WO2023064683A1 - Catalyseur et procédés de production de produits de xylène riches en o-xylène - Google Patents

Catalyseur et procédés de production de produits de xylène riches en o-xylène Download PDF

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WO2023064683A1
WO2023064683A1 PCT/US2022/077325 US2022077325W WO2023064683A1 WO 2023064683 A1 WO2023064683 A1 WO 2023064683A1 US 2022077325 W US2022077325 W US 2022077325W WO 2023064683 A1 WO2023064683 A1 WO 2023064683A1
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methylation
catalyst
xylene
zeolite
feed
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PCT/US2022/077325
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Krystle J. EMANUELE
Hsu Chiang
Umar ASLAM
Ali A. KHEIR
Xiaobo Zheng
Seth M. Washburn
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Exxonmobil Chemical Patents Inc.
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Priority to CN202280068927.1A priority Critical patent/CN118103139A/zh
Publication of WO2023064683A1 publication Critical patent/WO2023064683A1/fr

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    • 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
    • B01J29/7038—MWW-type, e.g. MCM-22, ERB-1, ITQ-1, PSH-3 or SSZ-25
    • 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
    • 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
    • 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
    • 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
    • C07C2/865—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 ether
    • 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
    • B01J2229/12—After treatment, characterised by the effect to be obtained to alter the outside of the crystallites, e.g. selectivation
    • B01J2229/123—After treatment, characterised by the effect to be obtained to alter the outside of the crystallites, e.g. selectivation in order to deactivate outer surface
    • 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
    • B01J2229/30—After treatment, characterised by the means used
    • B01J2229/36—Steaming
    • 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
    • B01J2229/30—After treatment, characterised by the means used
    • B01J2229/42—Addition of matrix or binder particles
    • 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

  • FIELD [0002] The present disclosure relates to methylation catalysts comprising surface modified zeolites and processes using said methylation catalysts for converting benzene and/or toluene via methylation with methanol and/or dimethyl ether to produce xylene products with higher than equilibrium o-xylene selectivity.
  • BACKGROUND [0003] 1,2-Dimethylbenzene (ortho-xylene or o-xylene) is a valuable chemical intermediate in the production of p-xylene with demand over the past two decades growing at about 2% per year.
  • o-Xylene is used mainly for the production of phthalic anhydride, which is a common intermediate in production of plasticizers, dyes, and enteric coatings for pharmaceuticals.
  • plasticizers plasticizers, dyes, and enteric coatings for pharmaceuticals.
  • o-xylene may be extracted from the BTX aromatics (benzene, toluene, and xylene isomers) in the catalytic reformate produced by catalytic reforming of petroleum naphtha.
  • o-xylene may be a co-product during toluene disproportionation, toluene transalkylation with C9+ aromatics, or toluene and/or benzene methylation.
  • the methylation of toluene and/or benzene is a favored route to the formation of xylenes because of the low cost of starting materials and the potential to provide high yields.
  • Methylation methods may use methanol and/or dimethyl ether as alkylation reagents.
  • the present disclosure relates to methylation catalysts comprising surface modified zeolites and processes using said methylation catalysts for converting benzene and/or toluene via methylation with methanol and/or dimethyl ether to produce xylene products with higher than equilibrium o-xylene selectivity.
  • a non-limiting example process of the present disclosure may comprise one or more of: contacting an aromatic hydrocarbon feed with a methylating agent feed in the presence of a methylation catalyst in a methylation reactor under methylation reaction conditions to produce a methylation product mixture effluent exiting the methylation reactor, wherein the aromatic hydrocarbon feed comprises benzene and/or toluene, the methylating agent feed comprises methanol and/or dimethyl ether, the methylation catalyst comprises a modified zeolite comprising (a) a zeolite of MWW framework type and (b) a surface modification agent on at least a portion of an outer surface of the zeolite, and the methylation product mixture effluent comprises o-xylene at a concentration of at least 27 wt%, based on a total weight of the xylenes in the methylation product mixture effluent.
