# US 2010/0168449 A1 · Spray dried zeolite catalyst

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 2010/0168449 A1
- Document ID: US20100168449A1
- Status: Published application
- Kind: A1
- Application number: 12/317,749
- Filed: 2008-12-29
- Published: 2010-07-01
- Earliest claimed: 2008-12-29
- Inventors: Roger A. Grey; Bernard Cooker; Edrick Morales
- Web page: https://patentgrep.com/patent/US20100168449A1

## CPC

- B01J 29/89: Silicates, aluminosilicates or borosilicates of titanium, zirconium or hafnium {(B01J29/005 takes precedence)}
- B01J 37/0009: {Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst}
- B01J 37/0045: {Drying a slurry, e.g. spray drying}
- B01J 37/0203: {the impregnation liquid containing organic compounds}
- C07D 301/12: with hydrogen peroxide or inorganic peroxides or peracids
- B01J 2229/26: to stabilize the total catalyst structure
- B01J 2229/32: Reaction with silicon compounds, e.g. TEOS, siliconfluoride
- B01J 2229/34: Reaction with organic or organometallic compounds
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- C07D: HETEROCYCLIC COMPOUNDS (macromolecular compounds C08)

## Abstract

An attrition-resistant catalyst is prepared contacting a spray dried zeolite with a modifying agent. The modifying agent is (i) a halogen-free compound hydrolyzable to an oxide selected from the group consisting of silica, alumina, titania, zirconia, niobia, and mixtures thereof; or (ii) a sol selected from the group consisting of silica, alumina, titania, zirconia, niobia, and mixtures thereof.

## Claims

### Claim 1

A catalyst preparation method comprising contacting a spray dried zeolite with a modifying agent to form the catalyst, wherein the modifying agent is (i) a halogen-free compound hydrolyzable to an oxide selected from the group consisting of silica, alumina, titania, zirconia, niobia, and mixtures thereof; or (ii) a sol selected from the group consisting of silica, alumina, titania, zirconia, niobia, and mixtures thereof.

### Claim 2 (depends on 1)

The method of claim 1 wherein the catalyst is calcined at a temperature of 200 to 1000° C.

### Claim 3 (depends on 1)

The method of claim 1 wherein the spray dried zeolite comprises a binder.

### Claim 4 (depends on 1)

The method of claim 1 wherein the modifying agent is a halogen-free compound hydrolyzable to an oxide selected from the group consisting of silica, alumina, titania, zirconia, niobia, and mixtures thereof.

### Claim 5 (depends on 1)

The method of claim 1 wherein the zeolite is a transition metal zeolite.

### Claim 6 (depends on 1)

The method of claim 1 wherein the zeolite is a titanium zeolite.

### Claim 7

A catalyst prepared by contacting a spray dried zeolite with a modifying agent, wherein the modifying agent is (i) a halogen-free compound that may hydrolyzable to an oxide selected from the group consisting of silica, alumina, titania, zirconia, niobia, and mixtures thereof; or (ii) a sol selected from the group consisting of silica, alumina, titania, zirconia, niobia, and mixtures thereof.

### Claim 8 (depends on 7)

The catalyst of claim 7 calcined at a temperature from 200 to 1000° C.

### Claim 9 (depends on 7)

The catalyst of claim 7 wherein the spray dried zeolite comprises a binder.

### Claim 10 (depends on 7)

The catalyst of claim 7 wherein the modifying agent is a halogen-free compound hydrolyzable to an oxide selected from the group consisting of silica, alumina, titania, zirconia, niobia, and mixtures thereof.

### Claim 11 (depends on 7)

The catalyst of claim 7 wherein the zeolite is a transition metal zeolite.

### Claim 12 (depends on 11)

An epoxidation process comprising reacting with an olefin and hydrogen peroxide in the presence of the catalyst of claim 11 to produce an epoxide.

### Claim 13 (depends on 12)

The process of claim 12 wherein the catalyst is calcined at a temperature from 200 to 1000° C.

### Claim 14 (depends on 11)

A direct epoxidation process comprising reacting an olefin, hydrogen, and oxygen in the presence of the catalyst of claim 11 and a noble metal.

### Claim 15 (depends on 14)

The process of claim 14 wherein the transition metal zeolite is a titanium zeolite.