JP2015501209A - リン変性ゼオライト触媒の製造方法 - Google Patents
リン変性ゼオライト触媒の製造方法 Download PDFInfo
- Publication number
- JP2015501209A JP2015501209A JP2014537146A JP2014537146A JP2015501209A JP 2015501209 A JP2015501209 A JP 2015501209A JP 2014537146 A JP2014537146 A JP 2014537146A JP 2014537146 A JP2014537146 A JP 2014537146A JP 2015501209 A JP2015501209 A JP 2015501209A
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- JP
- Japan
- Prior art keywords
- zeolite
- phosphorus
- catalyst
- zsm
- inorganic oxide
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
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- 239000003054 catalyst Substances 0.000 title claims abstract description 97
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical class O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 title claims abstract description 82
- 238000004519 manufacturing process Methods 0.000 title claims description 13
- 239000010457 zeolite Substances 0.000 claims abstract description 66
- 229910021536 Zeolite Inorganic materials 0.000 claims abstract description 64
- 229910052698 phosphorus Inorganic materials 0.000 claims abstract description 45
- 239000011574 phosphorus Substances 0.000 claims abstract description 44
- 239000011230 binding agent Substances 0.000 claims abstract description 31
- 239000013078 crystal Substances 0.000 claims abstract description 28
- 229910052809 inorganic oxide Inorganic materials 0.000 claims abstract description 20
- 239000007864 aqueous solution Substances 0.000 claims abstract description 18
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 15
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 15
- -1 phosphorus compound Chemical class 0.000 claims abstract description 15
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 14
- 239000003795 chemical substances by application Substances 0.000 claims abstract description 13
- 230000015572 biosynthetic process Effects 0.000 claims abstract description 10
- 125000004435 hydrogen atom Chemical group [H]* 0.000 claims abstract description 7
- 238000003786 synthesis reaction Methods 0.000 claims abstract description 7
- 238000000034 method Methods 0.000 claims description 41
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 32
- OKKJLVBELUTLKV-UHFFFAOYSA-N Methanol Chemical compound OC OKKJLVBELUTLKV-UHFFFAOYSA-N 0.000 claims description 24
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 16
- 239000000377 silicon dioxide Substances 0.000 claims description 15
- 230000008569 process Effects 0.000 claims description 11
- 238000006243 chemical reaction Methods 0.000 claims description 10
- 238000010438 heat treatment Methods 0.000 claims description 10
- 238000001125 extrusion Methods 0.000 claims description 9
- 229930195733 hydrocarbon Natural products 0.000 claims description 7
- 150000002430 hydrocarbons Chemical class 0.000 claims description 7
- 238000009835 boiling Methods 0.000 claims description 6
- 150000002894 organic compounds Chemical class 0.000 claims description 6