  • Another non-limiting example process of the present disclosure may comprise one or more of: providing a precursor catalyst comprising a zeolite of the MWW framework structure; loading the precursor catalyst in a methylation reactor; contacting the precursor catalyst in the methylation reactor with a surface modification agent to produce a methylation catalyst comprising a modified zeolite comprising the surface modification agent on at least a portion of an outer surface of the zeolite; and contacting the methylation catalyst in the methylation reactor with an aromatic hydrocarbon feed and a methylating agent feed under methylation reaction conditions to produce a methylation product mixture effluent, wherein the aromatic hydrocarbon feed comprises benzene and/or toluene, the methylating agent feed comprises methanol and/or dimethyl ether, and the methylation product mixture effluent comprises o- xylene at a concentration of at least 27 wt%, based on a total weight of the xylenes in the methylation product mixture effluent
  • Another non-limiting example process of the present disclosure may comprise one or more of: providing a precursor catalyst comprising a zeolite of the MWW framework structure; loading the precursor catalyst in a methylation reactor; contacting the precursor catalyst in the methylation reactor with water to produce a methylation catalyst comprising a modified zeolite comprising neutralized acid groups on at least a portion of an outer surface of the zeolite; and contacting the methylation catalyst in the methylation reactor with an aromatic hydrocarbon feed and a methylating agent feed under methylation reaction conditions to produce a methylation product mixture effluent, wherein the aromatic hydrocarbon feed comprises benzene and/or toluene, the methylating agent feed comprises methanol and/or dimethyl ether, and the methylation product mixture effluent comprises o-xylene at a concentration of at least 27 wt%, based on a total weight of the xylenes in the methylation product mixture effluent.
  • Another non-limiting example process of the present disclosure may comprise one or more of: providing a precursor catalyst comprising a zeolite of the MWW framework structure; subjecting the precursor catalyst to one or more treatments comprising contacting the precursor catalyst with an organosilicon compound, wherein each treatment is followed by calcining the precursor catalyst to produce the methylation catalyst, wherein the surface modification agent is silica; loading the methylation catalyst in a methylation reactor; and contacting the methylation catalyst in the methylation reactor with an aromatic hydrocarbon feed and a methylating agent feed under methylation reaction conditions to produce a methylation product mixture effluent, wherein the aromatic hydrocarbon feed comprises benzene and/or toluene, the methylating agent feed comprises methanol and/or dimethyl ether, and the methylation product mixture effluent comprises o-xylene at a concentration of at least 27 wt%, based on a total weight of the xylenes in the methylation product mixture effl
  • Another non-limiting example process of the present disclosure may comprise one or more of: providing a precursor catalyst comprising a zeolite of the MWW framework structure; contacting the precursor catalyst with a thermally decomposable organic compound at an elevated temperature at or above a decomposition temperature of the thermally decomposable organic compound to deposit the coke on the surface of the zeolite and produce a methylation catalyst; loading the methylation catalyst in a methylation reactor; and contacting the methylation catalyst in the methylation reactor with an aromatic hydrocarbon feed and a methylating agent feed under methylation reaction conditions to produce a methylation product mixture effluent, wherein the aromatic hydrocarbon feed comprises benzene and/or toluene, the methylating agent feed comprises methanol and/or dimethyl ether, and the methylation product mixture effluent comprises o-xylene at a concentration of at least 27 wt%, based on a total weight of the xylenes in the methylation
  • FIG. 1 schematically illustrates a process for converting benzene and/or toluene via methylation with methanol and/or DME to produce p-xylene according to one embodiment of this disclosure.
  • FIG. 2 schematically illustrates a process for converting benzene/toluene via methylation with methanol/dimethyl ether to produce p-xylene according to an embodiment of this disclosure.
  • FIG. 3A is a plot of the toluene conversion
  • FIG. 3B is a plot of xylene isomers selectivities based on the total weight of xylenes produced.
  • FIG.4A is a plot of the toluene conversion
  • FIG.4B is a plot of the xylene isomers selectivities based on the total weight of xylenes produced.
  • DETAILED DESCRIPTION [0018] The present disclosure relates to methylation catalysts comprising surface modified zeolites and processes using said methylation catalysts for converting benzene and/or toluene via methylation with methanol and/or dimethyl ether to produce xylene products with higher than equilibrium o-xylene selectivity.
  • the present disclosure includes methylation catalysts (and related methylation processes) comprising both a zeolite and a surface modification agent on at least a portion of the outer surface of the zeolite that under methylation reaction conditions produces a product mixture that comprises o-xylene at higher concentrations than in a thermodynamic equilibrium mixture of p-xylene, o-xylene, and m- xylene.
  • the thermodynamic equilibrium of said xylenes includes 26 wt% o-xylene.
  • at least some of the methylation catalysts described herein produce a product mixture with over 75 wt% o-xylene.
