Exxonmobil Chemical Patents Inc.

Exxonmobil Research and Engineering Company

Exxonmobile Chemical Patents Inc.

Robert Ellis Kay

Wenyih Frank Lai

Stephen John McCarthy

Christine Nicole Elia

Jason Wu

Kun Wang

Wieslaw J Roth

Scott Jeffrey Weigel

Ajit Bhaskar Dandekar

Mohan Kalyanaraman

Frederick Y Lo

Darryl Donald Lacy

Christopher Gordon Oliveri

Jeffrey T Elks

David O Marler

Robert C Lemon

Jianxin Jason Wu

Stephen J Mccarthy

Frank W Lai

Christopher G Oliveri

In a process for producing a molecular sieve material, water, at least one source of an oxide of a tetravalent and/or a trivalent element and at least one structure directing agent are mixed in a plough shear mixer/dryer/reactor equipped with a mixer having a Froude number of at least 1, to produce a molecular sieve synthesis mixture having a solids content of at least about 20 wt %. The molecular sieve synthesis mixture is heated in said reactor while agitating said mixture with said mixer to form crystals of said molecular sieve material and said molecular sieve crystals are subsequently recovered from said reactor.

Process for producing molecular sieve materials

This disclosure relates to a novel method of making and recovering M41S family molecular sieve materials using synthesis mixtures having high solids-content and without a purification step. The solids-content, for example, is in a range from about 20 wt. % to 50 wt. %. The method also includes the step of mixing at least a portion of the M41S made with another material to form a composition, wherein the amount of said material to be mixed with said M41S product is such that said composition having less than 10 wt. % free fluid. The material mixed with the M41S made includes metal oxides, metal nitrides, metal carbides and mixtures thereof, as well as absorptive material capable of absorbing mother liquor and selected from the group consisting of carbon silica, alumina, titania, zirconia and mixtures thereof. The amount of the wastewater generated by this novel method is reduced by at least 50% to as much as 100% as comparing with conventional method of making M41S materials. By reducing and/or eliminating at least a portion of the wastewater generated in the synthesis product, the new method reduces cost of making of M41S materials and provides a more environmentally-friendly synthesis product.

Method of making M41S family molecular sieve

This disclosure provides a molecular sieve composition having a first and second crystalline molecular sieve, made by the method comprising: (a) providing a reaction mixture comprising at least one source of ions of tetravalent element Y, at least one source of alkali metal hydroxide, water, optionally at least one seed crystal, and optionally at least one source of ions of trivalent element X, the reaction mixture having the following molar composition:Y:X=2 to infinity, preferably from about 2 to about 1000,OH:Y=0.001 to 2, preferably from 0.1 to 1,M:Y=0.001 to 2, preferably from 0.01 to 2wherein M is an alkali metal and the amount of water is at least sufficient to permit extrusion of the reaction mixture, wherein the reaction mixture is substantially free of crystalline molecular sieve; (b) extruding the reaction mixture to form a pre-formed extrudate of said first crystalline molecular sieve; and (c) crystallizing the pre-formed extrudate in a liquid medium comprising water under liquid phase crystallization conditions to form said molecular sieve composition.

Molecular sieve composition from pre-formed extrudates and process of use

A process is described for producing an M41S family molecular sieve. The process comprises preparing a synthesis mixture capable of forming said molecular sieve in a reactor, which is equipped with a mixer having a Froude number of at least 1, said synthesis mixture having a solids content of at least 20 wt %. The synthesis mixture is heated in the reactor while agitating the mixture with said mixer to form a product mixture comprising water and crystals of said molecular sieve material. Thereafter at least part of the water is removed from the product mixture in the reactor so as to decrease the water content of the product mixture inside the reactor by at least 5 wt %.

Synthesis and use of M41S family molecular sieves

This invention relates to stabilized aggregates of small primary crystallites of zeolite Y that are clustered into larger secondary particles. At least 80% of the secondary particles may comprise at least 5 primary crystallites. The size of the primary crystallites may be at most about 0.5 micron, or at most about 0.3 micron, and the size of the secondary particles may be at least about 0.8 micron, or at least about 1.0 &#x3bc;m. The silica to alumina ratio of the resulting stabilized aggregated Y zeolite may be 4:1 or more.

