JP5625026B2 - Improved catalyst composition - Google Patents

Description

The present invention relates to an improved catalyst composition. Said catalysts are used to influence various chemical transformations, in particular for the production of alkylaromatic compounds, in particular ethylbenzene and cumene, or for example olefin dimers such as ethylene, propylene, butene or mixtures thereof. It is effective to be used in a method for oligomerization of olefins such as trimers, tetramers, and the like.

Ethylbenzene and cumene, respectively, are valuable chemical products used in the industrial production of styrene monomers and the industrial production of phenol and acetone. Although ethylbenzene is produced by a number of different chemical processes, one of the important steps to obtain a commercial product level product is in the presence of a solid and acidic ZSM-5 zeolite catalyst in the gas phase. Among them, alkylating benzene with ethylene. Such a process for preparing ethylbenzene is described in US Pat. 3,751,504 (Keown), 4,547,605 (Kresge), and 4,016,218 (Haag).

The liquid phase process operates at a lower temperature than the corresponding gas phase process and produces a small amount of by-products, so that it has recently attracted attention to produce ethylbenzene from benzene and ethylene in the liquid phase. For example, US Pat. 4,891,548 (Innes) discloses a liquid phase synthesis method of ethylbenzene using zeolite beta. On the other hand, US Pat. 5,334,795 (Chu) discloses the liquid phase synthesis of ethylbenzene using MCM-22.

For many years, cumene has been industrially produced by alkylating benzene with propylene using Friedel-Craft catalysts, particularly solid phosphorus or aluminum chloride. However, in recent years, it has been found that zeolite beta catalyst systems are more active and have better selectivity for propylating benzene to cumene. For example, US Pat. 4,992,606 (Kushnerick) discloses the use of MCM-22 when alkylating benzene with propylene in the liquid phase.

When the alkylation process for producing ethylbenzene and cumene is carried out in the presence of a catalyst used in recent years, a polyalkylated product is always obtained in addition to a monoalkylated product. Usually, the polyalkylation product is transalkylated with benzene to produce additional monoalkylation products, such as ethylbenzene or cumene, which are then recycled to the alkylation reactor. Circulated. Alternatively, more frequently, it is fed to another transalkylation reactor having a transalkylation catalyst to recycle the polyalkylation product. Catalysts used for alkylation of aromatic compounds such as alkylating benzene with ethylene or propylene and transalkylation of polyalkylated products such as polyethylbenzene and polypropylbenzene are described in US Pat. 5,557,024 (Cheng) and includes MCM-22, PSH-3, SSZ-25, zeolite X, zeolite Y, zeolite beta, acidic dealuminated mordenite, and TEA-mordenite. The transalkylation of TEA-mordenite on small (<0.5 micron) crystalline forms is also described in US Pat. 6,984,764.

When the alkylation step is performed in the liquid phase, the transalkylation step is also preferably performed under liquid phase conditions. However, since the liquid phase process operates at a relatively low temperature, the bulky polyalkylated product must be converted to additional monoalkylated product without producing undesirable side products. Technical requirements are imposed especially on the catalysts used in the transalkylation process. The problem of by-products has become a serious problem in the production of cumene. In the production of cumene, there is a problem that the existing catalyst lacks a desired activity or produces a large amount of by-products such as ethylbenzene and n-propylenebenzene.

In the present invention, the proton density index (PDI) as defined herein is greater than 1.0, for example greater than 1.0 to about 2.0, for example from about 1.01 to about 1.85. The catalyst thus produced is used as a catalyst for the production of monoalkylated products, in particular for the alkylation of benzene to ethylbenzene, cumene or sec-butylbenzene, as a catalyst for the production of monoalkylated products. It has been discovered that it has a unique combination of activity, and, importantly, selectivity. This can eliminate or reduce technical difficulties in transalkylation reactions for the conversion of undesirably bulky polyalkylated products.

FIG. 1 shows a shallow bed COVERN device used in an embodiment including the present invention.

In one aspect of the invention, an improved catalyst is provided. This catalyst is used to carry out chemical transformations, and particularly comprises the step of contacting an alkylatable aromatic compound with an alkylating agent in the presence of the catalyst of the present invention, particularly at least partially in the liquid phase. It is useful in a method for selectively producing the monoalkylated aromatic compound. The catalyst comprises an acidic porous crystalline material and has a PDI greater than 1.0, such as greater than 1.0 to about 2.0, such as from about 1.01 to about 1.85. Yes. Another aspect of the present invention comprises an acidic porous crystalline material and has a PDI greater than 1.0, such as greater than 1.0 to about 2.0, such as from about 1.01 to about 1.85. An improved catalyst for use in a process for selectively producing monoalkylbenzene comprising reacting an alkylating agent with benzene under alkylation conditions in which said alkylation catalyst is present . This catalyst may be, for example, an acidic, crystalline molecular sieve having a zeolite beta structure, or 1.24 ± 0.25, 9.6 ± 0.15, 3.57 ± 0.07, and 3.24 ± 0.00. Including those having an X-ray diffraction pattern exhibiting a maximum lattice spacing (d-spacing maxima) of 07 angstroms. The catalyst has a PDI greater than 1.0, such as greater than 1.0 to about 2.0, for example, about 1.01 to about 1.85. More specifically, the catalyst comprises an acidic crystalline molecular sieve having a zeolite beta structure, an MWW structure such as MCM-22, or a mixture thereof.

For the use of the catalyst of the invention to alkylate an alkylatable aromatic compound, the alkylating agent comprises an alkylated aliphatic group having 1 to 5 carbon atoms. The alkylating agent is, for example, ethylene, propylene, butene, and the alkylatable aromatic compound includes benzene in such a case.

Suitable catalysts for the present invention are materials of MWW structure type, such as MCM-22, PSH-3, SSZ-25, ERB-1, ITQ-1, ITQ-2, ITQ-30, MCM-36, MCM- 49, MCM-56, and acidic crystalline silicates having the structure of these mixtures.

The present invention relates to an improved catalyst for use in a chemical conversion process that benefits from high activity and / or selectivity. One such method involves the production of alkylatable aromatic compounds, particularly monoalkylated aromatic compounds by alkylating benzene, particularly ethylbenzene, cumene, sec-butylbenzene. Other such methods include methods for producing oligomers from olefins. More specifically, the catalyst composition of the present invention comprises an acidic porous crystalline material and has a PDI greater than 1.0, such as greater than 1.0 and up to about 2.0, such as about 1. Manufactured to have a PDI from 01 to about 1.85.

