Process for the preparation of a catalyst support

Patent metadata

Field	Value
Publication number	US-9604204-B2
Application number	US-201113641710-A
Country	US
Kind code	B2
Filing date	Apr 18, 2011
Priority date	Apr 19, 2010
Publication date	Mar 28, 2017
Grant date	Mar 28, 2017

Abstract

Process for preparing a catalyst support which process comprises a) mixing pentasil zeolite having a bulk silica to alumina molar ratio in the range of from 20 to 150 with water, a silica source and an alkali metal salt, b) extruding the mixture obtained in step (a), c) drying and calcining the extrudates obtained in step (b), d) subjecting the calcined extrudates obtained in step (c) to ion exchange to reduce the alkali metal content, and e) drying the extrudates obtained in step (d); process for preparing a catalyst by furthermore impregnating such support with platinum in an amount in the range of from 0.001 to 0.1 wt % and tin in an amount in the range of from 0.01 to 0.5 wt %, each on the basis of total catalyst; ethylbenzene dealkylation catalyst obtainable thereby and a process for dealkylation of ethylbenzene which process comprises contacting feedstock containing ethylbenzene with such catalyst.

First claim

What is claimed is:

1. A process for preparing a catalyst support which process comprises
a) mixing pentasil zeolite having a bulk silica to alumina molar ratio in the range of from 20 to 150 with water, a silica source and an alkali metal salt,
b) extruding the mixture obtained in step (a),
c) drying and calcining the extrudates obtained in step (b),
d) treating the extrudates obtained in step (c) with an aqueous solution of fluorosilicate salt to provide fluorosilicate-treated extrudates;
e) subjecting the fluorosilicate-treated extrudates obtained in step (d) to ion exchange with an aqueous ammonium containing solution to reduce the alkali metal content, and
f) drying the extrudates obtained in step (e).

2. A process according to claim 1 , in which process the alkali metal salt is sodium hydroxide and/or waterglass.

3. A process according to claim 1 in which the mixture to be extruded comprises of from 45 to 60% wt of water, based on dry components.

4. A process as recited in claim 1 , wherein the silica source is selected from the group consisting of powder form silica, silica sol, and mixtures of powder form silica and silica sol.

5. A process as recited in claim 4 , wherein silica source is a mixture of powder form silica and silica sol in a weight ratio of powder form silica-to-silica sol in the range of from 1:1 to 10:1, and wherein the powder form silica comprises small particulates having a mean particle size in the range of from 2 to 10 μm as measured by ASTM C690-1992.

6. A process as recited in claim 5 , wherein the catalyst support comprises silica in the range of from 30 to 80 wt % and zeolite in the range of from 20 to 70 wt %.

7. A process as recited in claim 6 , wherein the fluorosilicate salt is represented by the formula: (A) 2/b SiF 6
wherein “A” is a metallic or non-non-metallic cation other than H + having the valence “b”.

8. A process as recited in claim 7 , wherein the fluorosilicate salt is ammonium hexfluorosilicate (AHS).

9. A process as recited in claim 8 , wherein extrudates obtained in step (f) have a flat plate crush strength of at least 120 N·cm −1 .

10. A process as recited in claim 9 , wherein extrudates obtained in step (f) have a B.E.T. surface area in the range of from 150 to 250 m 2 /g and a pore volume determined by mercury intrusion in the range of from 0.5 to 0.9 ml/g.

11. A process as recited in claim 10 , wherein the pentasil zeolite is ZSM-5 and is in the form of a powder comprising particles having diameters in the range of from 20 nm to 10 μm.

Assignees

• Domokos László
• Geerinck Peter
• Klazinga Aan Hendrik
• Shell Oil Co

Inventors

• Domokos László
• Geerinck Peter
• Klazinga Aan Hendrik

Classifications

• B01J35/70

  characterised by their crystalline properties, e.g. semi-crystalline (catalysts comprising carbon B01J21/18; molecular sieves B01J29/00) · CPC title

• B01J35/77

  Compounds characterised by their crystallite size · CPC title

• B01J35/37

  Crush or impact strength · CPC title

• B01J37/30

  Ion-exchange · CPC title

• C07C4/18

  Catalytic processes · CPC title