Saudi Basic Industries Corporation

Ghosh, Ashim Kumar

Harvey, Pamela

Pamela Lawyer Harvey

Ashim Kumar Ghosh

Neeta Kulkarni

Gopalakrishnan G Juttu

Manuel Castelan

Mohammad Shafiei

Roncalli J Twomey

In an embodiment, a method of forming a catalyst can comprises: treating a detemplated pentasil zeolite material with a phosphorus-containing compound to form a phosphorus treated zeolite; combining a hydrogenating material, the phosphorus treated zeolite, and a binder material to form a mixture; forming the mixture into a shaped body, wherein the mixture is formed into the shaped body without the mixture being heat-treated; and calcining the shaped body to form the catalyst. Combining the hydrogenating material with the phosphorus treated zeolite and the binder material occurs prior to forming of the shaped body.

Method of making a catalyst and catalyst made thereby

A method of converting hydrocarbons requires contacting a hydrocarbon stream containing alkylated aromatic hydrocarbons with a catalyst of a phosphorus-containing pentasil zeolite in a reactor. The phosphorus-containing pentasil zeolite having a phosphorus content of 7.5% or less by weight of zeolite, a pore volume of at least 0.2 ml/g, and aAl MAS NMR spectrum characterized by a peak at or near 50 ppm that is greater than any other peak in said spectrum. A benzene-enriched output stream is recovered from the reactor.

Method for conversion of aromatic hydrocarbons

This invention relates to a process for pretreating a zeolite catalyst, specifically a zeolite which has been modified with phosphorus. The catalyst may be used in a process for alkylation of aromatics, specifically toluene methylation. The pretreatment is first to contact the catalyst with the process reactants used in a process for alkylation of aromatics for at least two hours at conditions to produce an alkylated aromatic product and then with a gaseous stream containing oxygen at a temperature and for a time until there is no oxygen consumption. The zeolite may be a MFI zeolite. This pretreatment procedure for a phosphorus-modified zeolite catalyst produces a catalyst which has increased run time, i.e., decreased deactivation rate, compared to a fresh catalyst, even after successive regenerations.

Pretreatment of a phosphorus-modified zeolite catalyst for an aromatic alkylation process

A zeolite catalyst that may be used in aromatic alkylation is prepared by treating a zeolite with a phosphorus compound. The phosphorus-treated zeolite is calcined and contacted with liquid water, whereby an amount of phosphorus is removed from the phosphorus-treated zeolite. The phosphorus-treated zeolite is then heated. A method of preparing an aromatic product may also be carried out by contacting the prepared zeolite catalyst with an aromatic alkylation feed of an aromatic compound and an alkylating agent under reaction conditions suitable for aromatic alkylation.

Phosphorus-containing zeolite catalysts and their method of preparation

A catalyst is formed from a phosphorus-containing ZSM-5-type zeolite. The ZSM-5-type zeolite has a silica/alumina molar ratio of at least 200. The phosphorus-containing ZSM-5-type zeolite also has a phosphorus content of at least 8% by weight of zeolite and has multiple phosphorus species exhibited by at least twoP MAS NMR peaks with maxima at from about 0 to about &#x2212;50 ppm. The catalyst may be used in aromatic alkylation by contacting the catalyst with a feed of an aromatic hydrocarbon and an alkylating agent under reaction conditions suitable for aromatic alkylation.

Method of making a phosphorus-modified zeolite catalyst

A zeolite catalyst is prepared by treating a zeolite with a phosphorus compound to form a phosphorus-treated zeolite. The phosphorus-treated zeolite is heated to a temperature of about 300&#xb0; C. or higher and combined with an inorganic oxide binder material to form a zeolite-binder mixture. The zeolite-binder mixture is heated to a temperature of about 400&#xb0; C. or higher to form a bound zeolite catalyst. The bound zeolite may exhibit at least twoP MAS NMR peaks with maxima at from about 0 to about &#x2212;55 ppm, with at least one peak having a maximum at from about &#x2212;40 to about &#x2212;50 ppm. Zeolites containing 10-oxygen ring pores that have been prepared in such a way may be used in aromatic alkylation by contacting the bound zeolite catalyst with an aromatic alkylation feed of an aromatic compound and an alkylating agent under reaction conditions suitable for aromatic alkylation.

