Exxonmobil Chemical Patents Inc.

Exxon Chemical Patents, Inc.

Per Johan Sterte

Lubomira Borislavova Tosheva

Valentin Panov Valtchev

Gary David Mohr

Wilfried Jozef Mortier

Xiaobing Feng

Svetlana Ivanova Mintova

Brian John Schoeman

Brian J Schoeman

Jan-Erik Otterstedt

The invention involves a process for production of macrostructures of a microporous material. The process is characterized by the fact that seeds formed in or introduced by ion exchange or adsorption to a porous organic ion exchanger with the desired size, shape and porosity are made to grow and form a continuous structure by further deposition of inorganic material from a synthesis solution under hydrothermal conditions. The organic ion exchanger can be eliminated by chemical destruction or dissolution and, in so doing, leaves behind an inorganic microporous structure with the size and shape of the employed organic ion exchanger.

Process for production of macrostructures of a microporous material

There is provided macrostructures of porous inorganic material which can have controlled size, shape, and/or porosity and a process for preparing the macrostructures. The macrostructures comprise a three-dimension network of particles of porous inorganic materials. The process for preparing the macrostructures involves forming an admixture containing a porous organic ion exchanger and a synthesis mixture capable of forming the porous inorganic material and then converting the synthesis mixture to the porous inorganic material. After formation of the composite material, the porous organic ion exchanger can be removed from the composite material to obtain the macrostructures.

Macrostructures of porous inorganic material and process for their preparation

There is provided a process for converting hydrocarbons using a catalyst comprising macrostructures having a three-dimensional network of particles comprised of porous inorganic material. The particles of the macrostructures occupy less than 75% of the total volume of the macrostructures and are joined together to form a three-dimensional interconnected network comprised of pores having diameters greater than about 20 &#x212b;. The macrostructures can be made by forming an admixture containing a porous organic ion exchanger and a synthesis mixture capable of forming the porous inorganic material; converting the synthesis mixture to the porous inorganic material; and removing the porous organic ion exchanger from the inorganic material.

Hydrocarbon conversion process and catalyst useful therein

There is provided macrostructures of porous inorganic material which can have controlled size, shape, and/or porosity and a process for preparing the macrostructures. The macrostructures comprise a three-dimension network of particles of porous inorganic materials. The process for preparing the macrostructures involves forming an admixture containing a porous organic ion exchanger and a synthesis mixture capable of forming a porous inorganic material and then converting the synthesis mixture to a solid porous inorganic material. After formation of the composite material, the porous organic ion exchanger can be removed from the composite material to obtain the macrostructures, either before or after the porous inorganic material is hydrothermally treated with a structure directing agent to convert at least a portion of such porous inorganic material to a crystalline molecular sieve composition. The resulting macrostructure is composed of particles of the crystalline molecular sieve composition.

Porous inorganic macrostructure materials and process for their preparation

There is provided a process for converting hydrocarbons using a catalyst comprising macrostructures having a three-dimensional network of particles comprised of porous inorganic material. The particles of the macrostructures occupy less than 75% of the total volume of the macrostructures and are joined together to form a three-dimensional interconnected network comprised of pores having diameters greater than about 20 &angst;. The macrostructures can be made by forming an admixture containing a porous organic ion exchanger and a synthesis mixture capable of forming the porous inorganic material; converting the synthesis mixture to the porous inorganic material; and removing the porous organic ion exchanger from the inorganic material.

There is provided a catalyst containing porous macrostructures comprised of: (a) a three-dimensional network of particles of porous inorganic material (e.g., zeolites); and, (b) at least one metal (e.g., a catalytically active metal). The particles of the at least one macrostructure occupy less than 75% of the total volume of the at least one macrostructure and are jointed together to form a three-dimensional interconnected network. The three-dimensional interconnected network will usually be comprised of pores having diameters greater than about 20 &angst;. The macrostructures can be made by forming an admixture containing a porous organic ion exchanger (e.g., a polymer-based ion exchange resin) and a synthesis mixture (e.g., for zeolite formation) capable of forming the porous inorganic material and the at least one metal; converting the synthesis mixture to the porous inorganic material; and removing the porous organic ion exchanger from the inorganic material. The metal-containing macrostructures find application in hydrocarbon conversion (e.g., hydrogenation, dehydrogenation, dehydrocyclization, isomerization, hydrocracking, dewaxing, reforming, conversion of alkyl aromatics, etc.) and in the reduction of emissions of hydrocarbons, carbon monoxide, and/or oxides of nitrogen from an internal combustion engine.

Metal-containing macrostructures of porous inorganic oxide, preparation thereof, and use

The invention is comprised of a procedure for applying molecular sieve films to the surface of different substrates. This procedure is characterized in that microcrystals of the molecular sieves in question bind to the substrate surface in a first step as a monolayer, and are then, in a second step, allowed to grow into a thin, continuous and dense film. Molecular sieve films are of interest in application areas such as preparing membranes, catalysts, sensor devices and polymer reinforcing fillers.

Procedure for preparing molecular sieve films

The present invention relates to colloidal suspensions of discrete particles of colloidal zeolite and a method for preparing such zeolite from clear tetraalkylammonium stabilized aluminiumsilicate solutions. Smaller amounts of well defined and controlled metal hydroxide solutions are added to these alumiumsilicate solutions to enable the synthesis of a specific zeolite as well as to control zeolite yield. The colloidal suspensions are characterized by an average particle size of less than 250 nanometers and preferably, less than 200 nanometers together with the fact that the particle size distribution expressed as the geometric standard deviation is less than 1.30 and preferably less than 1.20. Zeolite sols synthesized according to this invention display Tyndall light scattering typical for colloidal suspensions as well as a very low rate of sedimentation due to the small particle size. Zeolite sols synthesized according to this invention can be prepared so as to contain negligable amounts of amorphous material.

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Lulea, Sweden

Per Johan Sterte