Exxonmobil Chemical Patents Inc.

Exxonmobil Research and Engineering Company

Dow Global Technolgoies LLC

Exxonmobile Chemical Patents Inc.

Albert Edward Schweizer

Stephen Neil Vaughn

Luc R M Martens

Machteld Maria Mertens

Shun Chong Fung

Kenneth Ray Clem

Yun-Feng Chang

Keith Holroyd Kuechler

Wilfried Jozef Mortier

Richard B Hall

Marcel J G Janssen

Ronald G Searle

Yi-Gang Xiong

Daniel A Hickman

Mark E Jones

William L Schuette

Robert J Wittenbrink

Daniel Francis Ryan

Luc Roger Martens

Luc Roger Marc Martens

Dean M Millar

Janet Renee Clark

Cornelius W M Van Oorschot

Yu Liu

Eric E Stangland

Raymond M Collins

John K Pierce

Simon G Podkolzin

Andrzej M Malek

Robert Gulotty

Duncan Coffey

The invention relates to a molecular sieve catalyst composition, to a method of making or forming the molecular sieve catalyst composition, and to a conversion process using the catalyst composition. In particular, the invention is directed to making a formulated molecular sieve catalyst composition from a slurry of formulation composition of a synthesized molecular sieve that has not been fully dried, a binder and an optional matrix material. In a more preferred embodiment, the weight ratio of the binder to the molecular sieve and/or the solid content of the slurry is controlled to provide an improved attrition resistant catalyst composition, particularly useful in a conversion process for producing olefin(s), preferably ethylene and/or propylene, from a feedstock, preferably an oxygenate containing feedstock.

Molecular sieve catalyst composition, its making and use in conversion processes

Molecular-sieve catalyst composition, its making and use in conversion processes

Hydrocarbon or oxygenate conversion process in which a feedstock is contacted with a non zeolitic molecular sieve which has been treated to remove most, if not all, of the halogen contained in the catalyst. The halogen may be removed by one of several methods. One method includes heating the catalyst in a low moisture environment, followed by contacting the heated catalyst with air and/or steam. Another method includes steam-treating the catalyst at a temperature from 400&#xb0; C. to 1000&#xb0; C. The hydrocarbon or oxygenate conversion processes include the conversion of oxygenates to olefins, the conversion of oxygenates and ammonia to alkylamines, the conversion of oxygenates and aromatic compounds to alkylated aromatic compounds, cracking and dewaxing.

Hydrocarbon conversion processes using non-zeolitic molecular sieve catalysts

An oxidative halogenation and optional dehydrogenation process involving contacting a reactant hydrocarbon having three or more carbon atoms, such as propane or propene, or a halogenated derivative thereof, with a source of halogen, and optionally, a source of oxygen in the presence of a rare earth halide or rare earth oxyhalide catalyst, so as to form a halogenated hydrocarbon product, such as allyl chloride, having three or more carbon atoms and having a greater number of halogen substituents as compared with the reactant hydrocarbon, and optionally, an olefinic co-product, such as propene. The less desired of the two products, that is, the halogenated hydrocarbon or the olefin as the case may be, can be recycled to the process to maximize the production of the desired product.

Oxidative halogenation and optional dehydrogenation of c3+hydrocarbons

Disclosed is a method of heat treating a molecular sieve. The method comprises providing a template-containing molecular sieve, heating the molecular sieve under conditions effective to remove a portion of the template from the molecular sieve, and cooling the heated molecular sieve to leave an amount of template effective to cover catalytic sites within the molecular sieve. A catalyst composition is also provided which comprises a molecular sieve having a microporous structure and a binder, wherein between 10 and 90 vol % of the microporous structure is occupied by a material, the material comprising a template or a carbonaceous residue of a template, and the catalyst composition exhibits a Davison Index of not greater than 30.

Heat treating a molecular sieve and catalyst

A catalyst component, a catalyst, and a process for making the component and catalyst are disclosed herein. Also disclosed herein is a fluid catalytic cracking process for converting petroleum feedstocks to lower boiling products wherein the feedstock is contacted with the catalyst. The catalyst component is a crystalline microporous oxide catalyst to which a compound for promoting dehydrogenation and increasing Lewis acidity is effectively added. This catalyst component can be included in an inorganic oxide matrix material and used as a catalyst. Preferably, the compound for promoting dehydrogenation and increasing Lewis acidity is effectively added to a non-framework portion of the crystalline microporous oxide.

Crystalline microporous oxide catalysts having increased Lewis acidity and methods for the preparation thereof

Disclosed is a molecular sieve catalyst which contains molecular sieve-containing attrition particles and virgin molecular sieve, the attrition particles having been recycled from a catalyst manufacture process or from a reaction system. The catalyst can be used in a variety of catalytic reaction processes. A desired process is making olefins from an oxygenate feedstock. The recovery and use of the attrition particles in the catalyst is beneficial in minimizing waste, thereby reducing problems relating to both environmental and economic constraints.

Synthesis of molecular sieve catalysts

Catalyst composition including attrition particles and method for making same

FCC process incorporating crystalline microporous oxide catalysts having increased Lewis acidity

An oxidative halogenation process involving contacting a reactant hydrocarbon selected from methane, a halogenated C hydrocarbon, or a mixture thereof with a source of halogen and, preferably, a source of oxygen in the presence of a rare earth halide or rare earth oxyhalide catalyst, so as to form a halogenated C hydrocarbon having a greater number of halogen substituents as compared with the reactant hydrocarbon. Preferably, the product is a monohalogenated methane, more preferably, methyl chloride. The oxidative halogenation process to form methyl halide can be integrated with downstream processes to produce valuable commodity chemicals, for example, methyl alcohol and/or dimethyl ether; light olefins, including ethylene, propylene, and butenes; higher hydrocarbons, including gasolines; vinyl halide monomer, and acetic acid. Hydrogen halide, which is a co-product of these downstream processes, can be recycled to the oxidative halogenation process.

Oxidative halogenation of C1 hydrocarbons to halogenated C1 hydrocarbons and integrated processes related thereto

Methods of calcining non-zeolitic molecular sieve catalyst to remove most, if not nearly all, of halogen contained in the catalyst. One method includes heating the catalyst in a low moisture environment, followed by contacting the heated catalyst with air and/or steam. Another method includes steam-treating the catalyst at a temperature from 400&deg; C. to 1000&deg; C. The calcination methods provides a catalyst that contains from about 10 ppmw to about 600 ppmw chlorine, preferably 10 ppmw to about 200 ppmw chlorine, more preferably 10 ppmw to about 80 ppmw chlorine.

Methods of removing halogen from non-zeolitic molecular sieve catalysts

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Midland, MI, United States of America

Albert Edward Schweizer