  • a high selectivity toward o-xylene in the reaction may be achieved with the methylation catalysts and relate methylation processes described herein.
  • the zeolites used in the methylation catalysts described herein are MWW framework type and have a surface modification agent on at least a portion of the outer surface of the zeolite, where the surface modification agent modifies the catalytic activity of the zeolite.
  • zeolites having a different framework e.g., ZSM-5 framework type and MFI framework type
  • the surface modification agent do not show increased selectivity towards o-xylene.
  • Cn compound or group, wherein n is a positive integer, means a compound or a group comprising carbon atoms therein at the number of n.
  • a “Cm to Cn” alkyl means an alkyl group comprising carbon atoms therein at a number in a range from m to n.
  • a C1-C3 alkyl means methyl, ethyl, n-propyl, or 1-methylethyl-.
  • Cn+ compound or group, wherein n is a positive integer, means a compound or a group comprising carbon atoms therein at the number of equal to or greater than n.
  • Cn- compound or group, wherein n is a positive integer, means a compound or a group comprising carbon atoms therein at the number of equal to or lower than n.
  • conversion refers to the degree to which a given reactant in a particular reaction (e.g., methylation, isomerization, etc.) is converted to products.
  • 100% conversion of toluene to xylene in a methylation refers to complete consumption of the toluene
  • 0% conversion of the toluene refers to no measurable reaction of the toluene.
  • the term “selectivity” refers to the degree to which a particular reaction forms a specific xylene isomer (o-xylene, m-xylene, or p-xylene), based on the total weight of all xylene isomers (o-xylene, m-xylene, or p-xylene) produced. For example, for the methylation of toluene, 50% selectivity for o-xylene means that 50% of the xylenes formed are o-xylene, and 100% selectivity for o-xylene means that 100% of the xylenes formed are o- xylene.
  • the selectivity is based on the product formed, regardless of the conversion of the particular reaction.
  • the selectivity for a given xylene isomer (o-xylene, m-xylene, or p-xylene) produced from a given reactant can be defined as weight percent (wt%) of that xylene isomer relative to the total weight of all xylene isomers (i.e., all of o-xylene, m-xylene, and p-xylene) formed from the given reactant in the reaction.
  • alkylation means a chemical reaction in which an alkyl group is transferred to an aromatic ring as a substitute group thereon from an alkyl group source compound.
  • Methods means alkylation in which the transferred alkyl group is a methyl.
  • methylation of benzene can produce toluene, xylenes, trimethylbenzenes, and the like; and methylation of toluene can produce xylenes, trimethylbenzenes, and the like.
  • the xylenes include 1,2-dimethylbenzene (ortho-xylene, or o-xylene), 1,3-dimethylbenzene (meta-xylene, or m-xylene), and 1,4-dimethylbenzene (para-xylene, or p-xylene).
  • 1,2-dimethylbenzene ortho-xylene, or o-xylene
  • 1,3-dimethylbenzene metal-xylene, or m-xylene
  • 1,4-dimethylbenzene para-xylene, or p-xylene.
  • One or more of these xylene isomers, particularly p-xylene and/or o-xylene are high-value industrial chemicals. They may be separated to make corresponding products.
  • the C9 hydrocarbons, though, are generally undesirable byproducts.
  • the term “precursor catalyst” is a formulated catalyst that contains a crystalline microporous material.
  • the precursor catalyst contains zeolites having MWW framework topology unit cells.
  • MWW zeolites have a 3-dimensional, four-connected framework structure of corner- sharing [TO 4 ] tetrahedra, where T may be a tetrahedrally coordinated atom.
  • Molecular sieves, such as MWW zeolites are often described in terms of the size of the ring that defines a pore, where the size is based on the number of T atoms in the ring.
  • Crystalline building blocks of the MWW framework type include those molecular sieves having an X-ray diffraction pattern comprising d-spacing maxima at 12.4 ⁇ 0.25, 6.9 ⁇ 0.15, 3.57 ⁇ 0.07 and 3.42 ⁇ 0.07 Angstrom.
  • the X-ray diffraction data used to characterize the material are obtained by standard techniques using the K-alpha doublet of copper as incident radiation and a diffractometer equipped with a scintillation counter and associated computer as the collection system.
  • methylation catalyst is a modified precursor catalyst comprising a zeolite of MWW framework type and a surface modification agent on at least a portion of the outer surface of the zeolite.