As used herein, the PDI, when used with a particular catalyst composition, measures the proton density of a freshly treated catalyst composition, measured at a given temperature, at the same given temperature. , Defined as the value divided by the proton density of the original untreated catalyst composition.

As used herein, the term “proton density” refers to the number of millimoles (mmol) of acidic and / or non-acidic protons per gram of catalyst composition. The proton density of both the freshly treated catalyst composition and the proton density of the original untreated catalyst composition are measured at room temperature, such as from about 20 ° C to about 25 ° C.

To characterize the amount of acidic and non-acidic protons on the catalyst sample as defined herein, the amount of protons on the catalyst sample can be measured by solid state nuclear magnetic resonance. These acidic and non-acidic protons are present as any hydrogen-containing moiety, or proton-containing moiety, including but not limited to H, H ⁺ , OH, OH ⁻ , and others. Nuclear magnetic resonance methods include, but are not limited to, magic angle spinning (MAS) NMR methods. Sample preparation is important when the amount of protons on a catalyst sample is measured by NMR. A small amount of water affects the fast ¹ H chemical exchange involving Bronsted acid sites and water molecules, greatly distorting the ¹ H NMR intensity.

The manufacturing method of the catalyst composition of this invention includes the following processes. (A); providing an untreated catalyst, that is, a first catalyst that has not been treated according to steps (b) and (c) of the present invention and comprises an acidic porous crystalline material. The first catalyst has a first hydration state measured in millimoles of proton per gram of catalyst. (B); the first catalyst of step (a) and water in a liquid phase or gas phase at a constant temperature of about 1 ° C. to about 500 ° C., preferably about 1 ° C. to about 99 ° C. A second catalyst having a second hydration state as measured in millimoles of proton per gram of catalyst for a period of at least 1 second, preferably from about 1 second to about 60 seconds at a temperature of Process. The second hydration state is greater than the first hydration state. That is, the product in step (b) has a higher proton density than the catalyst in step (a). (C); the second catalyst obtained in step (b) is preferably dried at a drying temperature of up to about 500 ° C., such as from about 20 ° C. to about 550 ° C., more preferably from about 100 ° C. to about 200 ° C .; Protons per gram of catalyst during the first and second hydration states with a drying time of about 0.01 hours, preferably about 0.1 to about 24 hours, more preferably about 1 to about 6 hours. Producing a catalyst composition having a third hydration state measured in millimoles. The product of step (c) has a proton density index greater than 1.0, for example greater than 1.0 to about 2.0, for example from about 1.01 to about 1.85.

During the drying step (c), acidic and / or non-acidic protons are removed from the catalyst contacted with the liquid or gaseous water formed in step (b). However, step (c) is carried out so as not to remove substantially all acidic and / or non-acidic protons of the catalyst obtained in step (b). The hydration state of the product of step (c) is higher than the catalyst of the starting step (a) and lower than the product of step (b). Increasing proton density does not simply mean that Lewis acid has been converted to Bronsted acid. While not intending to constrain the action relating to the present invention to any theory, a catalyst comprising an acidic porous crystalline material and having a first hydration state is selected for a specific temperature and time, liquid or gas. It can be considered that a catalyst having a second hydration state higher than the first hydration state is produced by contacting with water. This is followed by a controlled drying time and drying step under drying conditions in relation to the chemical reaction, the nature, type and / or amount of acidic and / or non-acidic protons on such a catalyst. To produce a catalyst composition having a third hydration state between the first and second hydration states, the catalyst composition having a proton density index greater than about 1.0. It will be. That is, such a catalyst composition containing an acidic porous crystalline material and treated with the method of the present invention is more in comparison with a catalyst of the same composition that has not been treated with such a method. Has a high proton density and / or a large number of acidic and non-acidic protons. In other words, the PDI was prepared in the same way and measured in the same way, divided by the proton density of the catalyst composition in the first hydration state divided by the proton density of the catalyst composition in the third hydration state. Is defined as

The term “aromatic” is understood in the technical field to which the invention pertains, which means an alkylatable aromatic compound which is useful as a raw material in processes where it is advantageous to use the catalyst of the invention. . The aromatic compound includes an alkyl-substituted and / or unsubstituted monocyclic or polycyclic compound. Aromatic compounds having heteroatoms are also useful.

Aromatic compounds suitable for alkylation herein have at least one hydrogen atom bonded directly to the aromatic ring. The aromatic ring may be substituted with one or more alkyl or aryl, alkaryl, alkoxy, aryloxy, cycloalkyl, halide, and / or other groups that do not interfere with the alkylation reaction.

Suitable aromatic compounds include benzene, naphthalene, anthracene, naphthacene, perylene, coronene, and phenanthrene, with benzene being preferred.

Generally, an alkyl group present as a substituent on an aromatic compound contains 1 to about 22 carbon atoms, and usually about 1 to about 8 carbon atoms, most commonly about 1 to about 4 carbon atoms. .

Suitable alkyl-substituted aromatic compounds are toluene, xylene, isopropylbenzene, n-propylbenzene, alpha-methylnaphthalene, ethylbenzene, methene, durene, cymene, butylbenzene, pseudocumene, o-diethylbenzene, m-diethylbenzene, p-diethylbenzene. , Isoamylbenzene, isohexylbenzene, pentaethylbenzene, pentamethylbenzene, 1,2,3,4-tetraethylbenzene, 1,2,3,5-tetramethylbenzene, 1,2,4, -triethylbenzene, 1, 2,3-trimethylbenzene, m-butyltoluene, p-butyltoluene, 3,5-diethyltoluene, o-ethyltoluene, p-methyltoluene, m-propyltoluene, 4-ethyl-m-xylene, dimethylnaphtha Including phenanthrene - down, ethyl naphthalene, 2,3-dimethyl anthracene, 9-ethyl-anthracene, 2-methyl anthracene, o- methyl anthracene, 9,10-dimethyl-phenanthrene, and 3-methyl. High molecular weight alkyl aromatic compounds can also be used as starting materials, including aromatic hydrocarbons produced by alkylating aromatic hydrocarbons with olefin oligomers. Such products are referred to in the art as alkylates and are hexylbenzene, nonylbenzene, dodecylbenzene, pentadecylbenzene, hexyltoluene, nonyltoluene, dodecyltoluene, pentadecyltoluene. Etc. Very common alkylates are those obtained as high boiling fractions in which the alkyl group appended to the aromatic ring can vary in size from about C _{6 to} about C ₂₀ . When cumene or ethylbenzene is a given product, the process of the present invention produces an acceptable or little by-product such as ethylene. The xylene content produced in such cases is less than about 500 ppm.