Stabilized aggregates of small crystallites of zeolite Y

A supported catalyst comprises a zeolite having a silica to alumina molar ratio of 500 or less, a first metal oxide binder having a crystallite size greater than 200 &#x212b; and a second metal oxide binder having a crystallite size less than 100 &#x212b;, wherein the second metal oxide binder is present in an amount less than 15 wt % of the total weight of the catalyst.

Dewaxing catalysts

This invention relates to aggregates of small primary crystallites of zeolite Y that are clustered into larger secondary particles. At least 80% of the secondary particles may comprise at least 5 primary crystallites. The size of the primary crystallites may be at most about 0.5 micron, or at most about 0.3 micron, and the size of the secondary particles may be at least about 0.8 micron, or at least about 1.0 &#x3bc;m. The silica to alumina ratio of the resulting stabilized aggregated Y zeolite may be 4:1 or more.

Aggregates of small crystallites of zeolite Y

This invention relates to hydrocracking catalysts utilizing stabilized aggregates of small primary crystallites of zeolite Y that are clustered into larger secondary particles. At least 80% of the secondary particles may comprise at least 5 primary crystallites. The size of the primary crystallites may be at most about 0.5 micron, or at most about 0.3 micron, and the size of the secondary particles may be at least about 0.8 micron, or at least about 1.0 &#x3bc;m. The silica to alumina ratio of the resulting stabilized aggregated Y zeolite may be 4:1 or more. This invention also relates to the use of such catalysts in hydrocracking processes for the conversion of heavy oils into lighter fuel products. The invention is particularly suited for the selective production of diesel range products from gas oil range feedstock materials under hydrocracking conditions.

Hydrocracking catalysts containing stabilized aggregates of small crystallites of zeolite Y associated hydrocarbon conversion processes

This disclosure provides a method of preparing a crystalline molecular sieve comprising: (a) providing a reaction mixture comprising at least one source of ions of tetravalent element Y, at least one source of alkali metal hydroxide, water, optionally at least one seed crystal, and optionally at least one source of ions of trivalent element X, the reaction mixture having the following molar composition:

Method of preparing a molecular sieve composition

A method of manufacturing a molecular sieve of the MCM-22 family, said method comprising the steps of (a) providing a mixture comprising at least one source of ions of tetravalent element, at least one source of alkali metal hydroxide, at least one directing-agent (R), water, and optionally at least one source of ions of trivalent element, said mixture having the following mole composition:

Process for manufacturing MCM-22 family molecular sieves

An MCM-22 family molecular sieve having an X-ray diffraction pattern of the as-synthesized MCM-22 family molecular sieve including d-spacing maxima at 12.4&#xb1;0.25, 3.57&#xb1;0.07 and 3.42&#xb1;0.07 Angstroms and at least one peak between 26.6&#xb0; and 29&#xb0; (2&#x3b8;). The peak between 26.6&#xb0; to 29&#xb0; (2&#x3b8;) has a two theta (2&#x3b8;) of about 26.9&#xb0;. A method of manufacturing an MCM-22 family molecular sieve, said method comprising the steps of (a) combining at least one silicon source, at least one source of alkali metal hydroxide, at least one directing-agent (R), water, and optionally one aluminum source, to form a mixture having the following mole composition:

MCM-22 family molecular sieve composition

A method of preparing a crystalline molecular sieve is provided, which method comprises

A process for producing ZSM-48 comprises crystallizing an aqueous reaction mixture comprising at least one source of silica, at least one source of alumina, at least one source of hydroxyl ions, at least one source of diquaternary alkylammonium, R, ions having the formula:(CH)N(CH)N(CH)and optionally ZSM-48 seed crystals, wherein said reaction mixture has a composition including the following molar ratios: 

Synthesis of high activity ZSM-48

This disclosure relates to a crystalline MCM-22 family molecular sieve having a platelet aggregates morphology wherein greater than 50 wt % of the molecular sieve having a crystal diameter greater than 1 &#x3bc;m as measured by the SEM. The crystalline MCM-22 family molecular sieve of this disclosure, wherein the platelet aggregates morphology is rosette habit morphology, or multiple layer plate's morphology.

Growing community of inventors

Easton, PA, United States of America

Robert Ellis Kay