Exxon Research and Engineering Company

Exxon Chemical Patents, Inc.

Exxonmobil Chemical Patents Inc.

Jar-Lin Kao

Shun Chong Fung

Thomas H Vanderspurt

Virginia R Cross

Mark J Potter

Kenneth R Poeppelmeier

Murray Nadler

Stephen Neil Vaughn

Kenneth Ray Clem

John Di-Yi Ou

John Joseph Steger

Hsiang-Ning Sun

Arie Bortinger

Freddie L Tungate

Edward K Dienes

Roque V Martir

Robert E Riley

Walter G Funk

Stuart Leon Soled

Gary Brice McVicker

Theodore D Trowbridge

Yao-Jyh Robert Huang

John Francis Walsh

Henry M Pogorzelski

Scott A Ramsey

Greg J De Martin

This invention is directed to a molecular sieve composition or a catalyst containing molecular sieve which has a relatively high residual silica index, preferably at least about 1.5. The molecular sieve or catalyst can be made by contacting a template-containing molecular sieve with a silicon containing material having an average kinetic diameter that is larger than the average pore diameter of the sieve or catalyst, and heating to leave residual silica at the sieve or catalyst surface. The molecular sieve or catalyst is particularly effective in making an olefin product from an oxygenate feedstock.

Treatment of molecular sieves with silicon containing compounds

An ion exchange method is provided for loading and uniformly distributing noble metals into a catalyst substrate comprising a zeolite to make a monofunctional, non-acidic reforming catalyst. The catalyst substrate is contacted with an aqueous loading solution comprising noble metal cations and non-noble metal cations. The loading solution is formulated such that the equivalents of non-noble metal cations remaining in the catalyst not ionically bonded to the zeolite when loading is complete is 1.2 to 6.0 times the equivalents of non-noble metal cations displaced from the zeolite when the noble metal cations ion exchange into the zeolite, and simultaneously the endpoint pH of the loading solution is between 10.0 and 11.5. The required 1.2 to 6.0 ratio is achieved when the ratio of moles of non-noble metal cations added to the loading solution to moles of noble metal added to the loading solution is between 1 and 10. The use of ion exchange method results in zeolite catalysts having reduced amounts of detrital material in the micropores of the zeolite.

Method for depositing catalyst metals into zeolite to produce hydrocarbon processing catalyst

A process for reforming naphtha-containing hydrocarbon feedstreams is disclosed wherein a naphtha stream containing at least about 25 wt % of C,to C,aliphatic and cycloaliphatic hydrocarbons is contacted with a modified reforming catalyst, e.g. ZSM-5, containing a dehydrogenation metal, e.g. zinc, which has been modified by contact with Group IIA alkaline earth metal, e.g. barium, or with an organosilicon compound in an amount sufficient to neutralize at least a portion of the surface acidic sites present on the catalyst. The resulting reformate contains a reduced content of C,to C,gas and a C,aromatic fraction having an enhanced content of para-xyelene.

Naphtha aromatization process

A process for reforming naphtha-containing hydrocarbon feedstreams is disclosed wherein a naphtha stream containing at least about 5 wt % of C9+ aromatics, at least about 25 wt % C.sub.5 to C.sub.9 aliphatic hydrocarbons and greater than 50 wt. ppm sulfur is contacted under reforming conditions with a bifunctional reforming catalyst, e.g. H.sup.+ ZSM-5, containing a dehydrogenation metal, e.g. zinc. The resulting reformate contains a higher ratio of C.sub.6 to C.sub.9 aromatics to C.sub.5 -C.sub.9 aliphatic hydrocarbon which boil near the boiling point of C.sub.6 to C.sub.8 aromatics present in the reformate, thereby facilitating separation of these aromatics form the reformate.

Catalytic upgrade of naphtha

The invention provides a crystalline type L zeolite reforming catalyst comprising cylindrically shaped crystals having a length of 0.6 microns or less and an average length: diameter ratio of less than about 0.5, the catalyst containing at least one Group VIII metal and from about 0.1 to 2 wt % halogen e.g., chlorine. Also provided is a method for activating or regenerating the catalyst wherein a fresh or de-coked catalyst is oxychlorinated, purged to remove excess chlorine and reduced. The catalysts are particularly useful for the reforming of C.sub.6 to C.sub.11 naphthas to produce reformates having a high content of C.sub.6 to C.sub.8 light aromatics and a reduced content of heavier C.sub.9 and C.sub.10 aromatics.