A reformate comprising a mixture of benzene, toluene, and / or xylene is a particularly useful feed for the alkylation process useful for using the catalyst of the present invention.

Alkylating agents useful as feedstocks for processes useful for using the catalysts of the present invention are typically capable of reacting with alkylatable aromatic compounds, preferably having alkyl groups having 1 to 5 carbon atoms. It includes any aliphatic or aromatic compound that can have one or more available alkylated aliphatic groups. Examples of suitable alkylating agents include olefins such as ethylene, propylene, butenes and pentenes (including 1-butene, 2-butene, and mixtures thereof), methanol, ethanol, propanol, butanol, and pentanol. Alcohols (including monoalcohol, dialcohol, and toei alcohol), aldehydes such as formaldehyde, acetaldehyde, propionaldehyde, butyraldehyde, and n-valeraldehyde, methyl chloride, ethyl chloride, propyl chloride, butyl chloride, and pentyl Includes alkyl halides such as chloride.

A mixture of light olefins is useful as an alkylating agent in the alkylation process using the catalyst of the present invention. Mixtures of light olefins are also useful as reactants in the oligomerization process of the present invention. Therefore, ethylene, propylene, butene, which are the main components of various purification streams, such as off-gas from gas plants containing fuel gas, ethylene, propylene, etc., naphtha cracking off-gas containing light olefins, purified FCC propane / propylene stream, etc. And / or mixtures of pentenes are also useful alkylating agents and oligomerization reactants. For example, a typical FCC light conversion olefin stream contains the following components:

Products obtained using the catalyst of the present invention are ethylbenzene obtained by reacting benzene with ethylene, cumene obtained by reacting benzene with propylene, ethyltoluene obtained by reacting toluene with ethylene, toluene And sec-butylbenzene from the reaction product of benzene and a mixture of heavy olefins obtained from n-butene (s) and oligomers of light olefins. Particularly preferred uses of the catalyst of the present invention are the production of cumene alkylated with benzene using propylene, the production of ethylbenzene by alkylating benzene with ethylene, and the alkylation of benzene with butene. Related to the production of sec-butylbenzene and oligomerization of ethylene, propylene, butylene, or mixtures thereof.

Organic conversion processes intended for use with the catalyst of the present invention include, but are not limited to, alkylation of aromatics and oligomerization of olefins. The organic conversion process contacts the reactants with the required catalyst in a suitable reaction zone, such as, for example, a fluidized bed reactor containing a fixed bed of the catalyst composition, under effective conversion conditions. Is done. Such conditions include a temperature of about 0 ° C. to about 1000 ° C., preferably about 0 ° C. to about 800 ° C., about 10.1 kPa-a (0.1 atm) to about 100,000 kPa-a (100 atm), Preferably, the pressure is about 12.5 kPa-a (0.125 atm) to about 50,000 kPa-a (500 atm), and about 0.01 to 500 hr ⁻¹ , preferably about 0.1 to about 100 hr ⁻¹ . Includes weight space velocity (WHSV) of raw material. When using a batch reactor, the reaction time is about 1 minute to about 100 hours, preferably about 1 hour to about 10 hours.

The alkylation process using the catalyst of the present invention comprises a fluidized reactor comprising an organic reactant, i.e. an alkylatable aromatic compound and an alkylating agent, under suitable alkylation conditions, e.g. a fixed bed of the catalyst composition. Contacting with the catalyst of the present invention in a suitable reactor such as Such conditions include a temperature of about 0 ° C. to about 500 ° C., preferably about 10 ° C. to about 260 ° C., about 20 kPa-a (0.2 atm) to about 25,000 kPa-a (250 atm), preferably Alkylation from about 101 kPa-a (1 atm) to about 5,500 kPa-a (55 atm), from about 0.1: 1 to about 50: 1, preferably from about 0.5: 1 to about 10: 1 A molar ratio of possible aromatic compounds to alkylating agents, and weight space velocities of raw materials based on alkylating agents of from about 0.1 to about 500 hr ⁻¹ , preferably from about 0.5 to about 100 hr ⁻¹ .

The reactants can be present in the gas phase or partially or completely in the liquid phase and are intact, i.e., not mixed or diluted with other materials. Alternatively, the reactants may be contacted with the alkylation catalyst composition using, for example, a carrier gas or diluent such as hydrogen or nitrogen.

When alkylating benzene with ethylene to produce ethylbenzene, the alkylation reaction is preferably performed at a temperature of about 150 ° C. to about 300 ° C., more preferably about 170 ° C. to about 260 ° C., about 20,000 kPa-a (200 Pressure), more preferably from about 2,000 kPa-a (20 atm) to about 5,500 kPa-a (55 atm), from about 0.1 to about 20 hr ⁻¹ , more preferably from about 0.5 to about Weight hourly space velocity (WHSV) based on an ethylene alkylating agent of 6 hr ⁻¹ and benzene in a reactor of about 0.5: 1 to about 30: 1, more preferably about 1: 1 to about 10: 1. It is preferably carried out in the liquid phase containing the molar ratio to ethylene.

When alkylating benzene with propylene to produce cumene, the reaction is carried out at a temperature of up to about 250 ° C, preferably up to about 150 ° C, such as from about 10 ° C to about 125 ° C, about 25,000 kPa-a (250 pressure) or less, for example, about 101 kPa-a (pressure 1 atm) to about 3,000 kPa-a (30 atm), about 0.1 hr ^-1 or about 250 hr ^-1, preferably from about ^{1hr -1} to about 50 hr ^- A liquid phase comprising a weight hourly space velocity (WHSV) based on ^one propylene alkylating agent and a benzene to propylene molar ratio of from about 0.5: 1 to about 30: 1, more preferably from about 1: 1 to about 10: 1. Done under.

