Hydrocarbon aromatization catalyst composition and method of formation

Patent metadata

Field	Value
Publication number	US-9446389-B2
Application number	US-201314105941-A
Country	US
Kind code	B2
Filing date	Dec 13, 2013
Priority date	Dec 13, 2013
Publication date	Sep 20, 2016
Grant date	Sep 20, 2016

Abstract

A method for forming a catalyst can comprise: heating a Ge-ZSM-5 zeolite powder at a temperature of 400 to 600° C.; ion-exchanging the heat-treated zeolite powder with an alkali metal and impregnating the heat-treated zeolite powder with noble metal; heating the ion-exchanged, impregnated zeolite powder to a temperature of 250 to 350° C.; mixing the second heat-treated zeolite powder with a solid silica binder and a colloidal silica binder to form a mixture, wherein if the solid silica has a purity of less than or equal to 66 wt % of silica oxide based on the total weight of the solid silica, then the mixture is free of an extrusion aide and the colloidal silica has a particle size of less than 20 nm as measured along a major axis; forming the mixture into a shaped body; and heating the shaped body to 100 to 350° C. to result in the catalyst.

First claim

We claim:

1. A method for forming a catalyst, comprising:
heating a Ge-ZSM-5 zeolite powder at a temperature of 400 to 600° C. to form a heat-treated zeolite powder;
ion-exchanging the heat-treated zeolite powder with an alkali metal and impregnating the heat-treated zeolite powder with noble metal to form an ion-exchanged, impregnated zeolite powder;
heating the ion-exchanged, impregnated zeolite powder to a temperature of 250 to 350° C. to form a second heat-treated zeolite powder;
mixing the second heat-treated zeolite powder with a solid silica binder and a colloidal silica binder to form a mixture, wherein the solid silica has a purity of less than or equal to 66 wt % of silica oxide based on the total weight of the solid silica, the mixture is free of an extrusion aide, and the colloidal silica has a particle size of less than 20 nm as measured along a major axis;
forming the mixture into a shaped body; and
heating the shaped body to 100 to 350° C. to result in the catalyst.

2. The method of claim 1 , wherein the heating the ion-exchanged, impregnated zeolite powder and/or the heating the shaped body further comprises heating at a temperature of less than 600° C. in a reducing environment.

3. The method of claim 1 , wherein alkali metal comprises at least one of Na, K, Rb, and Cs.

4. The method of claim 1 , wherein the zeolite is non-acidic.

5. The method of claim 4 , wherein a monovalent base to aluminum molar ratio in the zeolite after base exchange is greater than or equal to 0.9.

6. The method of claim 1 , wherein the colloidal silica has a particle size of 7 to 15 nm.

7. The method of claim 1 , wherein the shaped body contains less than 5 wt % non-silica oxides, based upon a total weight of the formed catalyst.

8. The method of claim 1 , wherein the noble metal comprises platinum.

9. The method of claim 1 , wherein the catalyst comprises 0.5 to 3 wt % platinum, based on the total weight of the catalyst.

10. The method of claim 1 , wherein the catalyst comprises 3.0 to 7.0 wt % Cs, based on the total weight of the catalyst.

11. The method of claim 1 , further comprising heating in a reducing environment at a temperature of less than 600° C. the ion-exchanged, impregnated zeolite powder and/or heating the shaped body.

12. A method for forming a catalyst comprising:
heating a Ge-ZSM-5 zeolite powder at a temperature of 400 to 600° C. to form a heat-treated zeolite powder;
ion-exchanging the heat-treated zeolite powder with cesium and impregnating the heat-treated zeolite powder with platinum to form a Cs—Pt/Ge-ZSM-5 zeolite powder;
heating the Cs—Pt/Ge-ZSM-5 zeolite powder to a temperature of 250 to 350° C. to form a second heat-treated zeolite powder;
mixing the second heat-treated zeolite powder with a solid silica binder and a colloidal silica binder to form a mixture, wherein,
the solid silica has a purity of less than or equal to 66 wt % of silica oxide based on the total weight of the solid silica, the mixture is free of an extrusion aide, and the colloidal silica has a particle size of less than 20 nm as measured along a major axis;

forming the mixture into a shaped body; and
heating the shaped body to 100 to 350° C. to form the catalyst;
wherein after the silica binder is added, the zeolite is heated to a temperature not exceeding 350° C. prior to use in the hydrocarbon conversion reaction.

13. A catalyst formed by the method of claim 1 .

14. A process for the conversion of hydrocarbons, comprising:
a) contacting a hydrocarbon stream containing alkanes, olefins, or a mixture thereof having 2 to 12 carbon atoms per molecule with the catalyst of claim 13 ;
b) converting the hydrocarbon stream into a product; and
c) recovering the product.

15. The process of claim 14 , wherein the converting comprises one or more of isomerizing, a cracking, a dehydrogenating, a dehydrocyclizing, and aromatizating.

16. The process of claim 15 , wherein the hydrocarbon stream comprises alkanes, olefins, or a mixture thereof having 6 to 12 carbon atoms per molecule and wherein the converting comprises aromatizing.

Assignees

• Saudi Basic Ind Corp

Inventors

• Ghosh Ashim Kumar
• Stevenson Scott
• Sullivan David
• Mihut Corina
• Kulkarni Neeta
• Simmons Meghann
• Mier Michael

Classifications

• B01J35/45

  Nanoparticles · CPC title

• B01J37/0201

  Impregnation · CPC title

• B01J37/0207

  Pretreatment of the support · CPC title

• C10G2300/104

  Light gasoline having a boiling range of about 20 - 100 °C · CPC title

• B01J37/30

  Ion-exchange · CPC title