 1 , wherein an average pore size of the uncalcined ZSM-5 nanoparticles is from 35 nm to 55 nm.

13. The method of producing an aromatization catalyst of claim 1 , wherein a BET surface area of the uncalcined ZSM-5 nanoparticles is from 300 m 2 /g to 600 m 2 /g.

14. The method of producing an aromatization catalyst of claim 1 , wherein a pore volume of the uncalcined ZSM-5 nanoparticles is from 0.3 ml/g to 0.45 ml/g.

15. The method of producing a catalyst of claim 1 , wherein the producing the plurality of uncalcined ZSM-5 nanoparticles via the dry-gel method comprises:
combining an alumina source, a structure directing agent, and a silica source to form a slurry;
optionally, introducing NaOH to the slurry such that the final concentration of NaOH in the slurry is from 0.000001 g/L to 0.1 g/L;
drying the slurry to form a dry-gel; and
autoclaving the dry-gel in a humidified autoclave to form the plurality of uncalcined ZSM-5 nanoparticles.

16. The method of producing an aromatization catalyst of claim 15 , wherein the water content of the dry-gel is less than 25 wt. %.

17. The method of producing an aromatization catalyst of claim 15 , wherein the dry-gel is not agitated during autoclaving.

Assignees

• Saudi Arabian Oil Co

Inventors

• Al-Eid Manal
• Ding Lianhui
• Alnaimi Essa

Classifications

• B01J2235/15

  X-ray diffraction · CPC title

• B01J35/45

  Nanoparticles · CPC title

• B01J2235/30

  Scanning electron microscopy; Transmission electron microscopy · CPC title

• Y02P20/52

  using catalysts, e.g. selective catalysts · CPC title

• C07C2529/40

  of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11 · CPC title