When alkylating benzene with an alkylating agent selected from the group consisting of 1-butene, 2-butene, and mixtures thereof to produce sec-butylbenzene, the reaction is carried out at about 50 ° C to about 250 ° C, preferably A temperature of about 100 ° C. to about 200 ° C., about 350 kPa-a (3.5) to about 3,500 kPa-a (35 atm), preferably about 700 kPa-a (7 atm) to about 2,700 kPa-a (27 Pressure), a weight hourly space velocity (WHSV) based on a propylene alkylating agent of about 0.1 to about 20 hr ⁻¹ , preferably about 1 to about 10 hr ⁻¹ , and about 1: 1 to about 10: 1, preferably Is carried out under a liquid phase comprising a molar ratio of benzene to butene alkylating agent of from about 1: 1 to about 4: 1.

The catalyst of the present invention can be one or more acidic porous crystalline materials, or zeolite beta (described in US Pat. No. 3,308,069), or such as 12.4 ± 0.25, 6.9 ± 0.00. Includes molecular sieves of the structure of the MWW structure type, including X-ray diffraction patterns including lattice spacing maximums at 15, 3.57 ± 0.07, and 3.42 ± 0.07 angstroms.

As used herein, the term “acidic porous crystalline material” refers to a porous crystalline material or a porous crystalline material or molecular sieve containing sufficient acidic protons to promote a hydrocarbon conversion reaction. means.

MWW structure type materials include MCM-22 (described in U.S. Pat. No. 4,954,325), PSH-3 (described in U.S. Pat. No. 4,439,409), SZ-25 (U.S. Pat. 826, 667), ERB-1 (described in European Patent No. 093032), ITQ-1 (described in US Patent No. 6,077,498), ITQ-2 (US Patent No. 6,231,751). ITQ-30 (described in WO 2005/118476), MCM-36 (described in US Pat. No. 5,250,277), MCM-49 (described in US Pat. No. 5,236,575), and MCM-56 (described in US Pat. No. 5,362,697). The catalyst may include unbonded or self-bonded molecular sieves, or the molecular sieves may be bonded using an oxidizing binder as is conventional, as described in detail below. In certain products of the catalyst, the average particle size of the catalyst or acidic porous crystalline material, or molecular sieve component is from about 0.05 to about 200 microns, such as from 20 to 200 microns.

When used as a catalyst for alkylation, the alkylation reactor effluent contains excess aromatic feed, monoalkylation product, polyalkylation product, and various impurities. The aromatic feed is recovered by distillation and recycled to the alkylation reactor. Usually, a portion of the recycle stream is removed to remove unreactive impurities from the loop. The material at the bottom of the distillation section is further distilled to separate the monoalkylated product from the polyalkylated product and other heavy components.

The polyalkylation product separated from the alkylation reactor effluent is reacted in a transalkyl reactor with additional aromatic feed over a suitable transalkylation catalyst and separated from the alkylation reactor. . The transalkylation catalyst is a mixture of one or more acidic porous crystalline materials, or zeolite beta, zeolite Y, mordenite, or 12.4 ± 0.25, 6.9 ± 0.15, 3.57. Includes molecular sieves of the structure of the MWW structure type, including X-ray diffraction patterns including maximum lattice spacing at ± 0.07 and 3.42 ± 0.07 angstroms.

X-ray diffraction data used to characterize the catalyst structure was conventionally obtained using an analyzer equipped with a copper K-alpha doublet as incident radiation, and a computer associated as a scintillation counter and (data) collection system. It can obtain by the method of. Examples of the substance having the X-ray diffraction line include MCM-22 (described in US Pat. No. 4,954,325), PSH-3 (described in US Pat. No. 4,439,409), SSZ-25 ( US Patent No. 4,826,667), ERB-1 (described in European Patent No. 093032), ITQ-1 (described in US Patent No. 6,077,498), ITQ-2 (US Patent No. No. 6,231,751), ITQ-30 (described in WO2005-118476), MCM-36 (described in US Pat. No. 5,250,277), MCM-49 (described in US Pat. No. 5,236,) 575), and MCM-56 (described in US Pat. No. 5,362,697), with MCM-22 being particularly preferred.

Zeolite beta is disclosed in US Pat. 3,308,069. Zeolite Y and mordenite may be natural, but U.S. Pat. U.S. Pat. No. 3,449,070, Ultrastable Y (USY), U.S. Pat. Rare earth exchanged Y (REY) described in U.S. Pat. One of the synthetic forms such as TER-mordenite described in 3,766,093 and 3,894,104 (ie, synthetic mordenite prepared from a reaction mixture containing tetraethylammonium directing agent) may be used. However, when TEA-mordenite is used as a transalkylation catalyst, the specific synthesis system described in the aforementioned patent is a mordenite product mainly comprising large crystals larger than 1 micron, usually 5 to 10 microns. Will result in Controlling the synthesis so that the resulting TEA-mordenite has an average crystal size of less than 0.5 microns yields a transalkylation catalyst having substantially enhanced activity for transalkylation in the liquid phase. .

The small crystalline TEA-mordenite required for transalkylation can be produced by crystallization from a synthetic mixture having a molar composition in the following range.

Crystallization is performed at a temperature of 90 to 200 ° C., for example, for 6 to 180 hours.

The catalyst of the present invention may contain an organic oxidant substrate or binder. Such substrate materials include synthetic or natural materials in addition to organic materials such as clay, alumina, silica, and / or metal oxides. The former is either natural or in the form of a gelatinous precipitate or gel of a mixture of silica and metal oxide. Natural clays composed of organic oxides include the montmorillonite and kaolin families. These are known as Dixie, McNamee, Georgia, and Froida clays, or others whose main constituents are halosite, kaolinite, dickite, nacrite, or anaxite, subbentonites and kaolins (such as ) Family. Such clays can be used as mined or after calcination, acid treatment, or chemical modification.

Certain useful catalyst matrix or binder materials used herein are silica, alumina, zirconia, titania, silica-alumina, silica-magnesia, silica-zirconia, silica-tria, silica-beryllia, silica-titania and others. And ternary materials such as silica-alumina-tria, silica-alumina-zirconia, silica-alumina-magnesia, and silica-magnesia-zirconia. The substrate may be in the form of a cogel. Mixtures of these components can also be used.

