Method of preparing hydrocarbon aromatization catalyst, the catalyst, and the use of the catalyst

Patent metadata

Field	Value
Publication number	US-9782758-B2
Application number	US-201313868296-A
Country	US
Kind code	B2
Filing date	Apr 23, 2013
Priority date	Apr 23, 2013
Publication date	Oct 10, 2017
Grant date	Oct 10, 2017

Abstract

In one embodiment, a formed catalyst can comprise: a Ge-ZSM-5 zeolite; a binder comprising silica with 1 to less than 5 wt % non-silica oxides; less than or equal to 0.1 wt % residual carbon; 0.4 to 1.5 wt % platinum; and 4.0 to 4.8 wt % Cs; wherein the weight percentages are based upon a total weight of the catalyst. In one embodiment, a method of making a formed catalyst can comprise: mixing an uncalcined Ge-ZSM-5 zeolite and a binder to form a mixture; forming the mixture into a formed zeolite; calcining the formed zeolite to result in the formed zeolite having less than or equal to 0.1 wt % of residual carbon; ion-exchanging the formed zeolite with cesium; depositing platinum on the formed zeolite; and heating the formed zeolite to result in a final catalyst; wherein the final catalyst comprises 4.0 to 4.8 wt % cesium and 0.4 to 1.5 wt % platinum.

First claim

We claim:

1. A formed catalyst comprising:
a Ge-ZSM-5 zeolite;
a binder comprising silica with 1 to less than 5 wt % non-silica oxides;
less than or equal to 0.1 wt % residual carbon;
0.4 to 1.5 wt % platinum; and
4.0 to 4.8 wt % Cs;
wherein the weight percentages are based upon a total weight of the catalyst.

2. The catalyst of claim 1 , wherein the zeolite comprises 1.0 to 10.0 wt % germanium in the framework.

3. The catalyst of claim 1 , wherein the catalyst comprises 4.0 to 4.6 wt % Cs.

4. The catalyst of claim 1 , wherein the catalyst comprises 4.0 to 4.5 wt % Cs.

5. The catalyst of claim 1 , wherein the form is cylindrical.

6. The catalyst of claim 5 , wherein the cylindrical form has a diameter of 1/16 inches (1.6 mm) to a diameter of ⅛ inches (3.2 mm).

7. The catalyst of claim 1 , wherein the formed catalyst has a flat crush strength of greater than 2.0 lb/mm, as determined on a ⅛ inch (3.2 mm) diameter cylindrical shaped extruded formed catalyst.

8. The catalyst of claim 7 , wherein the formed catalyst has a flat crush strength of greater than or equal to 2.4 lb/mm.

9. A method of making aromatic compounds from a naphtha feedstock comprising:
contacting the naphtha feedstock with a catalyst, wherein the catalyst comprises
a Ge-ZSM-5 zeolite;
a binder comprising silica with 1 to less than 5 wt % non-silica oxides;
less than or equal to 0.1 wt % residual carbon;
0.4 to 1.5 wt % platinum; and
4.0 to 4.8 wt % Cs;
wherein the weight percentages are based upon a total weight of the catalyst; and
aromatizing compounds in said naphtha feedstock.

10. The method of claim 9 , wherein the aromatizing comprises aromatizing n-hexane to benzene.

11. The method of claim 10 , wherein the aromatization of n-hexane to benzene has one or both of a selectivity of greater than or equal to 91 mol % and a conversion of greater than or equal to 14 mol %.

12. A method of making a formed catalyst comprising:
mixing an uncalcined Ge-ZSM-5 zeolite and a binder to form a mixture;
forming the mixture into a formed zeolite;
calcining the formed zeolite to result in the formed zeolite having less than or equal to 0.1 wt % of residual carbon;
ion-exchanging the formed zeolite with cesium;
depositing platinum on the formed zeolite; and
heating the formed zeolite to result in a final catalyst;
wherein the ion-exchanging comprises ion-exchanging to obtain 4.0 to 4.8 wt % cesium in the final catalyst; and
wherein the depositing comprises depositing to obtain 0.4 to 1.5 wt % platinum in the final catalyst.

13. The method of claim 12 , wherein the calcining occurs at a temperature of greater than 500° C.

14. The method of claim 12 , wherein the calcining occurs at 500 to 530° C. for greater than or equal to 11 hours, at greater than 530 to less than 550° C. for 2 to 11 hours, or at greater than or equal to 550° C. for greater than or equal to 2 hours.

15. The method of claim 12 , wherein the heating occurs after one or both of after ion-exchanging with cesium and after depositing platinum.

16. The method of claim 12 , wherein the ion-exchanging with cesium occurs before, after, or during depositing platinum.

17. The method of claim 12 , wherein the mixture further comprises an extrusion aid.

18. The method of claim 12 , wherein the binder comprises
a colloidal silica comprising 20 to 40 wt % silica, based on the weight of the colloidal silica; and
10 to 40 wt % a solid silica based upon the total weight of the binder.

19. The method of claim 18 , wherein the colloidal silica comprises 30 to 40 wt % silica.

20. The method of claim 18 , wherein the binder comprises 1 to less than 5 wt % non-silica oxides.

Assignees

• Saudi Basic Ind Corp

Inventors

• Ghosh Ashim Kumar
• Stevenson Scott
• Simmons Meghan
• Mier Michael

Classifications

• C07C5/41

  Catalytic processes · CPC title

• C10G45/70

  with catalysts containing platinum group metals or compounds thereof · CPC title

• C07C2529/44

  Noble metals · 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

• C07C15/04

  Benzene · CPC title