Oligomerization of ethylene to liquid transportation fuels with post synthesis treated ZSM-5 catalyst
AssigneePhillips 66 Company
InventorsJianhua Yao, Bruce B. Randolph
Life of this patent
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Abstract
A process for post synthesis treatment of ZSM-5 catalyst for converting ethylene to liquid fuel products providing substantially improved catalyst life. The treatment comprises either a base treatment, an acid treatment or a two-step treatment where one is with an acid and the other is with a base. The base treatment is provided by a weak sodium hydroxide such as less than 1 Molar concentration. The acid treatment is stronger acid where, for example, a hydrogen chloride solution at greater than 2 Molar concentration is used.
Claims14
An oligomerization process to produce transportation fuels, the process comprising directing a feed stream comprising ethylene to transportation fuel products in a reactor that contains a fixed bed of ZSM-5 catalyst that is essentially free of catalyst metals other than silica and alumina, wherein the ZSM-5 catalyst is supported by an alumina binder, wherein prior to the oligomerization, the ZSM-5 catalyst is provided with a post synthesis treatment comprising an acid wash and a base wash in series to resist coke formation in the zeolite crystallites and extend catalyst life, wherein the oligomerizing is conducted at a pressure between 0 psig and 800 psig, a temperature of between 260° C. and 420° C., and a gas hourly space velocity of between 1000 and 5000 inverse hours and wherein at least 85% of the ethylene is converted.
An oligomerization process to produce transportation fuels, the process comprising directing a feed stream comprising ethylene in a reactor that contains a fixed bed of ZSM-5 catalyst that is essentially free of catalyst metals other than silica and alumina, wherein the ZSM-5 catalyst is supported by an alumina binder, wherein prior to the oligomerization, the ZSM-5 catalyst is treated with a post synthesis treatment to resist coke formation in the zeolite crystallites and extend catalyst life, wherein the oligomerization is conducted at a pressure between 0 psig and 800 psig, a temperature of between 260° C. and 420° C., and a gas hourly space velocity of between 1000 and 5000 inverse hours, wherein at least 85% of the ethylene is converted, wherein the post synthesis treatment of the catalyst comprises a first base treatment with sodium hydroxide at between about 0.0075 and about 0.15 Molar concentration at a temperature above 35° C. for at least about 45 minutes, followed by a washing step using distilled water, followed by an acid treatment using hydrogen chloride at between about 1 and 10 Molar concentration at a temperature above 60° C. for at least about 45 minutes, followed by an additional washing step using distilled water, followed by a drying step for at least 4 hours at a temperature above about 105° C., followed by a calcining step for the catalyst at a temperature above 400° C. for at least about 3 hours.
Dependencies are inferred from the claim text.