Exxonmobil Chemical Patents Inc.

Exxonmobile Chemical Patents Inc.

Yun-Feng Chang

Stephen Neil Vaughn

Kenneth Ray Clem

Luc R M Martens

Machteld Maria Mertens

Luc Roger Martens

Albert Edward Schweizer

Christine Nicole Elia

Michael C Clark

Frederick Y Lo

Weiguo Hu

Jeffery W Sprinkle

Stuart Leon Soled

Daria N Lissy

Joseph Ernest Baumgartner

Luc Roger Marc Martens

Fran A Shipley

Jeffrey Wayne Sprinkle

Ian Nathaniel Walker

James Richardson Lattner

Stephen Harold Brown

Paul F Keusenkothen

Larry Lee Iaccino

James Harding Beech, Jr

Randall David Partridge

Wilfried Jozef Mortier

Marcel Johannes Janssen

Michael Peter Nicoletti

Marcel J G Janssen

John D Y Ou

Thomas Herman Colle

An Verberckmoes

J Scott Buchanan

Alistair Duncan Westwood

Elizabeth L Stavens

Gerald G McGlamery, Jr

David C Skouby

Rutton D Patel

Jesse Frederick Goellner

Julia Elizabeth Steinheider

Patricia A O'Neill-Burn

Mareel J Janssen

Richard C Senior

Thomas H Colle

Luc RM Martens

Jesse F Goellner

Stephan N Vaughn

Jr Gerald G Mcglamery

Julia E Steinheider

A process for producing a monoalkylated aromatic compound in an alkylation reaction zone, said process comprising the steps of:

Monoalkylated aromatic compound production

A process for producing a monoalkylated aromatic compound in an alkylation reaction zone, comprising providing upstream of said alkylation reaction zone a reactive guard bed having a catalyst of *BEA, MWW, or FAU framework structure and an alkylation feed wherein at least a portion of any reactive impurities are removed from the alkylation feed to form an effluent; and providing the effluent and a first catalytic particulate material which comprises MCM-56 and an alumina binder sized 50-60 mesh and having a ratio of surface area over volume ratio in the range of 241 to 2867 cm-1 and optionally additional alkylating agent to said alkylation reaction zone; and contacting said alkylatable aromatic compound and said alkylating agent with said catalytic particulate material in said alkylation reaction zone maintained under alkylation conditions, to form a product comprised of said monoalkylated aromatic compound.

This invention provides a process for manufacturing a catalyst with a desired attrition index, comprising the steps of selecting at least one molecular sieve having a morphology and size index (MSI) of from 1 to about 1000 to secure said desired attrition index of said catalyst.

Method of making and process for using molecular sieve catalyst

This invention provides a process for limiting the loss of catalyst particles through olefin product streams and regenerator flue gas streams exiting the reaction system. In particular, this invention provides for removing catalyst particles from the reactor using a water stream and from the regenerator using a two step separation process. The two step process involves the use of a catalyst fine separation unit.

Removal of catalyst fines from a reaction system

This invention provides a method of making a molecular sieve catalyst composition comprising the steps of: a) combining molecular sieve crystals with binder and liquid to form a binder-sieve mixture; b) combining the binder-sieve mixture with matrix material to form a binder-sieve-matrix mixture; c) mixing the binder-sieve-matrix mixture under conditions sufficient to form a slurry having a solids content of at least 40 wt %, based on total weight of the slurry; d) progressing the mixing until slurry viscosity decreases without significant additional dilution of the slurry, so that the slurry solids content does not significantly decrease; and e) drying the decreased viscosity slurry to produce a dried molecular sieve catalyst composition having an attrition rate index of not greater than 1 wt %/hr. The aforementioned catalyst compositions can be used in processes for making olefin product from oxygenate feedstock, which olefin products can be further used for making (co)polymer products.

Method of formulating a molecular sieve catalyst composition by controlling component addition

A method for recovering molecular sieve crystals from a synthesis mixture that comprises adding at least one flocculant having a certain molecular weight and a certain charge density that contribute to the acceleration of the settling rate of the molecular sieve crystals and compositions made from the method.

