Process for obtaining a catalyst composite

Patent metadata

Field	Value
Publication number	US-9227175-B2
Application number	US-201414206329-A
Country	US
Kind code	B2
Filing date	Mar 12, 2014
Priority date	Jan 25, 2008
Publication date	Jan 5, 2016
Grant date	Jan 5, 2016

Abstract

A process for obtaining a catalyst composite comprising the following steps:
a). selecting a molecular sieve having pores of 10- or more-membered rings b). contacting the molecular sieve with a metal silicate different from said molecular sieve comprising at least one alkaline earth metal and one or more of the following metals: Ga, Al, Ce, In, Cs, Sc, Sn, Li, Zn, Co, Mo, Mn, Ni, Fe, Cu, Cr, Ti and V, such that the composite comprises at least 0.1 wt % of silicate.

First claim

The invention claimed is:

1. A process for preparing a catalyst, comprising:
selecting a molecular sieve having pores of 10- or more-membered rings, wherein the molecular sieve is a zeolite; and
contacting the zeolite with a metal silicate, different from the zeolite, wherein the metal silicate comprises xonotlite (Ca 6 Si 6 O 17 (OH) 2 );
wherein the catalyst comprises at least 10 wt % of the zeolite and at least 0.1 wt % of silicate based on a total weight of the catalyst.

2. The process of claim 1 , wherein the molecular sieve has pores of 12- or more-membered rings.

3. The process of claim 1 , wherein the metal silicate is present in the catalyst composite in an amount of up to 10 wt %.

4. A process for preparing a catalyst, comprising:
selecting a molecular sieve having pores of 10- or more-membered rings, wherein the molecular sieve is a ZSM-5 zeolite;
contacting the ZSM-5 zeolite with a metal silicate, different from the ZSM-5 zeolite, wherein the metal silicate comprises xonotlite (Ca 6 Si 6 O 17 (OH) 2 );
wherein the catalyst comprises at least 10 wt % of the ZSM-5 zeolite and at least 0.1 wt % of silicate based on a total weight of the catalyst.

5. The process of claim 1 , wherein the zeolite is selected from the group consisting of MFI, MOR, MEL, clinoptilolite, FER, FAU, MWW, BETA, ZSM-21, ZSM-22, ZSM-23, ZSM-42, ZSM-57, and LTL, and combinations thereof.

6. The process of claim 1 , wherein the zeolite is selected from the group consisting of MFI, MOR, MEL, clinoptilolite and FER and combinations thereof, and wherein the molecular sieve is synthesized without direct addition of template.

7. The process of claim 1 , wherein the zeolite is a P-modified zeolite.

8. The process of claim 7 , wherein the zeolite is modified with P by undergoing a steam treatment step, whereby the zeolite is dealuminated, followed by a leaching step using an acid solution comprising a source of P.

9. The process of claim 1 , wherein the zeolite is brought into contact with the metal silicate by mechanically blending the zeolite with the metal silicate forming a precursor during preparation of the catalyst.

10. The process of claim 1 , wherein the zeolite is brought into contact with the metal silicate by physical blending of a previously prepared zeolite and a previously prepared metal silicate in situ in an XTO and/or OCP reaction medium.

11. The process of claim 1 , wherein the metal silicate further comprises CaAl 2 Si 2 O 8 , Ca 2 Al 2 SiO 7 , CaMg(Si 2 O 6 ) x , or combinations thereof.

12. The process of claim 1 , wherein the zeolite is selected from the group consisting of MFI, MOR, MEL, clinoptilolite, FER, FAU, MWW, BETA, ZSM-21, ZSM-22, ZSM-23, ZSM-42, ZSM-57, LTL, and combinations thereof, and wherein the zeolite is obtained without direction addition of template.

13. The process of claim 1 , wherein prior to and/or after contacting the metal silicate with the zeolite, the zeolite is treated according to one or more, of the following steps: steaming, leaching, washing, drying, calcination, impregnation, and ion exchanging.

14. The process of claim 1 , wherein the zeolite that is contacted with the metal silicate is a non-modified zeolite, and wherein the zeolite is modified with P after contacting the metal silicate.

15. The process of claim 14 , wherein the zeolite is modified with P by undergoing a steam treatment step, whereby the zeolite is dealuminated, followed by a leaching step using an acid solution comprising a source of P.

16. The process of claim 14 , wherein the zeolite is modified with P according to the following:
steaming at a temperature ranging from 400 to 870° C. for 0.01-200 hours;
leaching with an aqueous acid solution comprising the source of P at conditions effective to remove a substantial part of Al from the zeolite and to introduce at least 0.3 wt % of P;
separating solids from the aqueous acid solution; and
subjecting the solids to a calcination step.

17. A catalyst obtained from the process of claim 1 .

18. A process for preparing a catalyst comprising:
contacting a molecular sieve with xonotlite (Ca 6 Si 6 O 17 (OH) 2 ), wherein the molecular sieve has pores of 10- or more-membered rings and is a zeolite selected from the group consisting of MFI, MOR, MEL, clinoptilolite, FER, FAU, MWW, BETA, ZSM-21, ZSM-22, ZSM-23, ZSM-42, ZSM-57, and LTL, and combinations thereof;
wherein the catalyst comprises at least 10 wt % of the zeolite and at least 0.1 wt % of silicate based on a total weight of the catalyst.

Assignees

• Total Res & Technology Feluy

Inventors

• Nesterenko Nikolai
• Vermeiren Walter
• Van Donk Sander

Classifications

• B01J29/7046

  MTT-type, e.g. ZSM-23, KZ-1, ISI-4 or EU-13 · CPC title

• C07C1/20 Primary

  starting from organic compounds containing only oxygen atoms as heteroatoms · CPC title

• B01J29/40

  of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively · CPC title

• B01J37/28

  Phosphorising · CPC title

• B01J2229/42

  Addition of matrix or binder particles · CPC title