# US 10,369,552 B2 · Method of forming a catalyst with an ion-modified binder

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- Number: US 10,369,552 B2
- Document ID: US10369552B2
- Status: Granted
- Kind: B2
- Application number: 16/010,817
- Filed: 2018-06-18
- Published: 2018-10-18
- Granted: 2019-08-06
- Earliest claimed: 2008-12-29
- Assignees: Fina Technology, Inc.
- Applicants: Fina Technology, Inc.
- Inventors: Sivadinarayana Chinta; Joseph E Pelati
- Web page: https://patentgrep.com/patent/US10369552B2

## CPC

- B01J 29/061: {containing metallic elements added to the zeolite}
- B01J 29/06: Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
- B01J 29/064: containing iron group metals, noble metals or copper
- B01J 29/068: Noble metals
- B01J 29/072: Iron group metals or copper
- B01J 29/076: containing arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
- B01J 29/087: {X-type faujasite}
- B01J 29/088: {Y-type faujasite}
- B01J 29/143: {X-type faujasite}
- B01J 29/146: {Y-type faujasite}
- B01J 29/16: containing arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
- B01J 29/163: {X-type faujasite}
- B01J 29/166: {Y-type faujasite}
- B01J 29/185: {containing rare earth elements, titanium, zirconium, hafnium, zinc, cadmium, mercury, gallium, indium, thallium, tin or lead}
- B01J 29/24: Iron group metals or copper
- B01J 29/26: containing arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
- B01J 29/405: {containing rare earth elements, titanium, zirconium, hafnium, zinc, cadmium, mercury, gallium, indium, thallium, tin or lead}
- B01J 29/46: Iron group metals or copper
- B01J 29/48: containing arsenic, antimony, bismuth, vanadium, niobium tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
- B01J 29/505: {containing rare earth elements, titanium, zirconium, hafnium, zinc, cadmium, mercury, gallium, indium, thallium, tin or lead}
- B01J 29/56: Iron group metals or copper
- B01J 29/58: containing arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
- B01J 29/605: {containing rare earth elements, titanium, zirconium, hafnium, zinc, cadmium, mercury, gallium, indium, thallium, tin or lead}
- B01J 29/63: Iron group metals or copper
- B01J 29/64: containing arsenic, antimony, bismuth, vanadium, niobium, tantalum, polonium, chromium, molybdenum, tungsten, manganese, technetium or rhenium
- B01J 29/7053: {A-type}
- B01J 29/7057: {Zeolite Beta}
- B01J 29/7088: {MWW-type, e.g. MCM-22, ERB-1, ITQ-1, PSH-3 or SSZ-25}
- B01J 29/7607: {A-type}
- B01J 29/7615: {Zeolite Beta}
- B01J 29/7676: {MWW-type, e.g. MCM-22, ERB-1, ITQ-1, PSH-3 or SSZ-25}
- B01J 29/7807: {A-type}
- B01J 29/7815: {Zeolite Beta}
- B01J 29/7876: {MWW-type, e.g. MCM-22, ERB-1, ITQ-1, PSH-3 or SSZ-25}
- B01J 29/83: Aluminophosphates [APO compounds]
- B01J 29/84: Aluminophosphates containing other elements, e.g. metals, boron
- B01J 29/85: Silicoaluminophosphates [SAPO compounds]
- B01J 29/90: Regeneration or reactivation
- B01J 35/19: {Catalysts containing parts with different compositions}
- B01J 37/0009: {Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst}
- B01J 37/0018: {Addition of a binding agent or of material, later completely removed among others as result of heat treatment, leaching or washing,(e.g. forming of pores; protective layer, desintegrating by heat)}
- B01J 37/0201: {Impregnation}
- C07C 2/66: Catalytic processes
- B01J 2229/10: After treatment, characterised by the effect to be obtained
- B01J 2229/20: to introduce other elements in the catalyst composition comprising the molecular sieve, but not specially in or on the molecular sieve itself
- B01J 2229/24: to stabilize the molecular sieve structure
- B01J 2229/26: to stabilize the total catalyst structure
- B01J 2229/42: Addition of matrix or binder particles
- C07C 2521/04: Alumina
- C07C 2521/08: Silica
- C07C 2523/02: of the alkali- or alkaline earth metals or beryllium
- C07C 2523/06: of zinc, cadmium or mercury
- C07C 2523/14: of germanium, tin or lead
- C07C 2523/18: Arsenic, antimony or bismuth
- C07C 2523/22: Vanadium
- C07C 2523/34: Manganese
- C07C 2523/72: Copper
- C07C 2523/745: Iron
- C07C 2523/75: Cobalt
- Y02P 20/50: Improvements relating to the production of bulk chemicals
- Y02P 20/584: Recycling of catalysts
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- C07C: ACYCLIC OR CARBOCYCLIC COMPOUNDS
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

An alkylation catalyst having a zeolite catalyst component and a binder component providing mechanical support for the zeolite catalyst component is disclosed. The binder component is an ion-modified binder that can include metal ions selected from the group consisting of Co, Mn, Ti, Zr, V, Nb, K, Cs, Ga, B, P, Rb, Ag, Na, Cu, Mg, Fe, Mo, Ce, and combinations thereof. The metal ions reduce the number of acid sites on the zeolite catalyst component. The metal ions can range from 0.1 to 50 wt % based on the total weight of the ion-modified binder. Optionally, the ion-modified binder is present in amounts ranging from 1 to 80 wt % based on the total weight of the catalyst.

## Claims

### Claim 1

A method for preparing an alkylation catalyst, comprising:
adding metal ions to a binder to form an ion-modified binder, wherein the metal ions are selected from the group consisting of Mn, K, Cs, Rb, Ag, Na, Cu, Mg, and combinations thereof;
combining said ion-modified binder with a crystalline silicoaluminophosphate (SAPO) or an aluminophosphate (ALPO) to form an aggregate; and
processing the aggregate to form an alkylation catalyst;
wherein the ion-modified binder reduces a number of acid sites on the alkylation catalyst; and
wherein the metal ions on the ion-modified binder alter structural dimensions of the alkylation catalyst.

### Claim 2 (depends on 1)

The method of claim 1, wherein the metal ions are added to the binder by incipient wetness.

### Claim 3 (depends on 1)

The method of claim 1, wherein the metal ions comprise a cesium promoter that is combined with the binder in the form of cesium silicate.

### Claim 4 (depends on 3)

The method of claim 3, wherein the cesium silicate is Cs6Si10O23.

### Claim 5 (depends on 4)

The method of claim 4, wherein the cesium silicate is in the form of crystals that are prepared upon crystallization of glass Cs2O.4SiO2.

### Claim 6 (depends on 3)

The method of claim 3, wherein the binder is a silica-alumina material, and wherein crystals of the cesium silicate are added to a silica portion of the silica-alumina material.

### Claim 7 (depends on 1)

The method of claim 1, wherein the metal ions are added to the binder by:
adding a metal ion precursor to an aqueous solution;
pouring the aqueous solution over the binder; and
drying and calcining the binder to remove water, wherein the metal ions are deposited on a surface of the binder.

### Claim 8 (depends on 4)

The method of claim 4, wherein said combining comprises mixing said ion-modified binder with the crystalline silicoaluminophosphate or aluminophosphate, and said processing comprises shaping the mixture, and drying and calcining the shaped mixture.