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  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2/00—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms
  • C07C2/86—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms by condensation between a hydrocarbon and a non-hydrocarbon
  • C07C2/862—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms by condensation between a hydrocarbon and a non-hydrocarbon the non-hydrocarbon contains only oxygen as hetero-atoms
  • C07C2/864—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms by condensation between a hydrocarbon and a non-hydrocarbon the non-hydrocarbon contains only oxygen as hetero-atoms the non-hydrocarbon is an alcohol
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • B01J29/08—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
  • B01J29/082—X-type faujasite
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • B01J29/08—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
  • B01J29/084—Y-type faujasite
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • 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
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • B01J29/70—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups B01J29/08 - B01J29/65
  • B01J29/7007—Zeolite Beta
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J2229/00—Aspects of molecular sieve catalysts not covered by B01J29/00
  • B01J2229/10—After treatment, characterised by the effect to be obtained
  • B01J2229/18—After treatment, characterised by the effect to be obtained to introduce other elements into or onto the molecular sieve itself
  • B01J2229/186—After treatment, characterised by the effect to be obtained to introduce other elements into or onto the molecular sieve itself not in framework positions
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
  • B01J29/00—Catalysts comprising molecular sieves
  • B01J29/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites
  • B01J29/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • B01J29/08—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2/00—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms
  • C07C2/86—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms by condensation between a hydrocarbon and a non-hydrocarbon
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2529/00—Catalysts comprising molecular sieves
  • C07C2529/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites, pillared clays
  • C07C2529/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • C07C2529/08—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the faujasite type, e.g. type X or Y
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2529/00—Catalysts comprising molecular sieves
  • C07C2529/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites, pillared clays
  • C07C2529/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • C07C2529/18—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the mordenite type
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2529/00—Catalysts comprising molecular sieves
  • C07C2529/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites, pillared clays
  • C07C2529/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • C07C2529/40—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of the pentasil type, e.g. types ZSM-5, ZSM-8 or ZSM-11
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2529/00—Catalysts comprising molecular sieves
  • C07C2529/04—Catalysts comprising molecular sieves having base-exchange properties, e.g. crystalline zeolites, pillared clays
  • C07C2529/06—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof
  • C07C2529/70—Crystalline aluminosilicate zeolites; Isomorphous compounds thereof of types characterised by their specific structure not provided for in groups C07C2529/08 - C07C2529/65
• • C—CHEMISTRY; METALLURGY
  • C07—ORGANIC CHEMISTRY
  • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
  • C07C2529/00—Catalysts comprising molecular sieves
  • C07C2529/82—Phosphates
  • C07C2529/84—Aluminophosphates containing other elements, e.g. metals, boron
  • C07C2529/85—Silicoaluminophosphates (SAPO compounds)
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P20/00—Technologies relating to chemical industry
  • Y02P20/50—Improvements relating to the production of bulk chemicals
  • Y02P20/52—Improvements relating to the production of bulk chemicals using catalysts, e.g. selective catalysts

Definitions

• the present disclosure related to a process for the preparation of isomers of xylene.
• Xylene is monocyclic aromatic compound with two methyl groups attached to the benzene ring. It exists in three isomeric forms: ortho, meta and para-xylene. Usually, the individual isomers of xylene are separated and consumed in specific end-uses. Ortho-xylene is used primarily in the synthesis of phthalic acid, unsaturated polyester resins, alkyd resins; meta-xylene is key component for the synthesis of isophthalic acid and para-xylene is an important precursor to terephthalic acid and dimethyl terephthalate.
• alkylation catalysts such as A1C1 3 , HF and H 2 S0 4 employed in the Friedel-Crafts alkylation reaction have found to be environmentally hazardous. Therefore, in recent years, molecular sieve catalyst such as zeolites and silico aluminophosphate have attracted attention as alkylation catalysts, typically, due to their higher acidic properties, potential for regeneration and easy of separation from the reaction mixture.
• the term 'molecular sieve' is used to define class of materials that exhibits selected sorption properties.
• Figure 1 illustrates the XRD for the alkylation catalyst composite of the present disclosure, in which A represents XRD for the Ca-X zeolite catalyst composite, B represents XRD for the Mg-X zeolite catalyst composite, C represents XRD for the Sr-X zeolite catalyst composite and D represents XRD for the Ba-X zeolite catalyst cqmposite.
• Figure 2 illustrates the XRD for the Sr ion exchanged X zeolite catalyst composite of the present disclosure, in which:
• A represents XRD for the Sr -X zeolite catalyst composite obtained after refluxing Na X-zeolite with strontium nitrate
• B represents XRD for the Sr - X zeolite catalyst composite obtained after repeating the method step of refluxing Na X-zeolite with strontium nitrate two times;
• C represents XRD for the Sr - X zeolite catalyst composite obtained after repeating the method step of refluxing Na X-zeolite with strontium nitrate three times.
• Figure 3 illustrates amount of toluene alkylated using Mg-X zeolite catalyst composite, Ca-X zeolite catalyst composite, Sr-X zeolite catalyst composite and Ba-X zeolite catalyst composite of the present disclosure.