- 239000002253 acid Substances 0.000 claims description 5
- BHEPBYXIRTUNPN-UHFFFAOYSA-N hydridophosphorus(.) (triplet) Chemical compound [PH] BHEPBYXIRTUNPN-UHFFFAOYSA-N 0.000 claims description 5
- 238000005470 impregnation Methods 0.000 claims description 5
- 239000004215 Carbon black (E152) Substances 0.000 claims description 2
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 2
- 239000001301 oxygen Substances 0.000 claims description 2
- 229910052760 oxygen Inorganic materials 0.000 claims description 2
- 239000002994 raw material Substances 0.000 claims description 2
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 32
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 18
- 239000000203 mixture Substances 0.000 description 12
- 239000002808 molecular sieve Substances 0.000 description 12
- URGAHOPLAPQHLN-UHFFFAOYSA-N sodium aluminosilicate Chemical compound [Na+].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O URGAHOPLAPQHLN-UHFFFAOYSA-N 0.000 description 12
- VLKZOEOYAKHREP-UHFFFAOYSA-N n-Hexane Chemical compound CCCCCC VLKZOEOYAKHREP-UHFFFAOYSA-N 0.000 description 10
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 8
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 8
- 239000007787 solid Substances 0.000 description 8
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 6
- 239000000463 material Substances 0.000 description 6
- 238000007069 methylation reaction Methods 0.000 description 6
- 239000011148 porous material Substances 0.000 description 6
- 239000008367 deionised water Substances 0.000 description 5
- 229910021641 deionized water Inorganic materials 0.000 description 5
- 230000000694 effects Effects 0.000 description 5
- 230000011987 methylation Effects 0.000 description 5
- 239000002002 slurry Substances 0.000 description 5
- PAWQVTBBRAZDMG-UHFFFAOYSA-N 2-(3-bromo-2-fluorophenyl)acetic acid Chemical compound OC(=O)CC1=CC=CC(Br)=C1F PAWQVTBBRAZDMG-UHFFFAOYSA-N 0.000 description 4
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 4
- URLKBWYHVLBVBO-UHFFFAOYSA-N Para-Xylene Chemical group CC1=CC=C(C)C=C1 URLKBWYHVLBVBO-UHFFFAOYSA-N 0.000 description 4
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 4
- 229910052757 nitrogen Inorganic materials 0.000 description 4
- CTQNGGLPUBDAKN-UHFFFAOYSA-N O-Xylene Chemical compound CC1=CC=CC=C1C CTQNGGLPUBDAKN-UHFFFAOYSA-N 0.000 description 3
- 229910052680 mordenite Inorganic materials 0.000 description 3
- 230000001590 oxidative effect Effects 0.000 description 3
- 239000000243 solution Substances 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 238000010792 warming Methods 0.000 description 3
- 239000008096 xylene Substances 0.000 description 3
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 2
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 2
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 229910021529 ammonia Inorganic materials 0.000 description 2
- 239000003518 caustics Substances 0.000 description 2
- 239000004927 clay Substances 0.000 description 2
