Low metal content catalyst compositions and processes for making and using same
AssigneeExxonMobil Chemical Patents Inc.
InventorsTeng Xu, Stephen Neil Vaughn, Richard B. Hall, Kenneth Ray Clem, Jack W. Johnson
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Abstract
The invention provides low metal content molecular sieve catalyst compositions, processes for making such catalysts, and processes for using such catalysts in the conversion of an oxygenate into one or more light olefins. Preferably, the catalyst composition comprises a matrix material having a low metal content. By utilizing matrix materials having low metal contents, the amount of metal-catalyzed side reaction byproducts formed in a reaction system, particularly in an oxygenate-to-olefin reaction system, can be advantageously reduced.
Claims108
A catalyst composition, comprising:
- (a) a molecular sieve;
- (b) a clay matrix material containing less than about 10,000 wppm iron and iron-containing species, based on the total weight of the matrix material;
- and
- (c) optionally binder.
A catalyst composition, comprising:
- (a) a molecular sieve;
- (b) a clay matrix material containing less than about 15,000 wppm titanium and titanium-containing species, based on the total weight of the matrix material;
- and
- (c) optionally binder.
A catalyst composition, comprising:
- (a) a molecular sieve;
- (b) a clay matrix material containing less than about 1,500 wppm nickel and nickel-containing species, based on the total weight of the matrix material;
- and
- (c) optionally binder.
A catalyst composition, comprising:
- (a) a molecular sieve;
- (b) a clay matrix material containing less than about 1,500 wppm cobalt and cobalt-containing species, based on the total weight of the matrix material;
- and
- (c) optionally binder.
A process for forming a molecular sieve catalyst composition, the process comprising the steps of:
- (a) selecting a matrix material containing less than 10,000 wppm of iron and iron-containing species, based on the total weight of the matrix material;
- (b) forming a slurry containing the matrix material, a molecular sieve, a slurrying medium, and optionally a binder;
- and
- (c) drying the slurry to produce the molecular sieve catalyst composition.
A process for forming a molecular sieve catalyst composition, the process comprising the steps of:
- (a) selecting a matrix material containing less than 15,000 wppm of titanium and titanium-containing species, based on the total weight of the matrix material;
- (b) forming a slurry containing the matrix material, a molecular sieve, a slurrying medium, and optionally a binder;
- and
- (c) drying the slurry to produce the molecular sieve catalyst composition.
A process for forming a molecular sieve catalyst composition, the process comprising the steps of:
- (a) selecting a matrix material containing less than 1,500 wppm of nickel and nickel-containing species, based on the total weight of the matrix material;
- (b) forming a slurry containing the matrix material, a molecular sieve, a slurrying medium, and optionally a binder;
- and
- (c) drying the slurry to produce the molecular sieve catalyst composition.
A process for forming a molecular sieve catalyst composition, the process comprising the steps of:
- (a) selecting a matrix material containing less than 1,500 wppm of cobalt and cobalt-containing species, based on the total weight of the matrix material;
- (b) forming a slurry containing the matrix material, a molecular sieve, a slurrying medium, and optionally a binder;
- and
- (c) drying the slurry to produce the molecular sieve catalyst composition.
A catalyst composition, comprising:
- (a) a molecular sieve;
- (b) a clay matrix material containing less than about 1,500 wppm manganese and manganese-containing species, based on the total weight of the matrix material;
- and
- (c) optionally binder.
A catalyst composition, comprising:
- (a) a molecular sieve;
- (b) a clay matrix material containing less than about 1,500 wppm vanadium and vanadium-containing species, based on the total weight of the matrix material;
- and
- (c) optionally binder.
A process for forming a molecular sieve catalyst composition, the process comprising the steps of:
- (a) selecting a matrix material containing less than 1,500 wppm of manganese and manganese-containing species, based on the total weight of the matrix material;
- (b) forming a slurry containing the matrix material, a molecular sieve, a slurrying medium, and optionally a binder;
- and
- (c) drying the slurry to produce the molecular sieve catalyst composition.
A process for forming a molecular sieve catalyst composition, the process comprising the steps of:
- (a) selecting a matrix material containing less than 1,500 wppm of vanadium and vanadium-containing species, based on the total weight of the matrix material;
- (b) forming a slurry containing the matrix material, a molecular sieve, a slurrying medium, and optionally a binder;
- and
- (c) drying the slurry to produce the molecular sieve catalyst composition.
A catalyst composition, comprising:
- (a) a molecular sieve;
- (b) a clay matrix material;
- and
- (c) optionally binder, wherein the catalyst composition contains less than about 10,000 wppm iron and iron-containing species, based on the total weight of the catalyst composition.
A catalyst composition, comprising:
- (a) a molecular sieve;
- (b) a clay matrix material;
- and
- (c) optionally binder, wherein the catalyst composition contains less than about 15,000 wppm titanium and titanium-containing species, based on the total weight of the catalyst composition.
A catalyst composition, comprising:
- (a) a molecular sieve;
- (b) a clay matrix material;
- and
- (c) optionally binder, wherein the catalyst composition contains less than about 1,500 wppm nickel and nickel-containing species, based on the total weight of the catalyst composition.
A catalyst composition, comprising:
- (a) a molecular sieve;
- (b) a clay matrix material;
- and
- (c) optionally binder, wherein the catalyst composition contains less than about 1,500 wppm cobalt and cobalt-containing species, based on the total weight of the catalyst composition.
A catalyst composition, comprising:
- (a) a molecular sieve;
- (b) a clay matrix material;
- and
- (c) optionally binder, wherein the catalyst composition contains less than about 1,500 wppm manganese and manganese-containing species, based on the total weight of the catalyst composition.
A catalyst composition, comprising:
- (a) a molecular sieve;
- (b) a clay matrix material;
- and
- (c) optionally binder, wherein the catalyst composition contains less than about 1,500 wppm vanadium and vanadium-containing species, based on the total weight of the catalyst composition.
Dependencies are inferred from the claim text.