• A represents percent conversion of toluene
• B represents percent alkylation of toluene to m-xylene
• C represents percent alkylation of toluene to p-xylene
• C represents percent alkylation of toluene to o- xylene.
• a process for the preparation of isomers of xylene comprising the following steps: i. obtaining an alkylation catalyst composite comprising a molecular sieve loaded with at least one metal ion;
• reaction mixture comprising isomers of xylene; wherein the mass of the ortho-xylene in said reaction mixture is greater than the individual mass of para-xylene and meta-xylene.
• the molecular sieve is at least one zeolite selected from the group consisting of X-zeolite, Y-zeolite, beta-zeolite, ZSM-5 zeolite mordenite, ZSM-48, ZSM-22, ZSM-23, ZSM-57 and MCM-22.
• the molecular sieve is at least one silico aluminophosphate (SAPO) selected from the group consisting of SAPO-5, SAPO-11, SAPO- 17, SAPO- 18, SAPO-44, SAPO-34 and SAPO-48.
• SAPO silico aluminophosphate
• the metal is at least one selected ' from the group consisting of group I elements, group II elements, group III elements, lanthanides and transition metals.
• the metal is at least one selected from the group consisting of barium, strontium, magnesium and calcium.
• the ratio of toluene to methanol ranges between 1 : 1 and 4:1.
• the flow rate of toluene is maintained at a weight hourly space velocity of 1 to 5 per hr. of the activated alkylation catalyst composite.
• the inert gas is at least one selected from the group consisting of nitrogen, argon and helium.
• the flow rate of the inert gas ranges between 5 and 15 per min.
• Alkylation of toluene using the acidic alkylation catalyst predominantly produces meta and para isomers of xylene, while the basic alkylation catalyst produces ethyl benzene and styrene. Therefore, with the view of increasing the yield of ortho-xylene, the inventors of the present disclosure have conducted several experiments and trials using number of alkylation catalysts. The inventors surprisingly found that the basic alkylation catalyst composite comprising molecular sieve loaded with at least one metal ion can selectively be used for the preparation of the isomers of xylene typically, ortho-xylene. Accordingly, the inventors of the present disclosure have developed a novel process for alkylation of toluene using the basic alkylation catalyst composite.
• the alkylation catalyst composite comprising a molecular sieve loaded with at least one metal ion is activated at a temperature of 450 to 650°C for a time period of 30 min to 2 hrs. in a reactor to obtain an activated alkylation catalyst composite.
• the temperature for activating the alkylation catalyst composite is attained by heating the reactor at a rate of 4 to 10°C per minute.
• the molecular sieve may be zeolite selected from the group consisting of X-zeolite, Y-zeolite, beta-zeolite, ZSM-5 zeolite mordenite, ZSM-48, ZSM-22, ZSM-23, ZSM-57, MCM-22 and mixtures thereof.
• the molecular sieve may be silico aluminophosphate (SAPO) selected from the group consisting of SAPO- 5, SAPO-11, SAPO-17, SAPO-18, SAPO-44, SAPO-34, SAPO-48 and combinations thereof.
• SAPO silico aluminophosphate
• the metal loaded on molecular sieve is at least one selected from the group consisting of group I elements, group II elements, group III elements, lanthanides and transition metals.
• the metal loaded o molecular sieve is at least one selected from the group consisting of barium, strontium, magnesium and calcium.
• the activated alkylation catalyst composite is contacted with toluene and methanol at a temperature of 300 to 500°C to obtain a reaction mixture comprising isomers of xylene as ortho-xylene, meta- xylene and para-xylene.
• the mass of ortho-xylene present in the reaction mixture is greater the individual mass of para-xylene and meta-xylene.
• the ratio of toluene to methanol is maintained in the range of 1: 1 to 4:1 and the flow rate of toluene is maintained at a weight hourly space velocity of .1 to 5 per hr. of the activated catalyst.
• the method step of contacting the activated alkylation catalyst composite with toluene and methanol is carried out in the presence of inert gas selected from the group consisting of nitrogen, argon, helium and combinations thereof.
• inert gas selected from the group consisting of nitrogen, argon, helium and combinations thereof.
• the flow rate of inert gas is maintained in the range of 5 to 15 ml/min.
• Example 1 Preparation of Ba-X zeolite using Na-X zeolites: Step 1: Preparation of Na-X zeolite:
• Step II- Preparation of an alkylation catalyst composite (Ba-X zeolite catalyst composite) using Na-X zeolite:
• the Na-X zeolite was treated with 0.5 M of barium acetate solution using the method described in step I to obtain a Ba-X zeolite. In this process the sodium nitrate is replaced with barium acetate.
• Step III Preparation of isomers of xylene using Ba-X zeolite catalyst composite:
• Products were cooled in condenser maintained at 2°C and products are collected in gas liquid separator maintained at 5°C. Products were analyzed through gas chromatograph equipped with FID using a carbowax (polar) column of 60m x 0.25 um x 0.25 mm.
