Method of producing an aromatization catalyst

Patent metadata

Field	Value
Publication number	US-2022016609-A1
Application number	US-202016930462-A
Country	US
Kind code	A1
Filing date	Jul 16, 2020
Priority date	Jul 16, 2020
Publication date	Jan 20, 2022
Grant date	—

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 . (canceled)

16 . 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.

17 . The method of producing an aromatization catalyst of claim 17 , wherein the water content of the dry-gel is less than 25 wt. %.

18 . The method of producing an aromatization catalyst of claim 1 , 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

• B01J37/086

  Decomposition of an organometallic compound, a metal complex or a metal salt of a carboxylic acid · CPC title