Catalyst and process for isoparaffin-olefin alkylation
AssigneeMobil Oil Corporation
InventorsCynthia T.-W. Chu, Altaf Husain, Kathleen M. Keville, Daria N. Lissy
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Abstract
There are provided a catalyst, a method for making this catalyst, and a process for using this catalyst in the alkylation of an isoparaffin with an olefin to provide an alkylate. The catalyst may be made from an as-synthesized material which, upon calcination, is capable of generating zeolites designated MCM-22. The as-synthesized material is then combined with a binder material, such as alumina, by an extrusion process. The uncalcined bound material may then be ammonium exchanged, followed by a calcination treatment. The as-synthesized material may also be swollen with a suitable swelling agent, such as a cetyltrimethylammonium compound, prior to the binding process.
Claims17
An isoparaffin/olefin alkylation process which comprises reacting isoparaffin and olefin under alkylation conditions providing an alkylate product in the presence of a catalyst prepared by a method comprising the steps of:
- (a) preparing a reaction mixture comprising a source of at least one oxide, water and an organic directing agent, wherein said reaction mixture is capable of forming a crystalline oxide material upon being subjected to sufficient crystallization conditions, said crystalline oxide material, in as-synthesized form, having an X-ray diffraction pattern comprising the following lines:
- ______________________________________ d(A) I/I.sub.o ______________________________________ 12.18-12.73 m-vs 10.93-11.41 w-s 6.74-7.04 w-m 4.37-4.60 w-m 3.84-4.03 w-vs 3.50-3.62 w-m 3.37-3.51 m-vs 3.27-3.41 w-s;
- ______________________________________
- (b) maintaining said reaction mixture of step (a) under conditions sufficient to form said as-synthesized crystalline oxide material;
- (c) recovering said as-synthesized crystalline oxide material comprising residual organic directing agent;
- (d) mulling and extruding the uncalcined, as-synthesized crystalline material recovered in step (c) with a binder material under conditions sufficient to form an extrudate having a green strength sufficient to withstand processing as described in subsequent steps of this method, the crush strength of the green strength extrudate being capable of being improved by calcination thereof;
- (e) exchanging ions in the crystalline material in the green strength extrudate of step (d) with ammonium ions, said extrudate in this step not having been subjected to calcination conditions sufficient to decompose and/or oxidize the residue of the organic directing agent in the crystalline oxide material;
- and
- (f) calcining the exchanged extrudate of step (e) for the first time under conditions sufficient to (1) decompose ammonium ions, (2) decompose and/or oxidize residual organic directing agent, and (3) convert the green strength extrudate into a calcined extrudate having improved crush strength.
An isoparaffin/olefin alkylation process which comprises reacting isoparaffin and olefin under alkylation conditions providing an alkylate product in the presence of a catalyst prepared by a method comprising the steps of:
- (a) preparing a reaction mixture comprising a source of at least one oxide, water and an organic directing agent, wherein said reaction mixture is capable of forming a crystalline oxide material upon being subjected to sufficient crystallization conditions, said crystalline oxide material, in as-synthesized form, having an X-ray diffraction pattern comprising the following lines:
- ______________________________________ d(A) I/I.sub.o ______________________________________ 12.18-12.73 m-vs 10.93-11.41 w-s 6.74-7.04 w-m 4.37-4.60 w-m 3.84-4.03 w-vs 3.50-3.62 w-m 3.37-3.51 m-vs 3.27-3.41 w-s;
- ______________________________________
- (b) maintaining said reaction mixture of step (a) under conditions sufficient to form said as-synthesized crystalline oxide material;
- (c) recovering said as-synthesized crystalline oxide material comprising residual organic directing agent;
- (d) contacting said as-synthesized crystalline material of step (c) with an organic swelling agent under conditions sufficient to swell said as-synthesized material, thereby forming a non-pillared swollen material having an X-ray diffraction pattern comprising the following lines:
- ______________________________________ d(A) I/I.sub.o ______________________________________ >32.2 vs 12.41 .+-. 0.25 w-s 3.44 .+-. 0.07 w-s ______________________________________
- (e) mulling and extruding the uncalcined, non-pillared swollen material recovered in step (d) with a binder material under conditions sufficient to form an extrudate having a green strength sufficient to withstand processing as described in subsequent steps of this method, the crush strength of the green strength extrudate being capable of being improved by calcination thereof;
- (f) exchanging ions in the crystalline material in the green strength extrudate of step (e) with ammonium ions, said extrudate in this step not having been subjected to calcination conditions sufficient to decompose and/or oxidize the residue of the organic directing agent or the organic swelling agent in the non-pillared swollen material;
- and
- (g) calcining the exchanged extrudate of step (f) for the first time under conditions sufficient to (1) decompose ammonium ions, (2) decompose and/or oxidize residual organic directing agent and organic swelling agent, and (3) convert the green strength extrudate into a calcined extrudate having improved crush strength.
Dependencies are inferred from the claim text.