Method of recovering crystalline material and compositions therefrom

This invention is to a process for separating condensed water and entrained solids from an olefin stream so that fouling of the separation equipment by the entrained solids is reduced or eliminated. The process involves injecting an antifouling agent into a water condensing or quench system in an amount to maintain a zeta potential of fouling liquid and a zeta potential of the surface of the quench system both in a positive range or both in a negative range.

Method of separating condensed liquid from an olefin stream

A method for determining an amount of flocculant effective to recover a molecular sieve crystalline product that comprises the steps of (a) preparing a molecular sieve crystalline product mixture; (b) separating the molecular sieve crystalline product mixture into a plurality of samples; (c) mixing at least two of the plurality of samples with a quantity of flocculant to produce a plurality of flocculated samples, wherein at least two of the plurality of flocculated samples have a different ratio of flocculant to molecular sieve crystalline product mixture; (d) measuring the viscosity or zeta potential of at least two of the plurality of flocculated samples having a different ratio of flocculant to molecular sieve crystalline product mixture; (e) establishing a relationship between the quantity of flocculant and the viscosity or zeta potential measurements; and (f) determining from the relationship the amount of flocculant effective to recover the molecular sieve crystalline product.

Method of flocculation and formulation of crystalline materials

One aspect of the invention relates to a method for formulating a molecular sieve catalyst composition, the method comprising the steps of: (a) providing a synthesized molecular sieve having been recovered in the presence of a flocculant; (b) thermally treating the synthesized molecular sieve at a temperature from about 50&#xb0; C. to about 250&#xb0; C. and under other conditions sufficient to form a thermally treated synthesized molecular sieve having a first LOI less than 26% and a first micropore surface area; (c) aging the thermally treated synthesized molecular sieve for at least one year; (d) analyzing the aged, thermally treated molecular sieve to determine a second micropore surface area, wherein the second micropore surface area is 3% or less lower than the first micropore surface area; and (e) combining the aged, thermally treated synthesized molecular sieve, a binder, and optionally a matrix material to produce an aged, formulated molecular sieve catalyst composition.

Methods addressing aging in flocculated molecular sieve catalysts for hydrocarbon conversion processes

A hydrocarbon conversion process for producing an aromatics product containing of benzene, toluene, xylenes, or mixtures thereof. The process is carried out by converting precursors of benzene, toluene, and xylenes that are contained in a hydrocarbon feed (Cnon-aromatic cyclic hydrocarbons, Asingle-ring aromatic hydrocarbons having at least one alkyl group containing two or more carbon atoms; and Asingle-ring aromatic hydrocarbons having at least three methyl groups) to produce a product that contains an increased amount of benzene, toluene, xylenes, or combinations thereof compared to said hydrocarbon feed.

Process for the production of benzene, toluene, and xylenes

This invention provides methods of making molecular sieve catalyst particles, molecular sieve slurries that can be used in such methods, molecular sieve catalyst compositions and their use in catalytic hydrocarbon conversion processes. In one of its aspects, the invention provides a method of making molecular sieve catalyst particles, the method comprising the steps of: a) providing a solution or suspension of an aluminum-containing inorganic oxide precursor in a liquid medium; b) combining the solution or suspension of aluminum-containing inorganic oxide precursor with a molecular sieve, and optionally other formulating agents, to form a catalyst formulation slurry; c) aging the catalyst formulation slurry to generate in said slurry a percentage, or increase in said slurry the existing percentage, of aluminum atoms of the aluminum-containing precursor in the form of oligomers having a sharpAl NMR peak at 62-63 ppm; and d) forming molecular sieve catalyst particles from the catalyst formulation slurry. The catalyst compositions obtained by the methods of the present invention have improved attrition resistance, and are particularly useful in hydrocarbon conversion processes.

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

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.

A catalyst composition for use in the conversion of oxygenates to olefins comprises a first crystalline silicoaluminophosphate molecular sieve comprising at least one intergrown form of an AEI structure type material and a CHA structure type material, and a second crystalline material different from said first molecular sieve and resulting from dehydration of an aluminophosphate or silicoaluminophosphate hydrate.

Catalyst and process for the conversion of oxygenates to olefins

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 a molecular sieve catalyst composition of a molecular sieve, a binder and a matrix material, wherein the weight ratio of the binder to the molecular sieve 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.

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Houston, TX, United States of America

Yun-Feng Chang