Method of preparing an alkyl aromatic product with phosphorus-treated zeolite catalyst

Disclosed is a bound phosphorus-modified zeolite catalyst. Zeolite is treated with a phosphorus compound to form the phosphorus-treated zeolite. Binder material is treated with a mineral acid prior to being bound with the phosphorus-modified zeolite. The binder material includes inorganic oxide materials, such as alumina, clay, aluminum phosphate and silica-alumina, in particular, a binder of alumina or clay or their combinations. The mineral acid includes hydrochloric acid, nitric acid, phosphoric acid or sulfuric acid. The phosphorus-treated zeolite is combined with the acid-treated inorganic oxide binder material to form a zeolite-binder mixture. Water is added to form an extrudable paste which maybe shaped and is heated to a temperature of about 400&#xb0; C. or higher to form a bound phosphorus-modified zeolite catalyst. For aromatic alkylation, the bound phosphorus-modified zeolite catalyst is contacted with an aromatic alkylation feed of an aromatic compound and an alkylating agent under reaction conditions suitable for aromatic alkylation.

Bound phosphorus-modified zeolite catalyst, method of preparing and method of using thereof

Aromatic alkylation with phosphorus-modified zeolite catalyst

A method of treating a ZSM-5-type zeolite catalyst is carried out by treating a ZSM-5 zeolite catalyst having a silica/alumina mole ratio of at least about 200 with a phosphorus compound. The phosphorus-treated ZSM-5 zeolite catalyst is calcined and steamed. Steaming of the catalyst is carried out at a temperature of less than about 300&#xb0; C. The phosphorus-treated ZSM-5 zeolite catalyst has less than 0.05% by weight of the catalyst of any other element other than phosphorus provided from any treatment of the ZSM-5 zeolite with a compound containing said other element. The catalyst may be used in aromatic alkylation by contacting the catalyst with feed of an aromatic hydrocarbon and an alkylating agent within a reactor under reactor conditions suitable for aromatic alkylation. Water cofeed may be introduced water into the reactor during the aromatic alkylation reaction.

Method of hydrothermal treatment of phosphorus-modified zeolite catalyts

A method of modifying a zeolite catalyst to increase para-xylene selectivity of the zeolite catalyst in toluene methylation reactions is provided. The method includes forming a slurry of a ZSM-5-type zeolite and an aqueous solution of a phosphorus compound. Water is removed from the slurry to provide a non-steamed, phosphorus treated ZSM-5 zeolite catalyst without deposition of phosphorus onto the catalyst by organophosphorus vapor deposition. The resulting non-steamed, phosphorus treated ZSM-5 zeolite catalyst has a pore volume of from 0.2 ml/g or less and provides greater than 80% para-xylene selectivity of mixed xylenes when used in toluene methylation.

Method of preparing a xylene product

Phosphorus-containing zeolite catalyst

A method of modifying a ZSM-5-type zeolite catalyst to increase selectivity of the catalyst for para-isomers in aromatic alkylation reactions is provided. The method includes contacting a ZSM-5-type zeolite catalyst with a fluoride-containing compound. The fluoride-containing zeolite catalyst can be used in aromatic alkylation to provide di-alkyl aromatic products. A method of preparing a xylene product is also accomplished by providing a fluoride-treated ZSM-5-type zeolite catalyst within a reactor. The fluoride-treated ZSM-5 zeolite catalyst is contacted with a toluene/methanol feed under reaction conditions conditions suitable for toluene methylation to form a xylene product containing at least 50% para-xylene by total mixed xylenes.

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