Aromatic conversion processes and zeolite catalyst useful therein

• US 6,864,203 B2
• Filed: 02/28/2002
• Issued: 03/08/2005
• Est. Priority Date: 05/29/1996
• Status: Expired due to Fees

• Current Assignee: ExxonMobil Chemical Patents Inc. (Exxon Mobil Corporation)
• Original Assignee: ExxonMobil Chemical Patents Inc. (Exxon Mobil Corporation)
• Inventors: Verduijn, Johannes Petrus, Hendriksen, Dan Eldon, Smith, Robert Scott, Mohr, Gary David
• Primary Examiner(s): JOHNSON, CHRISTINA ANN
• Application Number:
  US10/086,758
• Publication Number:
  US 20020137977A1
• Time in Patent Office: 1,104 Days
• Field of Search: 502/61, 502/63, 502/64, 502/67, 502/78, 502/79, 502/73
• US Class Current: 502/67
• CPC Class Codes: B01J 2229/26 to stabilize the total catalyst structure
• CPC Class Codes: B01J 2229/42 Addition of matrix or binder particles
• CPC Class Codes: B01J 29/18 of the mordenite type
• CPC Class Codes: B01J 29/40 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 Class Codes: B01J 29/7007 Zeolite Beta
• CPC Class Codes: B01J 29/80 Mixtures of different zeolites
• CPC Class Codes: B01J 29/87 Gallosilicates; Aluminogallosilicates; Galloborosilicates B01J29/005 takes precedence
• CPC Class Codes: C07C 15/00 Cyclic hydrocarbons containing only six-membered aromatic rings as cyclic parts
• CPC Class Codes: C07C 15/08 Xylenes
• CPC Class Codes: C07C 2/66 Catalytic processes
• CPC Class Codes: C07C 2/861 the non-hydrocarbon contains only halogen as hetero-atoms
• CPC Class Codes: C07C 2/864 the non-hydrocarbon is an alcohol
• CPC Class Codes: C07C 2/865 the non-hydrocarbon is an ether
• CPC Class Codes: C07C 2/868 the non-hydrocarbon contains sulfur as hetero-atom
• CPC Class Codes: C07C 2529/035 Crystalline silica polymorphs, e.g. silicalites
• CPC Class Codes: C07C 2529/18 of the mordenite type
• CPC Class Codes: C07C 2529/40 of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11
• CPC Class Codes: C07C 2529/50 of the eroionite or offretite type, e.g. zeolite T
• CPC Class Codes: C07C 2529/65 of the ferrierite type, e.g. types ZSM-21, ZSM-35 or ZSM-38
• CPC Class Codes: C07C 2529/70 of types characterised by their specific structure not provided for in groups C07C2529/08 - C07C2529/65
• CPC Class Codes: C07C 2529/80 : Mixtures of different zeolites
• CPC Class Codes: C07C 2529/87 : Gallosilicates; Aluminogallosilicates; Galloborosilicates
• CPC Class Codes: C07C 5/2708 : with crystalline alumino-silicates, e.g. molecular sieves
• CPC Class Codes: C07C 6/126 : of more than one hydrocarbon
• CPC Class Codes: Y02P 20/52 : using catalysts, e.g. selective catalysts

Abstract

A process is provided for the alkylation, transalkylation, or isomerization of aromatic hydrocarbons. The processes comprises contacting aromatic hydrocarbons under conversion conditions with a zeolite bound zeolite catalyst. The zeolite bound zeolite catalyst comprises first crystals of a first large pore zeolite which are bound together by second crystals of a second zeolite.

Claims

1. A zeolite bound zeolite catalyst which does not contain significant amounts of non-zeolitic binder and comprises:

(a) first crystals of a large pore size first zeolite selected from the group consisting of EMT, MEI, and MOR, and

(b) a binder comprising second crystals of a second zeolite,

wherein said first crystals of said first zeolite have an average particle size of from 1 to 6 microns and the external surface acidity of said first crystals of said first zeolite is less than the acidity within the channels of said first zeolite.

2. The catalyst recited in claim 1, wherein said second crystals are intergrown and form at least a partial coating on said first crystals.

3. The catalyst recited in claim 2, wherein said second crystals of said second zeolite have an average particle size that is less than said first crystals of said first zeolite.

4. The catalyst recited in claim 3, wherein said catalyst is prepared from a silica bound extrudate comprising said first crystals of said first zeolite by converting the silica in said extrudate to said second zeolite.

5. The catalyst recited in claim 3, wherein the structure type of said first zeolite and said second zeolite are the same.

6. The catalyst recited in claim 5, wherein said first zeolite is an aluminosilicate zeolite or a gallium silicate zeolite.

7. The catalyst recited in claim 6, wherein said first zeolite and said second zeolite has a MOR structure.

8. The catalyst recited in claim 7, wherein the average particle size of the crystals of said second zeolite is from about 0.1 to about 0.5 microns.

9. The catalyst recited in claim 8, wherein said zeolite bound zeolite catalyst contains less than 5% by weight of non-zeolitic binder based on weight of said first zeolite and said second zeolite.

10. The catalyst recited in claim 9, wherein said second crystals are resistant attrition.

11. The catalyst recited in claim 1, wherein said first crystals of said first zeolite have an average particle size of from 1 to 6 microns and the external surface acidity of said first crystals of said first zeolite is at least 50% less than the acidity within the channels of said first zeolite.