# US 2014/0194276 A1 · Process for Obtaining a Catalyst Composite

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- Number: US 2014/0194276 A1
- Document ID: US20140194276A1
- Status: Published application
- Kind: A1
- Application number: 14/206,329
- Filed: 2014-03-12
- Published: 2014-07-10
- Earliest claimed: 2008-01-25
- Assignees: Total Research & Technology Feluy
- Applicants: Total Research & Technology Feluy
- Inventors: Nikolai Nesterenko; Walter Vermeiren; Sander Van Donk; Delphine Minoux
- Web page: https://patentgrep.com/patent/US20140194276A1

## CPC

- C07C 1/20: starting from organic compounds containing only oxygen atoms as heteroatoms
- B01J 21/16: Clays or other mineral silicates
- B01J 23/00: Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 (B01J21/16 takes precedence)
- B01J 27/16: containing oxygen {, i.e. acids, anhydrides and their derivates with N, S, B or halogens without carriers or on carriers based on C, Si, Al or Zr; also salts of Si, Al and Zr}
- B01J 29/06: Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
- B01J 29/08: of the faujasite type, e.g. type X or Y
- B01J 29/40: of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively
- B01J 29/60: of the type L, as exemplified by patent document US3216789
- B01J 29/65: of the ferrierite type, e.g. types ZSM-21, ZSM-35 or ZSM-38, as exemplified by patent documents US4046859, US4016245 and US4046859, respectively
- B01J 29/7007: {Zeolite Beta}
- B01J 29/7026: {MFS-type, e.g. ZSM-57}
- B01J 29/7038: {MWW-type, e.g. MCM-22, ERB-1, ITQ-1, PSH-3 or SSZ-25}
- B01J 29/7046: {MTT-type, e.g. ZSM-23, KZ-1, ISI-4 or EU-13}
- C07C 4/06: Catalytic processes {(C07C4/025 takes precedence)}
- C08F 10/06: Propene
- B01J 37/10: in the presence of water, e.g. steam
- B01J 37/28: Phosphorising
- B01J 2029/081: {Increasing the silica/alumina ratio; Desalumination}
- B01J 2229/16: to increase the Si/Al ratio; Dealumination
- B01J 2229/186: not in framework positions
- B01J 2229/42: Addition of matrix or binder particles
- C07C 2529/40: of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11
- Y02P 30/20: using bio-feedstock
- Y02P 30/40: Ethylene production
- C07C: ACYCLIC OR CARBOCYCLIC COMPOUNDS
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- C08F: MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

A process for obtaining a catalyst composite comprising the following steps: a). selecting a molecular sieve having pores of 10-or more-membered rings b). contacting the molecular sieve with a metal silicate different from said molecular sieve comprising at least one alkaline earth metal and one or more of the following metals: Ga, Al, Ce, In, Cs, Sc, Sn, Li, Zn, Co, Mo, Mn, Ni, Fe, Cu, Cr, Ti and V, such that the composite comprises at least 0.1 wt % of silicate.

## Claims

### Claim at position 1

1-35. (canceled)

### Claim 36

A process for preparing a catalyst, comprising:
selecting a zeolite; and
contacting the zeolite with a metal silicate, different from the zeolite, wherein the metal silicate comprises xonotlite (Ca6Si6O17(OH)2);
wherein the catalyst comprises at least 10 wt % of the zeolite and at least 0.1 wt % of silicate based on a total weight of the catalyst.

### Claim 37 (depends on 36)

The process of claim 36, wherein the zeolite has pores of 10-or more-membered rings.

### Claim 38 (depends on 36)

The process of claim 36, wherein the metal silicate comprises one or more metals selected from a group consisting of: Ga, Al, Ce, In, Cs, Sc, Sn, Li, Zn, Co, Mo, Mn, Ni, Fe, Cu, Cr, Ti, V, and combinations thereof.

### Claim 39 (depends on 36)

The process of claim 36, wherein the metal silicate is present in the catalyst composite in an amount of up to 10 wt %.

### Claim 40 (depends on 36)

The process of claim 36, wherein the zeolite is a ZSM-5 zeolite.

### Claim 41 (depends on 36)

The process of claim 36, wherein the zeolite is selected from the group consisting of MFI, MOR, MEL, clinoptilolite, FER, FAU, MWW, BETA, ZSM-21, ZSM-22, ZSM-23, ZSM-42, ZSM-57, and LTL, and combinations thereof.

### Claim 42 (depends on 36)

The process of claim 36, wherein the zeolite is selected from the group consisting of MFI, MOR, MEL, clinoptilolite and FER and combinations thereof, and wherein the molecular sieve is synthesized without direct addition of template.

### Claim 43 (depends on 36)

The process of claim 36, wherein the zeolite is a P-modified zeolite.

### Claim 44 (depends on 43)

The process of claim 43, wherein the zeolite is modified with P by undergoing a steam treatment step, whereby the zeolite is dealuminated, followed by a leaching step using an acid solution comprising a source of P.

### Claim 45 (depends on 36)

The process of claim 36, wherein the zeolite is brought into contact with the metal silicate by mechanically blending the zeolite with the metal silicate forming a precursor during preparation of the catalyst.

### Claim 46 (depends on 36)

The process of claim 36, wherein the zeolite is brought into contact with the metal silicate by physical blending of a previously prepared zeolite and a previously prepared metal silicate in situ in an XTO and/or OCP reaction medium.

### Claim 47 (depends on 36)

The process of claim 36, wherein the metal silicate comprises one or more of the following metals: Mg, Sr and Ba.

### Claim 48 (depends on 36)

The process of claim 36, wherein the metal silicate further comprises CaAl2Si2O8, Ca2Al2SiO7, CaMg(Si2O6)x, or combinations thereof.

### Claim 49 (depends on 36)

The process of claim 36, wherein the zeolite is selected from the group consisting of MFI, MOR, MEL, clinoptilolite, FER, FAU, MWW, BETA, ZSM-21, ZSM-22, ZSM-23, ZSM-42, ZSM-57, LTL, and combinations thereof, and wherein the zeolite is obtained without direction addition of template.

### Claim 50 (depends on 36)

The process of claim 36, wherein prior to and/or after contacting the metal silicate with the zeolite, the zeolite is treated according to one or more, of the following steps: steaming, leaching, washing, drying, calcination, impregnation, and ion exchanging.

### Claim 51 (depends on 36)

The process of claim 36, wherein the zeolite that is contacted with the metal silicate is a non-modified zeolite, and wherein the zeolite is modified with P after contacting the metal silicate.

### Claim 52 (depends on 51)

The process of claim 51, wherein the zeolite is modified with P by undergoing a steam treatment step, whereby the zeolite is dealuminated, followed by a leaching step using an acid solution comprising a source of P.

### Claim 53 (depends on 51)

The process of claim 51, wherein the zeolite is modified with P according to the following:
steaming at a temperature ranging from 400 to 870° C. for 0.01-200 hours;
leaching with an aqueous acid solution comprising the source of P at conditions effective to remove a substantial part of Al from the zeolite and to introduce at least 0.3 wt % of P;
separating solids from the aqueous acid solution; and
subjecting the solids to a calcination step.

### Claim 54 (depends on 36)

A catalyst obtained from the process of claim 36.

### Claim 55

A process for preparing a catalyst comprising:
contacting a zeolite with xonotlite (Ca6Si6O17(OH)2);
wherein the catalyst comprises at least 10 wt % of the zeolite and at least 0.1 wt % of silicate based on a total weight of the catalyst.