When the acidic porous crystalline material or molecular sieve and the binder or substrate are present, the relative proportions vary widely, and the content of the crystalline material or molecular sieve relative to the total catalyst is about 1 to about 99 weight percent. More typically from about 30 to about 80 weight percent. Of course, the catalyst may comprise a self-bonded material, or self-bonded molecular sieve, or an unbound material or unbound molecular sieve, and therefore the content of acidic porous crystalline material or molecular sieve. May be about 100%.

The catalyst of the present invention or its acidic porous crystalline material, or molecular sieve component may be, for example, a Group VI metal (eg, Cr and Mo), a Group VII metal (eg, Mn and Re), or a Group VIII metal (eg, Co, Ni, Pd, and Pt) or additional functionalities such as phosphorus may or may not be included.

Test Method The apparatus and raw material pretreatment method used in the non-limiting examples of the present invention are described below.

Apparatus A 300 ml Parr batch reaction tube equipped with a stir bar and a fixed catalyst basket was used for activity and selectivity measurements. The reaction tube was equipped with two removable tubes for introducing benzene and propylene, respectively.

Raw material pre-treatment Commercial grade benzene was prepared using Molecular Sieve 13X, Molecular Sieve 4A, Engelhard F-24 Clay, and Selexsorb CD. Polymer grade propylene obtained from a specific commercial gas phase source was prepared using Molecular Sieve 5A and Selexsorb CD. Ultra high purity nitrogen obtained from a specific commercial gas phase source was prepared using Molecular Sieve 5A and Selexsorb CD. All raw material treated materials were dried at 260 ° C. for 12 hours before use. Benzene, propylene, and nitrogen as used below refer to commercial grade benzene polymer grade propylene and ultra high purity nitrogen, respectively, and those that have been pretreated as described herein.

The following NMR method for determining proton density was used in the non-limiting examples of the present invention.

NMR method for determining proton density In the present invention, the NMR method for determining the proton density of the catalyst sample was performed as follows. The proton density of the catalyst sample was determined using a shallow bed COVERN device as shown in FIG. As shown in FIG. 1, the COVERN device is composed of an upper housing 5 and a lower housing 6, which are connected by a joint 12, and a mechanism 11 for lifting a glass trap door 16 on a catalyst bed 14, a vacuum line 20. The apparatus to be used and the heating means through the thermocouple 13 are provided. A glass tube 17 having an outer diameter of 5 mm is slid onto a 3 mm stainless steel rod 15 so as to cover the rod, and is positioned between the end cap 18 and the glass trap door 16. The stainless steel rod 15 is retracted by rotating the mechanism 11 so that the glass tube 17 lifts the glass trapper 16 over the catalyst bed 14. By gently rotating or shaking the COVERN device, a catalyst sample (not shown) falls into the MAS rotor 19. This method is effective for zeolite and metal oxide powders. Details regarding the operation of the COVERN device can be found in Xu, T .; Haw, J .; F. Top. Catal. 1997, 4, 109-118. This document is incorporated herein by reference.

To determine the proton density of the catalyst sample, the catalyst sample is thinly laid in the catalyst bed 14 of the COVERN device, and the temperature of the catalyst sample via thermocouple 13 is adjusted to a temperature suitable for the evaluation of the catalyst sample (before the specific NMR). The water was absorbed on the catalyst sample by the vacuum line 20 and was sufficiently removed. Typically, the catalyst sample is pretreated at a suitable temperature under such vacuum for 2 hours prior to MNR measurement.

The catalyst sample thus prepared is placed on a 5 mm NMR rotor, such as MAS rotor 19, the COVERN device is operated and the rotor is sealed with a Kel-F end cap. All operations are performed while the catalyst sample is being vacuumed to complete the sample for NMR testing. After a suitable NMR spectrum was obtained, the weight of the catalyst sample and the MAS 19 rotor containing the end cap 18 was measured to determine the weight of the end cap on the rotor and unpacked catalyst sample. The difference between the two weights is the amount of catalyst sample in the MAS rotor 19.

¹ H NMR tests were performed on a 400 MHz solid state NMR spectrometer operating at 399.8 MHz for ¹ H. Quantification of the ¹ H spectrum is obtained by using a rotor synchronized spin echo sequence (π / 2−t _D1 −π−t _D2 −Echo) using a spin speed of 8 to 12 kHz. Typically, 3.5-μs π / 2 pulses, 125-μs t _D1 , and 113.1 μs t _D2 are used for a spin speed of 9 kHz. The spectrum obtained using the solid echo sequence may show some background signal due to the spinning module and the end cap 18 of the MAS rotor 19. Background noise is removed from this spectrum by solid echo sequencing using DEPTH. The DEPTH sequence consists of 90 ° pulses (3.5-μs) first, followed by two 180 ° pulses. For a description of the DEPTH sequence, see Corey, D. et al. G. Ritchey, W .; M.M. J. et al. Magn. Reson. 1998, 80, 128. This document is incorporated herein by reference. A 10 second pulse delay is sufficient to quantify the proton density of the catalyst sample being tested. Acetone was used as the second standard for ¹ H shift (2.1 ppm). All shifts recorded were referenced to 0 ppm tetramethylsilane.

Various “as-synthesized” acidic porous crystalline materials have not been treated by the method of the present invention and are therefore in the first hydrated state of the present invention, the proton density of which is It becomes as follows.

Of course, these acidic porous crystalline materials in the third hydrated state treated by the method of the present invention have a proton density greater than the proton density of the same material in the first hydrated state described above. ing.

The following method for determining the proton density index (PDI) was used to illustrate a non-limiting example of the present invention.

Determination of proton density index The PDI of a particular catalyst composition is determined by the ratio of the proton density of the newly treated catalyst composition to the proton density of the original untreated catalyst composition. Such newly treated catalyst compositions are treated using the proton regulation techniques described herein or other techniques that can change proton density. The original untreated catalyst composition may or may not have been treated using the proton regulation techniques described herein or other techniques that can change the proton density. As mentioned above, the term “proton density” means the number of millimoles (mmol) of acidic and / or non-acidic protons per gram of catalyst composition. The proton density of the freshly treated catalyst composition and the proton density of the original untreated catalyst composition are measured at the same temperature, for example, a room temperature of about 20 ° C. to about 25 ° C. Therefore, the PDI of a particular catalyst composition is determined by replacing the newly treated catalyst composition measured at a given temperature with the proton density of the original untreated catalyst composition measured at the same given temperature. It is decided by dividing by.

The NMR spectrometer used to determine proton density is a Varian Infinity Plus 400 MHz solid state NMR with an Oxford AS400 magnet.