• Example 2 Preparation of an alkylation catalyst composite (Ca-X zeolite catalyst composite) using Na-X zeolite:
• the Na-Xizeolite was treated with 0.5 M of calcium nitrate (CaN0 3 ) solution using the step-I of Example 1 to obtain a Ca-X zeolite. In this process sodium nitrate is replaced with calcium nitrate.
• the isomers of xylene were prepared by employing the procedure described in the Example 1. In this process Ba-X zeolites catalyst composite is replaced with Ca-X zeolite catalyst composite
• Example 3 Preparation of an alkylation catalyst composite (Mg-X zeolite catalyst composite) using Na-X zeolite:
• the Na-X zeolite was treated with 0.5 M of Magnesium nitrate (MgN0 3 ) solution using the step-I of Example 1 to obtain a Mg-X zeolite. In this process sodium nitrate is replaced with Magnesium nitrate.
• MgN0 3 Magnesium nitrate
• the isomers of xylene were prepared by employing the procedure described in the Example 1. In this process Ba-X zeolite catalyst composite is replaced with Mg -X zeolites catalyst composite. ⁇
• Example 4 Preparation of the alkylation catalyst composite (Sr-X zeolite catalyst composite) using Na-X zeolites:
• the Na-X zeolite was treated with 0.5 M of Strontium nitrate (Sr(N0 3 ) 2 ) solution using Step-I of Example 1 to obtain a Sr -X zeolite.
• Strontium nitrate Sr(N0 3 ) 2
• Step-I of Example 1 To obtain a Sr -X zeolite.
• sodium nitrate is replaced with Strontium nitrate.
• the isomers of xylene were prepared by employing the procedure described in the Example 1. In this process Ba-X zeolite catalyst composite is replaced with Sr-X zeolites catalyst composite.
• Example 5 Preparation of Sr-beta zeolite catalyst composite: Step I Preparation Na-beta zeolites Catalyst:
• H-Beta zeolite 5 gm was treated with 20 ml of 0.5 M aqueous solution of sodium nitrate under reflux for 8 hrs., followed by filtration, washing with water until the filtrate became free from sodium ions, drying at 120 °C for 8 h and calcination at 550 °C for 4 h in air.
• the ratio of sodium nitrate to zeolite was maintained as 10: 1. The procedure was repeated twice to obtain Na- Beta zeolite.
• the Sr -beta zeolite catalyst was prepared by using the procedure described for the preparation of Na-beta zeolites (Step I). In this process sodium nitrate is replaced with Strontium nitrate (Sr(N0 3 ) 2 ).
• the isomers of xylene were prepared by employing the procedure described in the Example 1. In this process Ba-X zeolite catalyst composite is replaced with Sr-X beta zeolites catalyst composite. Table 5:
• Example 6 Preparation of an aikylation catalyst composite (Sr- ZSM-5 zeolite catalyst composite) using Na-ZSM-5 zeolite:
• the Sr- ZSM-5 zeolite was prepared by using the Step-I of the Example 6, in this process H-Beta zeolite is replaced with H-ZSM-5 zeolite.
• the isomers of xylene were prepared by employing the procedure described in the Example 1. In this process Ba-X zeolite catalyst composite is replaced with Sr- ZSM-5 zeolites catalyst composite. Table 6:
• Example 7 Preparation of an alkylation catalyst composite (Sr- Y zeolite catalyst composite) using H-Y zeolite:
• the Sr- ZSM-5 zeolite was prepared by using Step I of Example 6, in this process H- Beta zeolite is replaced with H-Y zeolite.
• the isomers of xylene were prepared by employing the procedure described in the Example 1. In this process Ba-X zeolite catalyst composite is replaced with Sr- Y zeolites catalyst composite Table 7:
• the catalytic activity of Sr- X zeolite catalyst composite was compared with the catalytic activity of Mg- X zeolite catalyst composite, Ca- X zeolite catalyst composite and Ba- X zeolite.(shown in Figure 3 and Table 8)
• Table 8 Percent alkylation of toluene using the alkylation catalyst comprising Sr metal ion loaded zeolites.
• the zeolite catalysts were analyzed in the 20 range of 5° to 70° with scanning rate of 0.02 degrees per second at temperature of 25°C. XRD pattern for zeolite catalysts shown in figure 1.
• the zeolite catalyst was analyzed in the 20 range of 10 to 70° with scanning rate of 0.02 degrees per second at temperature of 25°C.
• AAS Atomic Absorption Spectrometry
• the percent sodium (Na) exchanged with the metal ions selected from the group consisting of magnesium(Mg), calcium(Ca), strontium(Sr) and barium(Ba) was determined by Atomic Absorption Spectrometry.
• the isomers of xylene were prepared by employing the procedure described in the Example 1. In this process Ba-X zeolite catalyst composite is replaced with commercially available Na-X zeolite catalyst.
• the isomers of xylene were prepared by employing the procedure described in the Example 1. In this process Ba-X zeolite catalyst composite is replaced with commercially available H-Beta and H-ZSM-5. The amount of the xylene produced by the Sr- X zeolite composite was then compared with amount of the xylene produced using H-Beta and HZSM-5 Table 11:

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