  • a surface modification agent interacts with a surface of the zeolite to modify the catalytic activity of the zeolite. Said interactions may be chemical interactions (e.g., covalent bonding, hydrogen bonding, chemisorption, or any combination thereof) and/or physical interactions (e.g., a deposit or coating, adsorption, or any combination thereof).
  • WHSV is based on the combined flow rate of the aromatic hydrocarbon feed and the methylating agent feed.
  • the present disclosure includes processes for converting benzene and/or toluene via methylation with methanol and/or dimethyl ether to produce o-xylene with higher than equilibrium selectivity, which may be achieved using a methylation catalyst that comprises a modified zeolite comprising (a) a zeolite of MWW framework type and (b) a surface modification agent on at least a portion of an outer surface of the zeolite.
  • the methylation catalyst may be produced by modifying a precursor catalyst.
  • the modified precursor catalyst, modified to render higher than equilibrium o-xylene selectivity, is referred herein as the methylation catalyst.
  • Surface modification may be achieved by contacting the catalyst with a surface modification agent.
  • the surface modification agent interacts with a surface of the zeolite to modify the catalytic activity of the zeolite. Said interactions may be chemical interactions (e.g., covalent bonding, hydrogen bonding, chemisorption, or any combination thereof) and/or physical interactions (e.g., a deposit or coating, adsorption, or any combination thereof). Examples of surface modification agents that are described in more detail herein include silica, coke, a bulky N-containing organic molecule, or a combination thereof.
  • Examples of zeolite of MWW framework types suitable for use in the precursor catalyst may include, but are not limited to, MCM-22, PSH-3, SSZ-25, ERB-1, ITQ-1, ITQ-2, MCM-36, MCM-49, MCM-56, EMM-10, EMM-12, EMM-13, UZM-8, UZM-8HS, UZM-37, UCB-3, and mixtures of two or more thereof.
  • the zeolite of the precursor catalyst may be contaminated with other crystalline materials, such as ferrite or quartz. These contaminants may be present in quantities of ⁇ 10 wt% (e.g., ⁇ 5 wt%).
  • the zeolite of the precursor catalyst may be pre-modified with cations or metal impregnation techniques, which may include, but are not limited to, ion- exchange, incipient wetness impregnation, framework metal substitution, and the like. These cations and/or metal modifications may have occurred during the formulation of the precursor catalyst. Examples of elements that may be present in the zeolite of the precursor catalyst may include, but are not limited to, H, alkali metals, alkaline-earth metals, transition metals, and any combination thereof. [0036]
  • the precursor catalyst may be formulated without any binder, in a self-bound form. Alternatively, the precursor catalyst may be formulated with a binder material.
  • a binder can be resistant to the temperatures and other conditions employed in the methylation reaction. That is, the precursor catalyst may comprise (a) zeolites having MWW framework type, and optionally (b) binder. Such binder materials may be active or inactive. Such binder materials may be synthetic and/or naturally occurring.
  • useful binders are clay (e.g., bentonite, kaolin), oxides such as alumina, silica, silica-alumina, zirconia, titania, magnesia, and mixtures, combinations, and composites thereof.
  • the binders can impart desirable mechanical properties such as crush strength to and/or aid in forming (e.g., extrusion) the precursor catalyst.
  • the precursor catalyst can comprise from 10 wt%, 20 wt%, 30 wt%, to 40 wt%, 50 wt%, 60 wt%, to 70 wt%, 80 wt%, or 90 wt%, of the MWW framework zeolite, based on the total weight of the precursor catalyst, and the remainder being a binder material.
  • the precursor catalyst may optionally comprise other zeolite as well.
  • the precursor catalyst may be modified, either before introduction into the methylation reactor (ex-situ) or in-situ of the methylation reactor, by contacting the catalyst with a modification agent, such as a silicon-containing agent, a coke-forming agent, a bulky N-containing organic molecule, or a combination thereof.
  • a modification agent such as a silicon-containing agent, a coke-forming agent, a bulky N-containing organic molecule, or a combination thereof.
  • Silica Modification of a Precursor Catalyst [0038]
  • the precursor catalyst may be modified with silica.
  • Silica modification may be effected by subjecting the precursor catalyst to one or more treatments with a silicon-containing agent (e.g., an organosilicon compound in a liquid carrier), each treatment being followed by calcination of the treated material in an oxygen-containing atmosphere (e.g., air).
  • a silicon-containing agent e.g., an organosilicon compound in a liquid carrier
  • an oxygen-containing atmosphere e.g., air
  • the precursor catalyst to be silica-modified includes a binder
  • a non-acidic binder such as silica.
