# US 2019/0168192 A1 · Alloyed zeolite catalyst component, method for making and catalytic application thereof

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- Number: US 2019/0168192 A1
- Document ID: US20190168192A1
- Status: Published application
- Kind: A1
- Application number: 16/270,436
- Filed: 2019-02-07
- Published: 2019-06-06
- Earliest claimed: 2011-02-17
- Assignees: AMG Chemistry and Catalysis Consulting, LLC
- Applicants: Amg Chemistry and Catalysis Consulting, LLC
- Inventors: Anne Mae Gaffney
- Web page: https://patentgrep.com/patent/US20190168192A1

## CPC

- B01J 29/068: Noble metals
- B01J 23/40: of the platinum group metals
- B01J 23/70: of the iron group metals or copper
- B01J 23/89: combined with noble metals
- B01J 29/064: containing iron group metals, noble metals or copper
- 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 29/42: containing iron group metals, noble metals or copper
- B01J 29/44: Noble metals
- B01J 29/90: Regeneration or reactivation
- B01J 37/0201: {Impregnation}
- B01J 37/0215: {Coating}
- B01J 37/035: {Precipitation on carriers}
- B01J 37/04: Mixing {(B01J37/0009, B01J37/0018 take precedence)}
- B01J 37/06: Washing {(B01J37/0009, B01J37/0018 take precedence)}
- B01J 37/08: Heat treatment {(B01J37/0009, B01J37/0018 take precedence)}
- B01J 37/16: Reducing
- B01J 37/28: Phosphorising
- B01J 38/12: Treating with free oxygen-containing gas
- C10B 49/22: according to the "fluidised bed" technique
- C10B 53/07: {of solid raw materials consisting} of synthetic polymeric materials, e.g. tyres (recovery or working-up of waste materials of organic macromolecular compounds or compositions based thereon by dry-heat treatment for obtaining partially depolymerised materials C08J11/10; production of liquid hydrocarbon mixtures from rubber or rubber waste C10G1/10)
- C10B 57/06: containing additives
- C10G 1/10: from rubber or rubber waste
- C10G 45/70: with catalysts containing platinum group metals or compounds thereof
- B01J 35/69: bimodal
- B01J 37/088: {Decomposition of a metal salt}
- B01J 37/10: in the presence of water, e.g. steam
- B01J 2229/18: to introduce other elements into or onto the molecular sieve itself
- B01J 2229/183: in framework positions
- B01J 2229/186: not in framework positions
- B01J 2229/40: Special temperature treatment, i.e. other than just for template removal
- B01J 2229/42: Addition of matrix or binder particles
- C10G 2300/1003: Waste materials
- C10G 2300/4081: Recycling aspects
- C10G 2400/20: C2-C4 olefins
- C10G 2400/22: Higher olefins
- C10G 2400/30: Aromatics
- Y02P 20/143: the feedstock being recycled material, e.g. plastics
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- C10B: DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS (cracking oils C10G; underground gasification of minerals E21B43/295)
- C10G: CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION (cracking to hydrogen or synthesis gas C01B; cracking or pyrolysis of hydrocarbon gases to individual hydrocarbons or mixtures thereof of definite or specified constitution C07C; cracking to cokes C10B); RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS

## Abstract

The presently disclosed and claimed inventive concept(s) generally relates to a solid catalyst component comprising a zeolite with a modifier and at least one Group VIII meal alloyed with at least one transition metal. The presently disclosed and claimed inventive concept(s) further relates to a method of making the solid catalyst component and a process of converting mixed waste plastics into low molecular weight organic compounds using the solid catalyst component.

## Claims

### Claim at position 1

-13. (canceled)

### Claim 14

A process of converting a mixed waste plastic into a low molecular weight organic compound, comprising the steps of
(a) feeding particles of the mixed waste plastic and a solid catalyst component into a fluidized bed reactor, the solid catalyst component comprising (i) a modified zeolite and (ii) alloyed metals comprising at least one noble metal alloyed with at least one transition metal, wherein the zeolite is selected from the group consisting of chabazite, erionite, faujasite, ferrierite, mordenite, offretite, TEA-mordenite, zeolite A, zeolite beta, zeolite boron beta, zeolite L, zeolite X, zeolite Y, zeolite ZK-5, Breck-6, HZSM-5, ITQ-1, ITQ-21, MCM-22, MCM-36, MCM-39, MCM-41, MCM-48, PSH-3, SUZ-4, EU-1, SAPO-5, SAPO-11, SAPO-34, (S)AIPO-31, SSZ-23, SSZ-32, TUD-1, VPI-5, ZSM-4, ZSM-5, ZSM-8, ZSM-11, ZSM-12, ZSM-20, ZSM-21, ZSM-22, ZSM-23, ZSM-34, ZSM-35, ZSM-38, ZSM-48, ZSM-50, ZSM-57, and combinations thereof, and wherein the modified zeolite is modified with a modifier selected from the group consisting of (1) phosphorous, (2) boron, (3) phosphorous and boron, (4) an additive selected from the group consisting of gallium, zinc, zirconium, niobium, tantalum, and combinations thereof, and (5) combinations thereof;
(b) heating the particles of the mixed waste plastic and the solid catalyst component at a temperature effective to produce a coarse filler, inorganic components, coke, a volatile organic component, and a spent catalyst component;
(c) withdrawing a first stream comprising the volatile organic component from the reactor;
(d) withdrawing a second stream comprising the spent catalyst component, the coke, the coarse filler and the inorganic components from the reactor;
(e) heating the second stream in a regenerator in the presence of oxygen, air, or a blend of oxygen with an inert gas at a temperature effective to convert the coke to a mixture of carbon monoxide, carbon dioxide and water, and to regenerate the solid catalyst component; and
(f) separating the regenerated solid catalyst component from the coarse filler and the inorganic components.

### Claim 15 (depends on 14)

The process of claim 14, wherein the inert gas of step (e) is nitrogen, steam, or combinations thereof.

### Claim 16 (depends on 14)

The process of claim 14, wherein the volatile organic component comprises a light C2-C6 olefinic product stream.

### Claim 17 (depends on 16)

The process of claim 16, further comprising the step:
(g) recycling the light C2-C6 olefinic product stream back to the fluidized bed reactor to produce a high molecular weight organic compound.

### Claim 18 (depends on 17)

The process of claim 17, wherein the high molecular weight organic compound is selected from the group consisting of benzene, toluene, xylene and combinations thereof.

### Claim 19 (depends on 14)

The process of claim 14, wherein hydrogen is added into the step (a).

### Claim 20 (depends on 14)

The process of claim 14, wherein a hydrogen source is added into the step (a).

### Claim 21 (depends on 14)

The process of claim 14, wherein the particles of the mixed waste plastic in step (a) have an average diameter of less than about 1 cm.

### Claim 22 (depends on 14)

The process of claim 14, wherein the temperature of step (b) is in a range of from about 450° C. to about 750° C.

### Claim 23 (depends on 14)

The process of claim 14, wherein prior to step (a), the particles of the mixed waste plastic are fed into a thermal reactor and undergo pyrolysis.

### Claim 24 (depends on 23)

The process of claim 23, wherein the pyrolysis is performed using a two-step temperature program comprising (i) raising the temperature to a range of from about 300° C. to about 330° C. for at least two hours; and (ii) raising the temperature to a range of from about 400° C. to about 450° C.

### Claim 25 (depends on 24)

The process of claim 24, wherein the pyrolysis produces mixed waste plastic having less than about 15 ppm halogenated hydrocarbons.