- 229910052570 clay Inorganic materials 0.000 description 2
- 238000000354 decomposition reaction Methods 0.000 description 2
- 239000010410 layer Substances 0.000 description 2
- 150000003613 toluenes Chemical class 0.000 description 2
- 239000004254 Ammonium phosphate Substances 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- 229910004298 SiO 2 Inorganic materials 0.000 description 1
- 238000002441 X-ray diffraction Methods 0.000 description 1
- AFCIMSXHQSIHQW-UHFFFAOYSA-N [O].[P] Chemical compound [O].[P] AFCIMSXHQSIHQW-UHFFFAOYSA-N 0.000 description 1
- 229910001413 alkali metal ion Inorganic materials 0.000 description 1
- 230000002152 alkylating effect Effects 0.000 description 1
- ILRRQNADMUWWFW-UHFFFAOYSA-K aluminium phosphate Chemical compound O1[Al]2OP1(=O)O2 ILRRQNADMUWWFW-UHFFFAOYSA-K 0.000 description 1
- 229910000148 ammonium phosphate Inorganic materials 0.000 description 1
- 235000019289 ammonium phosphates Nutrition 0.000 description 1
- 150000001491 aromatic compounds Chemical class 0.000 description 1
- 150000004945 aromatic hydrocarbons Chemical class 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- 239000012159 carrier gas Substances 0.000 description 1
- 238000004523 catalytic cracking Methods 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 238000006555 catalytic reaction Methods 0.000 description 1
- 238000001311 chemical methods and process Methods 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000018044 dehydration Effects 0.000 description 1
- 238000006297 dehydration reaction Methods 0.000 description 1
- 150000001983 dialkylethers Chemical class 0.000 description 1
- MNNHAPBLZZVQHP-UHFFFAOYSA-N diammonium hydrogen phosphate Chemical compound [NH4+].[NH4+].OP([O-])([O-])=O MNNHAPBLZZVQHP-UHFFFAOYSA-N 0.000 description 1
- 238000007323 disproportionation reaction Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 235000012438 extruded product Nutrition 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 238000004231 fluid catalytic cracking Methods 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 238000005342 ion exchange Methods 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- JCCNYMKQOSZNPW-UHFFFAOYSA-N loratadine Chemical compound C1CN(C(=O)OCC)CCC1=C1C2=NC=CC=C2CCC2=CC(Cl)=CC=C21 JCCNYMKQOSZNPW-UHFFFAOYSA-N 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 239000003607 modifier Substances 0.000 description 1
- NBIIXXVUZAFLBC-UHFFFAOYSA-K phosphate Chemical compound [O-]P([O-])([O-])=O NBIIXXVUZAFLBC-UHFFFAOYSA-K 0.000 description 1
- 229940085991 phosphate ion Drugs 0.000 description 1
- 229910001392 phosphorus oxide Inorganic materials 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000001294 propane Substances 0.000 description 1
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 1
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 239000011541 reaction mixture Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000007363 ring formation reaction Methods 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 229910001415 sodium ion Inorganic materials 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000010561 standard procedure Methods 0.000 description 1
