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US 11,872,544 B2Granted
Modified ZSM-5 catalyst for converting light hydrocarbons to liquid fuels
AssigneePhillips 66 Company
InventorJianhua Yao
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Abstract
Methods for modifying a ZSM-5 zeolite by contacting the zeolite with an alkaline solution prior to combining with a binder material to produce a modified ZSM-5 catalyst extrudate that has substantially longer catalyst life, relative to an untreated ZSM-5 catalyst, for converting light olefins to products that may be used as a liquid transportation fuel blend stock. The alkaline solution is optionally sodium hydroxide. The binder is optionally alumina, bentonite or silica.
Claims31
A modified HZSM-5 catalyst produced by:
- a) contacting an NaZSM-5 zeolite that is free of binder material and template with an alkaline solution characterized by a pH of at least 11 for at least 1 hr to produce a modified NaZSM 5 zeolite;
- b) diluting the alkaline solution with water, then performing ion-exchange on the modified NaZSM-5 zeolite by contacting the modified NaZSM-5 zeolite with an acidic solution characterized by a pH in the range from 1.0 to 6.5 to convert the modified NaZSM-5 zeolite to a modified HZSM-5 catalyst intermediate;
- c) drying the modified HZSM-5 catalyst intermediate to produce a dried HZSM-5 catalyst intermediate;
- d) calcining the dried HZSM-5 catalyst intermediate to produce a modified HZSM-5 catalyst, wherein the modified HZSM-5 catalyst comprises an increased mesopore volume relative to an untreated HZSM-5 catalyst, wherein mesopores within the catalyst are defined as pores in the range from 2 to 50 nm in diameter.
1 more element
A method for producing a modified ZSM-5 catalyst, comprising:
- a) contacting an NaZSM-5 zeolite that is free of binder material and template with an alkaline solution characterized by a pH of at least 11 for at least 1 hr to produce a modified NaZSM-5 zeolite;
- b) diluting the alkaline solution with water, then performing ion-exchange on the modified NaZSM-5 zeolite by contacting the modified NaZSM-5 zeolite with an acidic solution characterized by a pH in the range from 1.0 to 6.5 to convert the modified NaZSM-5 zeolite to a modified HZSM-5 catalyst intermediate;
- c) drying the modified HZSM-5 catalyst intermediate to produce a dried HZSM-5 catalyst intermediate;
- d) calcining the dried HZSM-5 catalyst intermediate to produce a modified HZSM-5 catalyst.
1 more element
A modified HZSM-5 catalyst produced by:
- a) contacting an NaZSM-5 zeolite that is free of binder material and template with an alkaline solution characterized by a pH of at least 11 for at least 1 hr to produce a modified NaZSM-5 zeolite;
- b) diluting the alkaline solution with water, then performing ion-exchange on the modified NaZSM-5 zeolite by contacting the modified NaZSM-5 zeolite with an acidic solution characterized by a pH in the range from 1.0 to 6.5 to convert the modified NaZSM-5 zeolite to a modified HZSM-5 catalyst intermediate;
- c) drying the modified HZSM-5 catalyst intermediate to produce a dried HZSM-5 catalyst intermediate;
- d) calcining the dried HZSM-5 catalyst intermediate to produce a modified HZSM-5 catalyst, wherein the modified HZSM-5 catalyst comprises an increased mesopore volume relative to an untreated HZSM-5 catalyst, wherein mesopores within the catalyst are defined as pores in the range from 2 to 50 nm in diameter;
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- e) forming a mixture of the modified HZSM-5 catalyst produced in step d) with at least one binder material to produce a modified HZSM-5 catalyst extrudate.
3 more elements
Dependencies are inferred from the claim text.