Molecular sieve compositions, catalyst thereof, their making and use in conversion processes
AssigneeExxonMobil Chemical Patents Inc.
InventorsTeng Xu, Stephen N. Vaughn, Richard B. Hall, Doron Levin, James Clark Vartuli
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Abstract
The invention relates to a catalyst composition, a method of making the same and its use in the conversion of a feedstock, preferably an oxygenated feedstock, into one or more olefin(s), preferably ethylene and/or propylene The catalyst composition comprises a molecular sieve and at least one metal oxide, such as a magnesium oxide that, when saturated with acetone and contacted with said acetone for 1 hour at 25° C., converts more than 80% of the acetone.
Claims65
A catalyst composition comprising:
- (a) a metal oxide which has a surface area greater than 20 m2/g, which has been calcined at temperature greater than 200° C., and which, when saturated with acetone and contacted with said acetone for 1 hour at 25° C., converts more than 80% of the acetone;
- (b) a binder;
- (c) a matrix material;
- and
- (d) a molecular sieve having an average pore size less than 5 Å.
A catalyst composition comprising a molecular sieve and at least one oxide of a metal selected from Group 2 of the Periodic Table of Elements, wherein said metal oxide has an uptake of carbon dioxide at 100° C. of at least 0.03 mg/m2 of the metal oxide.
A method for making a catalyst composition, the method comprising physically mixing first particles comprising a molecular sieve with second particles comprising at least one oxide of a metal selected from Group 2 of the Periodic Table of Elements, wherein said metal oxide has an uptake of carbon dioxide at 100° C. of at least 0.03 mg/m2 of the metal oxide.
A method of making a catalyst composition, the method comprising combining a molecular sieve, a binder, a matrix material, and at least one metal oxide that, when saturated with acetone and contacted with said acetone for 1 hour at 25° C., converts more than 25% of the acetone.
A method of making a catalyst composition, the method comprising (a) combining a molecular sieve, a binder and a matrix material to produce a catalyst precursor;
- and (b) adding to the catalyst precursor a metal oxide that has been calcined to a temperature in the range of from 200° C. to 700° C.
A method of making a catalyst composition, the method comprising:
- (i) synthesizing a molecular sieve from a reaction mixture comprising at least one templating agent and at least two of a silicon source, a phosphorous source and an aluminum source;
- and
- (ii) recovering the molecular sieve synthesized in step (i);
- (iii) calcining a magnesium oxide or a magnesium oxide precursor at a temperature in the range of from about 200° C. to about 700° C. to produce an active magnesium oxide;
- and
- (iv) physically mixing the molecular sieve recovered in step (i) and said active magnesium oxide.
A process for converting a feedstock into one or more olefin(s) in the presence of a molecular sieve catalyst composition comprising a molecular sieve, a binder, a matrix material and a metal oxide that, when saturated with acetone and contacted with said acetone for 1 hour at 25° C., converts more than 80% of the acetone.
A process for producing one or more olefin(s), the process comprising:
- (a) introducing a feedstock comprising at least one oxygenate to a reactor system in the presence of a catalyst composition comprising
- a small pore molecular sieve, a binder, a matrix material, a magnesium oxide that has been calcined in the temperature range of from 200° C. to 700° C., and a Group 3 metal oxide;
- (b) withdrawing from the reactor system an effluent stream containing the one or more olefins;
- and
- (c) passing the effluent stream through a recovery system;
- and
- (d) recovering at least the one or more olefin(s).
An integrated process for making one or more olefin(s), the integrated process comprising:
- (a) passing a hydrocarbon feedstock to a syngas production zone to produce a synthesis gas stream;
- (b) contacting the synthesis gas stream with a catalyst to form an oxygenated feedstock;
- and
- (c) converting the oxygenated feedstock into the one or more olefin(s) in the presence of a molecular sieve catalyst composition comprising a small pore molecular sieve having an average pore size less than 5A and an metal oxide having a surface area of greater than 80 m2/g.
Dependencies are inferred from the claim text.