In the non-limiting examples of the present invention, the following catalytic activity measurement method was used.

Catalytic activity test method To prepare a catalyst composition for reactivity test, a specific amount of catalyst sample was placed in the presence of air at an ex-situ drying temperature (hereinafter referred to as "specific Ex-suit drying"). And dried for 2 hours in an oven. The catalyst sample was removed from the oven and weighed. A quartz chip was laid under the basket and the catalyst sample was placed in the basket above the first layer of quartz. The quartz chip was then placed on the catalyst sample. The basket containing the catalyst sample and crystal was dried in the presence of air for 16 hours in an oven at a specific Ex-situ drying temperature.

The reactor and all lines were washed with a suitable solvent (such as toluene) before each test. The reactor and all lines were air dried to remove any wash solvent. The basket containing the catalyst sample and crystal was removed from the oven and immediately placed in the reactor to assemble the reactor. The reactor temperature was set to in-situ drying temperature (hereinafter referred to as “specific In-situ drying temperature”) and purged with 100 SCCM of nitrogen for 2 hours.

The reactor temperature was then reduced to 130 ° C., the nitrogen purge was stopped, and the reactor vent was closed. 156.1 grams of benzene was added to a 300 ml (cc) transport tube and tested in a closed system. After applying a pressure of 790 kPa-a (100 psig) from a nitrogen source to the benzene tube, the benzene was transferred to the reactor. The agitation speed was set to 500 rpm and the reactor was allowed to equilibrate for 1 hour.

A 75 cc Hoke transport tube was filled with 28.1 grams of liquid propylene, connected to a reaction tube, and a 2.69 kPa-a (300 psig) nitrogen source was connected. After 1 hour of benzene stirring time, the propylene was transported from the Hoke transport tube to the reactor. A 2.69 kPa-a (300 psig) nitrogen source was left coupled to the propylene tube and the reactor was opened during the test time to maintain the pressure at 2.69 kPa-a (300 psig). The liquid product samples were sampled 30, 60, 120, 150, 180, and 240 minutes after the addition of propylene. These samples were then analyzed by gas chromatography with a Flame Ionization Detector in a manner known to those skilled in the art.

In these examples, the selectivity of the catalyst sample for the desired isopropylbenzene (cumene) product (hereinafter “catalytic selectivity”) is isopropylbenzene (IPB / IP) over diisopropylbenzene after propylene conversion reaches 100%. Calculated as the ratio of DIPB). A higher IPB / DIPB ratio means that the catalyst sample has a higher selectivity for isopropylenebenzene (cumene). In these examples, the catalytic activity of a catalyst sample (hereinafter “catalytic activity”) was determined by calculating a second order dynamic rate coefficient using mathematical techniques well known to those skilled in the art.

The following proton content adjustment techniques were used in the tests described in the non-limiting examples of the present invention.

Proton content control technology
A. Proton content control technology # 1
In one embodiment of the present invention, a catalyst sample containing an acidic porous crystalline material and having a first hydration state measured in millimoles of proton per gram of catalyst is placed in a suitable container. Liquid water, in particular deionized water, was slowly put into the container from below and the catalyst sample was evacuated. Water was added until the sample was completely immersed in the water, and the water level reached about 1/4 ″ (0.635 cm) above the catalyst sample. The catalyst sample and water were allowed to flow for at least about 1 second, preferably about 1 A catalyst sample having a second hydration state was produced by standing for a specific contact time (hereinafter referred to as “contact time”) of minutes to about 60 minutes or more. The second hydration state has a higher value than the first hydration state (measured in millimoles of proton per gram of catalyst). After the contact time, the water is poured into another container, the catalyst sample is allowed to air dry at room temperature for at least 8 hours, and has a third hydration state (measured in millimoles per gram of catalyst sample). Got.

B. Proto content adjustment technology # 2
A sample of the catalyst may be in a gas phase (which may or may not contain a suitable support such as nitrogen), a specific contact temperature (hereinafter referred to as “contact temperature”) and a specific contact pressure (hereinafter referred to as “contact pressure”). )) In contact with water.

In a further embodiment of the invention, the catalyst sample treated with proton content adjustment technique # 1 is then treated with proton content adjustment technique # 2.

In yet another embodiment of the invention, the catalyst sample is first treated with proton content adjustment technique # 2 and then with proton content adjustment technique # 1.

Non-limiting examples of catalyst samples produced by the method of the present invention and the use of such catalyst samples for alkylation tests are illustrated by reference to the following examples.

Example 1
The catalyst sample of Example 1 consists of 80% by weight of MCM-49 and 20 wt% of alumina _(Al 2 _{O 3).} The proton density was determined by the NMR procedure for proton density measurement described above at a specific NMR pretreatment temperature of 250 ° C. The proton density was 1.71 mmol per gram of catalyst (first hydration state).

A 0.5 gram portion of the catalyst sample of Example 1 was tested using the catalytic reactivity test method described above at a specific Ex-situ drying temperature of 250 ° C and a specific In-situ drying temperature of 170 ° C. . The catalyst selectivity of this catalyst sample was 5.92 as measured by isopropylbenzene versus diisopropylbenzene (IPB / DIPB). The catalyst activity of this catalyst sample was 363.

Example 2
Another portion of the catalyst sample of Example 1 was treated with Proton Content Control Technique # 1 at a specific contact time of about 1 hour to provide a treated catalyst sample of Example 2 having a third hydration state. Got. The proton density of the third hydrated state of this treated catalyst sample was measured using the NMR method for determining proton density in the manner described above at a specific NMR pretreatment temperature of 250 ° C. 1.85 mmol per gram (third hydration state).

For the 0.5 gram portion of the treated catalyst sample of Example 2, using the above-described catalytic reactivity test method at a specific Ex-situ drying temperature of 250 ° C. and a specific In-situ drying temperature of 170 ° C. A test was conducted. The catalyst selectivity of this catalyst sample was 6.94 as measured by IPB / DIPB. The catalyst activity of this catalyst sample was 383.

The PDI of the catalyst sample of Example 2 was 1.08, which increased the 8% proton content (measured in mmol of protons per gram of catalyst) compared to the catalyst sample of Example 1. Compared to the catalyst sample of Example 1, the catalyst selectivity (IPB / DIPB) of the catalyst sample of Example 2 was increased by 17% and the catalyst activity was increased by 5.5%.