- 238000010025 steaming Methods 0.000 description 1
- CBXCPBUEXACCNR-UHFFFAOYSA-N tetraethylammonium Chemical group CC[N+](CC)(CC)CC CBXCPBUEXACCNR-UHFFFAOYSA-N 0.000 description 1
- VSAISIQCTGDGPU-UHFFFAOYSA-N tetraphosphorus hexaoxide Chemical compound O1P(O2)OP3OP1OP2O3 VSAISIQCTGDGPU-UHFFFAOYSA-N 0.000 description 1
- BGQMOFGZRJUORO-UHFFFAOYSA-M tetrapropylammonium bromide Chemical compound [Br-].CCC[N+](CCC)(CCC)CCC BGQMOFGZRJUORO-UHFFFAOYSA-M 0.000 description 1
Classifications
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- B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
- B01J29/40—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11, as exemplified by patent documents US3702886, GB1334243 and US3709979, respectively
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- B01J21/00—Catalysts comprising the elements, oxides, or hydroxides of magnesium, boron, aluminium, carbon, silicon, titanium, zirconium, or hafnium
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
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- B82Y40/00—Manufacture or treatment of nanostructures
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- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B39/00—Compounds having molecular sieve and base-exchange properties, e.g. crystalline zeolites; Their preparation; After-treatment, e.g. ion-exchange or dealumination
- C01B39/54—Phosphates, e.g. APO or SAPO compounds
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- C07C1/22—Preparation of hydrocarbons from one or more compounds, none of them being a hydrocarbon starting from organic compounds containing only oxygen atoms as heteroatoms by reduction
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Abstract
Description
前記方法は、
(a)別個の(別々の又は個別の)無機系酸化物バインダーの不在下、又は実質的にアルミニウムを有しない別個の無機系酸化物バインダーの存在下、合成したままのゼオライト結晶を成形した触媒体に形成する工程;
(b)ゼオライト結晶を水素型に変換する工程;
(c)ゼオライト結晶の合成に使用されるいずれの(又はいかなる)有機構造規定剤(有機構造指向剤又は有機指向剤:organic directing agent)も除去する工程;
(d)成形した触媒体をリン化合物の水溶液で処理する工程;及び
(e)処理した触媒体を加熱して、水を除去しリン化合物を酸化物型に変換する工程
を含む。
・通常の一次結晶性構成要素単位格子(この単位格子はMWW構造トポロジー(MWW framework topology)を有する)でできているモレキュラーシーブ(単位格子は、3次元空間においてタイル状にされる場合、結晶構造を表す原子の空間的配置である。こうした結晶構造は、「Atlas of Zeolite Framework Types」、第5版、2001に記載されており、この開示内容全体は、参照により、本明細書に組み込まれている)、
・こうしたMWW構造トポロジー単位格子の2次元タイリング(tiling)であり、1つの単位格子厚、好ましくは1つのc−単位格子厚の単層を形成する、通常の二次構成要素でできているモレキュラーシーブ、
・1つ又は複数の1つの単位格子厚の層である、通常の二次構成要素でできているモレキュラーシーブ(ここで、2つ以上の単位格子厚の層は、1つの単位格子厚の少なくとも2つの単層を、積み重ねる、充填する、又は結合させることで作成することができる。こうした二次構成要素の積み重ねは、規則的な方法、不規則的な方法、無作為な方法、又はこれらの任意の組み合わせであることができる)及び、
・MWW構造トポロジーを有する単位格子の任意の規則的な又は無作為的な2次元的な又は3次元的な組み合わせによって作成されるモレキュラーシーブ
のうちの1つ又は複数を含む。
初めにアルミナ(固形分として約200グラム)を混合機に加え、乾燥加温した。次いで、脱イオン水(約100グラム)を加えてアルミナを湿らし、その後、目標のリン濃度を達成するためにある量のリン酸(それぞれの固形分として約0、約61、約122、又は約183.2グラム)を加えた。次いで、Na−ZSM−5結晶(固形分として約800グラム)及び追加の脱イオン水を加えて、混合物を約10〜30分間加温して望まれる押し出し成形の粘度を達成した。これにより、4つの異なるリン濃度(それぞれ約0、約1.7、約3.4、及び約4.2重量%)を有する混合物を調製した。次いで、それぞれの混合物を約1/16’’円柱物に押し出し成形した。押し出し成形物を、約250°F(約121℃)で一晩(約8〜16時間)乾燥させ、次いで約1000°F(約538℃)で約3時間、窒素中で前焼成した。次いで、それぞれの押し出し成形物を、1Nの硝酸アンモニウムの水溶液で2回交換した。得られた交換した触媒を、約250°F(約121℃)で一晩乾燥させ、次いで約1000°F(約538℃)で約3時間、空気中で焼成した。
