Highly selective alkylation process with low zeolite catalyst composition

Patent metadata

Field	Value
Publication number	US-2016289140-A1
Application number	US-201514674832-A
Country	US
Kind code	A1
Filing date	Mar 31, 2015
Priority date	Mar 31, 2015
Publication date	Oct 6, 2016
Grant date	—

Abstract

A method for alkylation of a feedstock is described. The method includes contacting the feedstock comprising at least one alkylatable aromatic compound and an alkylating agent with a first alkylating catalyst composition under alkylating conditions, the first alkylating catalyst composition comprising UZM-8 zeolite and a binder, the first alkylating catalyst composition having 2-20 wt % UZM-8 zeolite and the catalyst having a nitrogen to zeolite aluminum molar ratio of between about 0.01 to about 0.040; wherein a total alkylated selectivity at a temperature and a molar ratio of alkylatable aromatic compound to alkylating agent is greater than 99.0%.

First claim

What is claimed is:

1 . A method for alkylation of feedstock comprising:
contacting the feedstock comprising at least one alkylatable aromatic compound and an alkylating agent with a first alkylating catalyst composition under alkylating conditions, the first alkylating catalyst composition comprising UZM-8 zeolite, nitrogen, and a binder, the first alkylating catalyst composition having 2-20 wt % UZM-8 zeolite, and the catalyst having a nitrogen to zeolite aluminum molar ratio of between about 0.01 to about 0.040 to produce a product stream; wherein a total alkylated selectivity at a temperature and a molar ratio of alkylatable aromatic compound to alkylating agent is greater than 99.0%; and contacting the product stream with a second alkylating catalyst to convert the uncoverted olefins existing from the first alkylating catalyst.

2 . The method of claim 1 wherein the first alkylating catalyst composition has about 10 wt % UZM-8 zeolite.

3 . The second alkylating catalyst of claim 1 comprises zeolite UZM-8, UZM-37, MCM-22, BEA, FAU or a mixture of thereof at a combined zeolite content of greater than 30 wt %.

4 . The second alkylating catalyst of claim 2 comprises zeolite UZM-8, UZM-37, MCM-22, BEA, FAU or a mixture of thereof at a combined zeolite content of greater than 30 wt %.

5 . The method of claim 1 further comprising contacting the feedstock with at least one additional catalyst composition before contacting the feedstock with the first alkylating catalyst composition, the at least one additional catalyst composition capable of reacting with one or more of nitrogen, oxygenate species, sulfur, or metals, to reduce a level of nitrogen, oxygen, sulfur, or metals in the feedstock.

6 . The method of claim 1 further comprising contacting the effluent exiting the first alkylating catalyst with the second alkylating catalyst composition comprising a zeolite and a binder, the second alkylating catalyst composition having greater than 30 wt % zeolite.

7 . The method of claim 1 wherein the alkylating conditions include a temperature of from about 90° C. to about 230° C., a pressure of from about 1.3 MPa to about 4.8 MPa, a molar ratio of alkylatable aromatic compound to alkylating agent of from about 1 to about 5, and a feed hourly weight space velocity based on the alkylating agent of from about 0.5 to about 10 hr −1 .

8 . The method of claim 1 wherein the alkylatable aromatic compound is benzene, the alkylating agent is propylene, and the propylene conversion across the first catalyst composition is greater than 90%.

9 . The method of claim 1 wherein the alkylatable aromatic compound is benzene, the alkylating agent is propylene, and the propylene conversion across the first catalyst composition is greater than 95%.

10 . The method of claim 1 wherein the alkylatable aromatic compound is benzene, the alkylating agent is ethylene, and the ethylene conversion across the first catalyst composition is greater than 80%.

11 . The method of claim 1 wherein the alkylatable aromatic compound is benzene, the alkylating agent is ethylene, and the ethylene conversion across the first catalyst composition is greater than 90%.

12 . The method of claim 1 wherein the alkylatable aromatic compound is benzene, the alkylating agent is butene, and the butene conversion across the first catalyst composition is greater than 95%.

13 . The method of claim 1 wherein the alkylatable aromatic compound is benzene, the alkylating agent is butene, and the butene conversion across the first catalyst composition is greater than 97%.

14 . The method of claim 2 wherein the second alkylating catalyst is made up of less than 50% and preferably less than 30% of the total alkylating catalysts.

15 . A method for alkylation of feedstock comprising:
contacting the feedstock comprising at least one alkylatable aromatic compound and an alkylating agent with at least one additional catalyst composition, the at least one additional catalyst composition capable of reacting with one or more of nitrogen, oxygen, sulfur, or metals, forming a feedstock having a reduced level of nitrogen, oxygen, sulfur, or metals; contacting the feedstock with the reduced level of nitrogen, oxygen, sulfur, or metals with a first alkylating catalyst composition under alkylating conditions, the first alkylating catalyst composition comprising UZM-8 zeolite and a binder, the first alkylating catalyst composition having about 2-20 wt % UZM-8 zeolite; wherein a total alkylated selectivity at a temperature and a molar ratio of alkylatable aromatic compound to alkylating agent is greater than 99.0%; and contacting the product stream with a second alkylating catalyst to convert the uncoverted olefins existing from the first alkylating catalyst.

16 . The method of claim 15 wherein the first alkylating catalyst composition has about 2 wt % to about 10 wt % UZM-8 zeolite.

17 . The method of claim 15 further comprising contacting the effluent exiting the first alkylating catalyst with a second alkylating catalyst composition comprising a zeolite and a binder, the second alkylating catalyst composition having greater than 30 wt % zeolite.

18 . The method of claim 15 further comprises second alkylating catalyst composition comprises a zeolite selected from zeolite UZM-8, UZM-37, MCM-22, BEA, FAU, and a mixture of thereof at a combined zeolite content of greater than 30 wt %.

19 . The method of claim 15 wherein the alkylating conditions include a temperature of from about 90° C. to about 230° C., a pressure of from about 1.3 MPa to about 4.8 MPa, a molar ratio of alkylatable aromatic compound to alkylating agent of from about 1 to about 5, and a feed hourly weight space velocity based on the alkylating agent of from about 0.5 to about 10 hr −1 .

20 . The method of claim 15 where the second alkylating catalyst is made up of less than 50 and preferably less than 30% of the total alkylating catalysts.

Assignees

• Uop Llc

Inventors

• Schmidt Robert J
• Jan Deng-Yang
• Cox Pelin

Classifications

• C07C2529/70

  of types characterised by their specific structure not provided for in groups C07C2529/08 - C07C2529/65 · CPC title

• B01J29/08

  of the faujasite type, e.g. type X or Y · CPC title

• B01J29/7038

  MWW-type, e.g. MCM-22, ERB-1, ITQ-1, PSH-3 or SSZ-25 · CPC title

• C07C2/66 Primary

  Catalytic processes · CPC title

• B01J29/70

  of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65 · CPC title