Example 3
The catalyst sample of Example 3 consists of 80 wt% zeolite beta and 20 wt% alumina. The proton density was determined by the NMR procedure for proton density measurement described above at a specific NMR processing temperature of 250 ° C. The proton density was 2.48 mmol per gram of catalyst (first hydration state).

A 1.0 gram portion of the catalyst sample of Example 3 was tested using the above-described catalytic reactivity test method at a specific Ex-situ drying temperature of 250 ° C. and a specific In-situ drying temperature of 170 ° C. It was. The catalyst selectivity of this catalyst sample was 5.62 as measured by IPB / DIPB. The catalyst activity of this catalyst sample was 23.

Example 4
Another portion of the catalyst sample of Example 3 was tested using the proton content adjustment technique # 1 at a specific contact time of about 1 hour, and the treated catalyst sample of Example 4 having a third hydration state Got. The proton density of this treated catalyst sample was measured using the NMR method for determining proton density in the manner described above at a specific NMR pretreatment temperature of 250 ° C. and determined to be 2.77 mmol ( (Third hydration state).

A 1.0 gram portion of the catalyst sample of Example 4 was tested using the catalytic reactivity test method described above at a specific Ex-situ drying temperature of 250 ° C. and a specific In-situ drying temperature of 170 ° C. . The catalyst selectivity of this catalyst sample was 9.35 as measured by IPB / DIPB. The catalyst activity of this catalyst sample was 4.

The PDI of the catalyst sample of Example 4 was 1.12 and had an increased 12% proton content (measured in mmol of protons per gram of catalyst) compared to the catalyst sample of Example 3. Compared to the catalyst sample of Example 3, the catalyst selectivity (IPB / DIPB) of the catalyst sample of Example 2 was increased by 66% and the catalyst activity was 17.4% of the catalyst sample of Example 3.

Example 5
The catalyst sample of Example 1 was treated with steam saturated nitrogen according to proton content adjustment technique # 2 at a contact temperature of 200 ° C. and a contact pressure of 445 kPa-a (50 psig). The resulting catalyst was treated with Proton Content Control Technique # 1 to obtain a treated catalyst sample of Example 5 having a third hydration state. The proton density of this treated catalyst sample was measured using the NMR method for determining proton density in the manner described above at a specific NMR pretreatment temperature of 250 ° C. and determined to be 1.76 mmol ( (Third hydration state).

A 0.5 gram portion of the treated catalyst sample of Example 5 was tested using a catalytic reactivity test method at a specific Ex-situ drying temperature of 250 ° C and a specific In-situ drying temperature of 170 ° C. went. The catalyst selectivity of this catalyst sample was 6.80 as measured by IPB / DIPB. The catalyst activity of this catalyst sample was 377.

The PDI of the catalyst sample of Example 5 was 1.03, which increased the 3% proton content (measured in mmol of protons per gram of catalyst) compared to the catalyst sample of Example 1. Compared to the catalyst sample of Example 1, the catalyst selectivity (IPB / DIPB) of the catalyst sample of Example 5 was increased by 15% and the catalyst activity was increased by 4%.

Example 6
The catalyst sample of Example 6 consists of 80 wt% MCM-49 and 20 wt% alumina. The proton density was determined by the NMR procedure for proton density measurement described above at a specific NMR pretreatment temperature of 150 ° C. The proton density was 2.59 mmol per gram of catalyst (first hydration state).

For the 0.5 gram portion of the treated catalyst sample of Example 6, using the catalytic reactivity test method described above at a specific Ex-situ drying temperature of 150 ° C. and a specific In-situ drying temperature of 150 ° C. A test was conducted. The catalyst selectivity of this catalyst sample was 5.92 as measured by the weight ratio of isopropylbenzene to diisopropylbenzene (IPB / DIPB). The catalyst activity of this catalyst sample was 275.

Example 7
Another portion of the catalyst sample of Example 6 was tested using Proton Content Control Technique # 1 at a specific contact time of about 1 hour, and the treated catalyst sample of Example 7 having a third hydration state Got. The proton density of the third hydrated state of this treated catalyst sample was measured using the NMR method for determining proton density by the method described above at a specific NMR pretreatment temperature of 150 ° C. 3.16 mmol per gram (third hydration state).

For the 0.5 gram portion of the treated catalyst sample of Example 7, using the catalytic reactivity test method described above at a specific Ex-situ drying temperature of 150 ° C. and a specific In-situ drying temperature of 150 ° C. A test was conducted. The catalyst selectivity of this catalyst sample was 7.81 as measured by the weight ratio of IPB / DIPB. The catalyst activity of this catalyst sample was 251.

The catalyst sample of Example 7 had a PDI of 1.22 and an increased 22% proton content (measured in mmol of protons per gram of catalyst) compared to the catalyst sample of Example 6. Compared to the catalyst sample of Example 6, the catalyst selectivity (IPB / DIPB) of the catalyst sample of Example 7 is increased by 32%, and the catalyst activity is 91% of the catalyst sample of Example 6, slightly decreased. Was.

Example 8
The catalyst sample in this example consists of 65 wt% MCM-22 and 35 wt% alumina. The proton density was determined by the NMR procedure for proton density measurement described above at a specific NMR processing temperature of 250 ° C. The proton density was 1.46 mmol per gram of catalyst (first hydration state).

A 1.0 gram portion of the catalyst sample of Example 8 was tested using the catalytic reactivity test method described above at a specific Ex-situ drying temperature of 250 ° C. and a specific In-situ drying temperature of 170 ° C. It was. The catalyst selectivity of this catalyst sample was 5.46 as measured by weight ratio of isopropylbenzene to diisopropylbenzene (IPB / DIPB). The catalyst activity of this catalyst sample was 272.

Example 9
A part of the sample of Example 8 in which at least one part was deactivated was regenerated by the following two steps. First, the catalyst sample was heated at a temperature of 385 ° C. in an atmosphere having 2.0 vol% hydrogen and hydrocarbons. The oxygen concentration was first increased to 0.4% by volume and then again increased to 0.7% by volume while the catalyst temperature reached a maximum of 467 ° C. Next, the catalyst is heated to 450 ° C. in 101 kPa-a (1 atm) having an oxygen concentration of 0.7 vol% and the oxygen concentration is brought to 7.0 vol% while maintaining the maximum catalyst temperature at 510 ° C. Increased.