  • the organosilicon compound, which is used to modify the precursor catalyst may, for example, be a silicone, a siloxane, a silane, or mixture thereof. These organosilicon compounds may be solids in pure form, provided that they are soluble or otherwise convertible to the liquid form upon combination with the liquid carrier medium.
  • the organosilicon compounds may also be liquids in pure form (e.g., tetraethylorthosilicate, or TEOS).
  • TEOS tetraethylorthosilicate
  • the molecular weight of the silicone, siloxane or silane compound employed as a modification agent may be between 80 g/mol and 20,000 g/mol, and preferably within the approximate range of 150 g/mol to 10,000 g/mol.
  • Representative modification silicone compounds include dimethyl silicone, diethyl silicone, phenylmethyl silicone, methylhydrogen silicone, ethylhydrogen silicone, phenylhydrogen silicone, methylethyl silicone, phenylethyl silicone, diphenyl silicone, methyltrifluoropropyl silicone, ethyltrifluoropropyl silicone, polydimethyl silicone, tetrachlorophenylmethyl silicone, tetrachlorophenylethyl silicone, tetrachlorophenylhydrogen silicone, tetrachlorophenylphenyl silicone, methylvinyl silicone, and ethylvinyl silicone.
  • the modifying silicone, siloxane, or silane compound need not be linear, but may be cyclic, for example, hexamethyl cyclotrisiloxane, octamethyl cyclotetrasiloxane, hexaphenyl cyclotrisiloxane, and octaphenyl cyclotetra-siloxane. Mixtures of these compounds may also be used as modification agents, as may silicones with other functional groups. [0041] Typically, the kinetic diameter of the organosilicon compound that is used to modify the precursor catalyst is larger than the MWW framework pore diameter, in order to avoid entry of the organosilicon compound into the zeolite pores.
  • organosilicon modification agents particularly when the modification agent is dissolved in an organic carrier or emulsified in an aqueous carrier, include, but are not limited to, dimethylphenyl methyl polysiloxane (e.g., Dow-550) and phenylmethyl polysiloxane (e.g., Dow-710).
  • Dow-550 and Dow-710 are available from Dow Chemical Co., Midland, Mich.
  • the liquid carrier for the organosilicon compound may be an organic material, such as a linear, branched or cyclic hydrocarbon having five or more, especially seven or more, carbon atoms per molecule (e.g., an alkane, such as heptane, octane, nonane, undecane, decane, or dodecane), or mixtures thereof.
  • the boiling point of the organic material e.g., alkane
  • the boiling point of the organic material may be greater than about 70 °C.
  • Mixtures of low volatility organic materials, such as hydrocracker recycle oil, may be employed as carriers.
  • a precursor catalyst may undergo one or more treatments comprising contacting the precursor catalyst with an organosilicon compound, which may impregnate the precursor catalyst with the organosilicon compound.
  • the catalyst is calcined at a ramp rate from 0.2 °C/minute to 5 °C/minute to a temperature greater than 200 °C, but below the temperature at which the crystallinity of the zeolite is adversely affected.
  • This calcination temperature will preferably be below 600 °C, for example within the approximate range of 250 °C to 600 °C, and preferably within the approximate range of 350 °C to 550 °C.
  • the duration of heating at the calcination temperature may be from 1 hour to 24 hours (e.g., from 2 hours to 6 hours).
  • the precursor catalyst has become a methylation catalyst comprising (a) a zeolite of MWW framework type and (b) silica on at least a portion of an outer surface of the zeolite.
  • the precursor catalyst may be modified to include silica on at least a portion of the zeolite surface either (a) before introduction into the methylation reactor (ex-situ) or (b) in-situ of the methylation reactor before the methylation reaction takes place.
  • the precursor catalyst may be silica-modified by contacting the precursor catalyst with at least one organosilicon compound in a liquid carrier and subsequently calcining the silicon-containing catalyst in an oxygen-containing atmosphere (e.g., air) under calcining conditions.
  • an oxygen-containing atmosphere e.g., air
  • the treatment with the organosilicon compound and subsequent calcination may occur in series multiple time to achieve a desired amount of silica on a surface of the zeolite.
  • the methylation catalyst having silica on a surface of the zeolite of MWW framework type may be introduced into (or otherwise placed in) a methylation reactor followed by exposing the methylation catalyst to methylation reaction conditions (described further herein) in the presence of an aromatic hydrocarbon feed and a methylating agent feed.