Naphtha reforming catalyst and process

A process for isomerizing a nonequilibrium xylene feed mixture is disclosed. The isomerization is conducted in the presence of hydrogen and at pressures in excess of 75 psig over a ZSM-5 type catalyst containing about 0.1 to 5 wt % of at least one metal selected from the group consisting of zinc, copper, silver and gallium. In another embodiment, the catalyst may further contain an oxide of at least one element selected from silicon, germanium and tin. The process produces a product containing about or above equilibrium quantities of para-xylene with low xylene loss.

Xylene isomerization process

A process for reforming a hydrocarbon fraction substantially free of dimethylbutanes. The hydrocarbon is separated into a fraction comprising the C.sub.5 - hydrocarbons and the dimethylbutanes, a light fraction excluding dimethyl butanes, and a heavy fraction. The light fraction is reformed in the presence of a monofunctional catalyst, and the heavy fraction is reformed in the presence of a bifunctional catalyst.

Process for reforming a dimethylbutane-free hydrocarbon fraction

The present invention is a process for regenerating deactivated catalyst or redispersing catalytic metal in a fresh catalyst comprising at least one Group VIII catalytic metal, zeolite, an inert binder. The process comprises coke burn, hydrogen reduction, catalyst conditioning, oxychlorination, low pressure stripping, and low pressure final hydrogen reduction.

Method of regenerating deactivated catalyst

A process for producing zeolite aggregates involves providing a formable paste composed of zeolite, a binder composed of an organic/metal oxide containing aluminum, a peptizing agent and water; forming the paste into an aggregate, preferably by extruding into an extrudate; curing the aggregate; hydro-thermally calcining the aggregate; and washing the hydro-thermally calcined aggregate with a washing medium, preferably followed by rinsing with a rinsing medium to remove residual washing medium from the aggregate. The washed and rinsed aggregate may then be permitted to equilibrate or is subjected to a drying procedure. Preferably, the washed and rinsed aggregate is again subjected to curing/hydro-thermal calcining. The resultant aggregates, such as extrudates, have an exterior surface with openings and interstitial spaces between particles of binder and zeolite which communicate by such openings between the exterior surface of the aggregate and micropores of the zeolite; the aggregates also exhibit characteristics of crush strength greater than about 0.9 pounds per millimeter and a loss by attrition of less than about 3.0%. Regenerable catalysts, such as reforming catalysts, based on such aggregate also exhibit a catalyst activity pass through to the zeolite bound in the aggregate of at least 70% of the initial catalyst activity of freshly prepared zeolite, as well as exhibiting more than about 70% of the reforming benzene yield that the reforming catalyst exhibited when similarly tested prior to being exposed to a hydrocarbon stream under specified reforming conditions of the catalyst activity test procedures.

Zeolite aggregates and catalysts

The present invention discloses an alcohol coupling process in which a vaporized mixture of starting alcohols, preferably methanol and ethanol, is reacted with syngas in the presence of a large pore L zeolite, Y zeolite or large port mordenite, to form at least one alcohol coupling product having a greater number of carbon atoms than all of the starting alcohols. The large pore zeolite preferably has a substantial absence of strongly acidic catalytic sites and the reaction preferably produces the product alcohol in the substantial absence of C.sub.6+ oxygenates.

Noble metal large pore zeolyte catalyst for methanol-ethanol coupling

Zeolites washed with aqueous solutions or water to exhibit pH in the range of 9.4 to 10.0 and preferably 9.6 to 10.0 which can be converted to reforming catalysts with enhanced activity, selectivity and activity maintenance. Also processes for washing the zeolite to the target pH range and processes for using catalysts made with the washed zeolite to reform naphtha feeds.

Zeolites for reforming catalysts

Zeolites washed with aqueous solutions or water or exhibit pH in the range of 9.4 to 10.0 and preferably 9.6 to 10.0 which can be converted to reforming catalysts with enhanced activity, selectivity and activity maintenance. Also processes for washing the zeolite to the target pH range and processes for using catalysts made with the washed zeolite to reform naphtha feeds.

A class of bound catalysts which exhibit superior activity maintenance in dehydrocyclization reactions are defined as a type L zeolite having exchangeable cations of which at least 75% are selected from Group IA and calcium and barium cations and containing well dispersed particles of at least one Group VIII noble metal where at least 90% of the noble metal thereof is dispersed in the form of particles having a diameter less than 7 .ANG.. The catalysts may also be identified as type L zeolites loaded with at least one Group VIII noble metal which have a terminal cracking index (as a measure of production of pentanes versus butanes from hexane) of at least 1.5.

Growing community of inventors

Houston, TX, United States of America

Jar-Lin Kao