This catalyst sample was treated according to Proton Content Control Technique # 1 with a contact time of about 1 hour to obtain a treated catalyst of Example 9 having a third hydration state. The proton density of this treated catalyst was determined using the MNR method for determining proton density, as described above, at a specific NMR processing temperature of 250 ° C., and 1.97 mmol per gram of catalyst. (Third hydration state).

Using the catalytic reactivity test method described above for a 1.0 gram portion of the treated catalyst sample of Example 9 at a specific Ex-situ drying temperature of 250 ° C. and a specific In-situ drying temperature of 170 ° C. The test was conducted. The catalyst selectivity of this catalyst sample was 6.29 as measured by IPB / DIPB weight ratio. The catalyst activity of this catalyst sample was 174.

The catalyst sample of Example 9 had a PDI of 1.35 and an increased 35% proton content (measured in mmol of protons per gram of catalyst) compared to the catalyst sample of Example 8. Compared to the catalyst sample of Example 8, the catalyst selectivity (IPB / DIPB) of the catalyst sample of Example 9 was increased by 15% and the catalyst activity was 64% of the catalyst sample of Example 8.

Example 10
The catalyst sample of Example 6 was treated in steam saturated nitrogen with a contact time of 220 ° C. and a contact pressure of 445 kPa-a (50 psig) according to proton content control technique # 2. The resulting catalyst sample was treated with Proton Content Control Technique # 1 to obtain a treated catalyst sample of Example 10 having a third hydration state. The proton density of the treated catalyst sample was determined using the NMR procedure described above for adjusting proton density at a specific NMR pretreatment temperature of 150 ° C. The proton density was 2.67 mmol per gram of catalyst (third hydration state).

A 0.5 gram portion of the treated catalyst sample of Example 10 was tested according to the catalytic reactivity test method at 150 ° C. Ex-situ drying temperature and 150 ° C. In-situ drying temperature. The catalyst selectivity of this catalyst sample was 7.90 as measured by IPB / DIPB. The catalyst activity of this catalyst sample was 244.

The PDI of the catalyst sample of Example 10 was 1.03, which increased the 3% proton content (measured in mmol of protons per gram of catalyst) compared to the catalyst sample of Example 6. Compared to the catalyst sample of Example 6, the catalyst selectivity (IPB / DIPB) of the catalyst sample of Example 10 was increased by 20%, and the catalyst activity was slightly decreased to 80% of the catalyst sample of Example 6. .

Example 11 (comparative example)
The catalyst sample of Example 11 is made of amorphous tungsten zirconia (WZrO ₂ ). The proton density was determined according to the NMR method for determining proton density, as described above, at a specific NMR pretreatment temperature of 250 ° C. The proton density was 0.37 mmol per gram of catalyst (first hydration state).

A 0.5 gram portion of the catalyst sample of Example 11 was tested according to the catalytic reactivity test method at a specific Ex-situ drying temperature of 250 ° C. and a specific In-situ drying temperature of 170 ° C. The catalytic activity was 13.70 as determined by the weight ratio of isopropylbenzene to diisopropylbenzene (IPD / DIPB). The catalyst activity of this catalyst sample was 1.

Example 12 (comparative example)
The catalyst sample of Example 11 was treated according to proton content adjustment technique # 1 with a contact time of about 1 hour to produce a treated catalyst sample of Example 12 having a third hydration state. The proton density of the treated sample was 0.41 mmol per gram of catalyst, determined as described above according to the NMR method to determine the proton density, at a specific NMR pretreatment temperature of 250 ° C. ( Third hydration state).

A 0.5 gram portion of the treated catalyst of Example 12 was tested according to the catalytic reactivity test method at an Ex-situ drying temperature of 250 ° C and an In-situ drying temperature of 170 ° C. The catalyst selectivity of this catalyst sample was 9.62 as measured by IPB / DIPB weight ratio. The catalyst activity of this catalyst sample was 1.

The PDI of the catalyst sample of Example 12 was 1.11 and the proton content was increased by 11% compared to the catalyst of Example 11 (measured in mmol of protons per gram of catalyst). However, the catalyst selectivity (IPB / DIPB) of the catalyst sample of Example 12 was reduced by 29.8% compared to the catalyst sample of Example 11. The catalytic activity was the same as the catalyst sample of Example 11.

Patents, patent applications, test methods, priority documents, documents, publications, manuals, etc., cited in this specification are hereby incorporated by reference if permitted by the system.

In the present specification, when a plurality of lower limit values and upper limit values are described, a range consisting of arbitrary lower limit values and upper limit values is also intended.

Although exemplary embodiments of the present invention have been specifically described, other modifications within the spirit and scope of the invention that would be readily made by those skilled in the art are also within the scope of the invention. Accordingly, it is not intended that the scope of the appended claims be limited to the description of the examples and the detailed description of the invention. Rather, it should be considered to include all features of the patentability of the present invention, including all technical features deemed equivalent by those of ordinary skill in the art to which this invention belongs.

Claims (6)

A method of producing a catalyst composition, the method comprising:
(A) providing a first catalyst having a first proton density and having an acidic porous crystalline material that is a zeolite beta and having a first proton density;
(B) contacting the liquid catalyst with the first catalyst to add a proton to produce a second catalyst having a second proton density, wherein the value of the second proton density is the same under the same conditions And (c) drying the second catalyst of step (b) at a drying temperature of up to about 550 ° C., so that at least one from the second catalyst A step of removing a proton to produce a catalyst composition having a third proton density, wherein the catalyst activity of the catalyst composition is greater than the catalyst activity of the second catalyst, and the value of the third proton density is: And including being between the value of the first proton density and the value of the second proton density measured under the same conditions. The method of claim 1, wherein step (b) is conducted at a contact temperature of about 1 ° C to about 99 ° C for about 1 minute to about 60 minutes. The method of claim 1, wherein step (c) is carried out at a drying temperature of about 100 ° C to about 200 ° C for about 0.01 to about 24 hours. The process of claim 1, wherein the catalyst composition obtained in step (c) has a proton density index greater than 1.0 and less than 2.0. The method of claim 4, wherein the catalyst composition obtained in step (c) has a proton density index of from about 1.01 to about 1.85. 6. The process of claim 5, wherein the third proton density is greater than 2.24 mmol per gram of catalyst.

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