ZSM−5(固形分として約800グラム)及びVersal(商標)300アルミナ(固形分として約200グラム)を混合機に加え、乾燥加温した。加温の際、約492グラムの脱イオン水を加えて望まれる押し出し成形の粘度を達成した。次いで、混合物を約1/16’’円柱物に押し出し成形した。押し出し成形物を、約250°F(約121℃)で一晩(約8〜16時間)乾燥させ、次いで約1000°F(約538℃)で約3時間、窒素中で前焼成した。次いで、押し出し成形物を、1Nの硝酸アンモニウムの水溶液で2回交換した。交換した触媒を、約250°F(約121℃)で一晩乾燥させ、次いで約1000°F(約538℃)で約3時間、空気中で焼成した。次いで、押し出し成形物を、リン酸水溶液を使用して、約2、約4、又は約6重量%のリンの目標濃度(実際の濃度を以下の表1に示す)で初期湿潤を介して含浸させた。次いで、含浸した結晶を、約250°F(約121℃)で一晩乾燥させ、その後約1000°F(約538℃)で約3時間、空気中で焼成した。
ZSM−5(固形分として約800グラム)及びUltrasil(商標)VN3SPシリカ(固形分として約100グラム)を混合機に加え、乾燥加温した。次いで、Ludox(商標)−40シリカ(約100グラム)を混合物に加え、その後、約60グラムの約50重量%腐食性(水酸化ナトリウム)溶液を加えた。加温の際、約85グラムの脱イオン水を加えて望まれる押し出し成形の粘度を達成した。次いで、混合物を約1/16’’円柱物に押し出し成形した。押し出し成形物を、約250°F(約121℃)で一晩(約8〜16時間)乾燥させ、次いで約1000°F(約538℃)で約3時間、窒素中で前焼成した。次いで、押し出し成形物を、1Nの硝酸アンモニウムの水溶液で2回交換した。交換した触媒を、約250°F(約121℃)で一晩乾燥させ、次いで約1000°F(約538℃)で約3時間、空気中で焼成した。次いで、押し出し成形物を、リン酸水溶液を使用して、約2、約4、又は約6重量%のリンの目標濃度(実際の濃度を以下の表1に示す)で初期湿潤を介して含浸させた。次いで、含浸した結晶を、約250°F(約121℃)で一晩乾燥させ、その後約1000°F(約538℃)で約3時間、空気中で焼成した。
ZSM−5結晶(固形分として約1.4kg)を混合機に加え、乾燥加温した。次いで、加温の際、約190グラムの脱イオン水を加えた。約10分後、約450グラムの水と混合した約28グラムの約50重量%腐食性(水酸化ナトリウム)溶液を混合物に加え、更に約5分間加温した。次いで、混合物を約1/10’’四葉条物に押し出し成形した。押し出し成形物を、約250°F(約121℃)で一晩(約8〜16時間)乾燥させ、次いで約1000°F(約538℃)で約3時間、窒素中で前焼成した。次いで、押し出し成形物を、1Nの硝酸アンモニウムの水溶液で2回交換した。交換した触媒を、約250°F(約121℃)で一晩乾燥させ、次いで約1000°F(約538℃)で約3時間、空気中で焼成した。次いで、押し出し成形物を、リン酸水溶液を使用して、約2、約4、又は約6重量%のリンの目標濃度(実際の濃度を以下の表1に示す)で初期湿潤を介して含浸させた。次いで、含浸した結晶を、約250°F(約121℃)で一晩乾燥させ、その後約1000°F(約538℃)で約3時間、空気中で焼成した。
実施例1〜4のZSM−5を含む押し出し成形物を、リン含有量について分析し、約1000°F(約538℃)及び約14.7psia蒸気分圧で約96時間蒸気処理した。次いで、調製したままの触媒、及び蒸気処理したままの触媒を、定常のアルファ試験におけるヘキサン分解測定によって酸活性について分別した。実施例1〜4の押し出し成形物のアルファ値及びリン濃度を、以下の表1に示す。実施例1及び2のアルミナ含有触媒は、蒸気処理後の実施例3及び4のシリカが結合した触媒、及び自己結合した触媒よりはるかに低いアルファ活性を有することを、この結果は示している。蒸気処理後に約14及び約11アルファ値を保持するPを伴わない同一の触媒と比較して、約0.8重量%のPを伴うシリカが結合した触媒、及び自己結合した触媒はともに、蒸気処理後に約110アルファ値を保持する。
Claims (13)
- リン変性ゼオライト触媒の製造方法であって、
(a)別個の無機系酸化物バインダーの不在下、又は実質的にアルミニウムを有しない別個の無機系酸化物バインダーの存在下のいずれかにおいて、ゼオライト結晶を成形した触媒体に形成する工程;
(b)前記ゼオライト結晶を水素型に変換する工程;
(c)前記ゼオライト結晶の合成に使用されるいずれの有機構造規定剤も除去する工程;
(d)前記成形した触媒体をリン化合物の水溶液で処理する工程;及び
(e)前記処理した触媒体を加熱して、水を除去し前記リン化合物を酸化物型に変換する工程
を含む方法。 - 5重量%未満のアルミニウムを含む別個の無機系酸化物バインダーの存在下において、前記ゼオライト結晶を、成形した触媒体に形成する、請求項1に記載の方法。
- 前記ゼオライト結晶を、前記形成工程(a)の前にシリカバインダーと混合する、請求項1又は2に記載の方法。
- 前記形成工程(a)を、押し出し成形によって遂行する、請求項1〜3のいずれかに記載の方法。
- 前記変換工程(b)を、前記形成工程(a)の前に遂行する、請求項1〜4のいずれかに記載の方法。
- 前記除去工程(c)を、前記形成工程(a)の前に遂行する、請求項5に記載の方法。
- 前記処理工程(d)は、例えばリン酸素酸の水溶液を使用して含浸するなどの含浸によって遂行する、請求項1〜6のいずれかに記載の方法。
- (e)の前記加熱は、約0.2時間〜約5.0時間、約350℃〜約650℃の温度で実施する、請求項1〜7のいずれかに記載の方法。
- 前記ゼオライトは、約20〜約200、例えば約20〜約150のシリカのアルミナに対するモル比を有する、請求項1〜8のいずれかに記載の方法。
- 前記ゼオライトは、ZSM−5を含む、請求項1〜9のいずれかに記載の方法。
- 請求項1〜10のいずれかに記載の方法によって製造されるリン変性ゼオライト触媒。
- 有機化合物変換条件下、原料を請求項11に記載のリン変性ゼオライト触媒と接触させることを用いて有機化合物を変換する方法。
- 前記有機化合物変換は、メタノールをガソリンの沸点範囲で沸騰する炭化水素に変換することを含む、請求項12に記載の方法。
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