Methods of producing catalysts comprising one or more oxides of nickel and one or more oxides of silver

Patent metadata

Field	Value
Publication number	US-12138622-B2
Application number	US-202217970839-A
Country	US
Kind code	B2
Filing date	Oct 21, 2022
Priority date	Oct 21, 2022
Publication date	Nov 12, 2024
Grant date	Nov 12, 2024

Abstract

According to embodiments, a method of producing a catalyst composition may include forming a slurry including an initial zeolite material, a surfactant, silica, and metal precursors, wherein the metal precursors contain a nickel-containing compound and a silver-containing compound, extruding the slurry to produce an extrudate, drying and calcining the extrudate to form a dried and calcined extrudate, hydrothermally treating the dried and calcined extrudate to form a hydrothermally-treated extrudate, and drying and calcining the hydrothermally-treated extrudate to produce the catalyst composition, wherein the catalyst composition includes zeolite, one or more oxides of nickel, and one or more oxides of silver.

First claim

What is claimed is:

1. A method of producing a catalyst composition, the method comprising:
forming a slurry comprising an initial zeolite material, a surfactant, silica, and metal precursors, wherein the metal precursors comprise a nickel-containing compound and a silver-containing compound;
extruding the slurry to produce an extrudate;
drying and calcining the extrudate to form a dried and calcined extrudate;
hydrothermally treating the dried and calcined extrudate to form a hydrothermally-treated extrudate, wherein the hydrothermal treatment is at a temperature of from 50° C. to 250° C.; and
drying and calcining the hydrothermally-treated extrudate to produce the catalyst composition, wherein the catalyst composition comprises zeolite, one or more oxides of nickel, and one or more oxides of silver.

2. The method of claim 1 , wherein forming the slurry comprises mixing at least the initial zeolite material, the surfactant, a colloidal silica suspension comprising the silica, and a metal precursor solution comprising the metal precursors.

3. The method of claim 2 , wherein the colloidal silica suspension comprises silica and water.

4. The method of claim 2 , wherein the colloidal silica suspension comprises from 20 wt. % to 50 wt. % silica based on a total weight of the colloidal silica suspension.

5. The method of claim 1 , wherein the initial zeolite material comprises ZSM-5 zeolite.

6. The method of claim 1 , wherein the nickel-containing compound is chosen from nickel nitrate, nickel nitrate hexahydrate, or combinations thereof.

7. The method of claim 1 , wherein the silver-containing compound is chosen from silver nitrate, silver nitrate hydrate, or combinations thereof.

8. The method of claim 1 , wherein the catalyst composition comprises from 0.5 wt. % to 1 wt. % oxides of nickel based on a total weight of the catalyst composition.

9. The method of claim 1 , wherein the catalyst composition comprises from 0.5 wt. % to 1 wt. % oxides of silver based on a total weight of the catalyst composition.

10. The method of claim 1 , wherein the surfactant comprises tetrapropylammonium bromide (TPABr), tetrapropylammonium hydroxide (TPAOH), tetraethylammonium hydroxide (TEAOH), or combinations thereof.

11. The method of claim 1 , wherein the hydrothermal treatment is performed in an autoclave.

12. The method of claim 1 , wherein the hydrothermal treatment is at a temperature of from 150° C. to 250° C.

13. The method of claim 1 , wherein the hydrothermal treatment is for a time period of from 1 day to 5 days.

14. The method of claim 1 , wherein the hydrothermal treatment is conducted with a solid to liquid weight ratio of from 1:2 to 1:4.

15. The method of claim 1 , wherein:
the catalyst composition comprises from 0.5 wt. % to 1 wt. % oxides of nickel based on the total weight of the catalyst composition; and
the catalyst composition comprises from 0.5 wt. % to 1 wt. % oxides of silver based on the total weight of the catalyst composition.

16. The method of claim 1 , wherein:
hydrothermal treatment is performed in an autoclave;
the hydrothermal treatment is at a temperature of from 150° C. to 250° C.; and
the hydrothermal treatment is for a time period of from 1 day to 5 days.

17. A method of catalytically cracking butene, the method comprising:
producing a catalyst composition by the method of claim 1 ;
contacting the catalyst composition with a stream comprising butene such that at least a portion of the butene is catalytically cracked to produce one or more products.

18. The method of claim 17 , wherein the one or more products comprise propylene and ethylene.

Assignees

• Saudi Arabian Oil Co

Inventors

• Khokhar Munir D
• Madden Anne
• Shaikh Sohel K

Classifications

• B01J23/66

  Silver or gold · CPC title

• C10G11/05 Primary

  Crystalline alumino-silicates, e.g. molecular sieves · CPC title

• C09K23/003

  Organic compounds containing only carbon and hydrogen · CPC title

• B01J35/393

  Metal or metal oxide crystallite size · CPC title

• B01J21/08

  Silica · CPC title