  • the precursor catalyst in an in-situ process, may be introduced into (or otherwise placed in) a methylation reactor.
  • the precursor catalyst may be silica-modified by contacting the precursor catalyst with at least one organosilicon compound in a liquid carrier and subsequently calcining the silicon-containing catalyst in an oxygen-containing atmosphere (e.g., air) under calcining conditions.
  • an oxygen-containing atmosphere e.g., air
  • the treatment with the organosilicon compound and subsequent calcination may occur in series multiple time to achieve a desired amount of silica on a surface of the zeolite.
  • This process results in a methylation catalyst having silica on a surface of the zeolite of MWW framework type. While still in the methylation reactor, the methylation catalyst may be exposed to methylation reaction conditions in the presence of an aromatic hydrocarbon feed and a methylating agent feed.
  • modifying the zeolite surface of the precursor catalyst with silica inactivates some acid sites and forms a surface shield that modifies the catalytic activity of the zeolite to result in an increased o-xylene selectivity compared to the precursor catalyst that was not modified.
  • a methylation catalyst having silica on a surface of the zeolite may comprise at least 0.1 wt% added silica based on the total weight of the methylation catalyst, or 0.1 wt% to 30 wt% added silica, or 1 wt% to 10 wt% added silica, or 5 wt% to 25 wt% added silica, or 10 wt% to 30 wt% added silica, based on the total weight of the MWW framework zeolite in the methylation catalyst.
  • Added silica means silica introduced onto the methylation catalyst as a result of silica modification.
  • Coke modification typically involves contacting the precursor catalyst with a coke-forming agent (e.g., a thermally decomposable organic material) under coke-forming conditions, e.g., at an elevated temperature in excess of the decomposition temperature of said organic material but below the temperature at which the crystallinity of the precursor catalyst or portion thereof is adversely affected.
  • a coke- forming agent e.g., a thermally decomposable organic material
  • Coke modification may take place naturally (e.g., as the methylation reaction occurs) and/or by addition of said decomposable organic compound before or during the methylation reaction.
  • the contact temperature for coke modification may range from 200 °C to 650 °C (e.g., from 375 °C to 650 °C, from 300 °C to 550 °C, or from 250 °C to 400 °C).
  • Organic materials which may be used for this coke modification process, can encompass a wide variety of materials including, but not limited to, hydrocarbons (e.g., paraffins, cycloparaffins, olefins, cycloolefins, aromatics, the like, and any combination thereof), oxygen-containing organic materials (e.g., alcohols, aldehydes, ethers, ketones, phenols, the like, and any combination thereof), and heterocyclics (e.g., thiophenes, pyrroles, pyridines, the like, and any combination thereof).
  • a hydrogen co-feed may be used to deter the excessive build-up of coke.
  • the precursor catalyst may be modified with coke on at least a portion of the zeolite surface (a) before introduction into the methylation reactor (ex-situ), (b) in-situ of the methylation reactor before the methylation reaction takes place, (c) in-situ of the methylation reactor during the methylation reaction, or (d) any combination thereof.
  • the precursor catalyst may be coke-modified by contacting the precursor catalyst with decomposable organic compound under coking conditions to cause coke to deposit on a surface of the zeolite of the precursor catalyst.
  • the resultant methylation catalyst may be exposed to methylation reaction conditions in the presence of an aromatic hydrocarbon feed and a methylating agent feed. During the methylation reaction, further coke-modification may be performed, for example, if the selectivity towards o-xylene reduces below a threshold value.
  • the precursor catalyst having coke on a surface of the zeolite of MWW framework type may be introduced into (or otherwise placed in) a methylation reactor.
  • the precursor catalyst may be introduced into (or otherwise placed in) a methylation reactor.
  • the precursor catalyst may be coke-modified by contacting the precursor catalyst with a decomposable organic compound under coking conditions to cause coke to deposit on a surface of the zeolite of the precursor catalyst. Said coke-modification may occur before and/or during the methylation reaction.
  • Coke-modified methylation catalysts may comprise at least 1 wt% coke based on the total weight of the methylation catalyst, or 1 wt% to 40 wt% coke, or 1 wt% to 20 wt% coke, or 10 wt% to 30 wt% coke, or 20 wt% to 40 wt% coke.
  • Adsorptive modification typically involves contacting the catalyst with a stream containing bulky N-containing organic molecules at a temperature effective to adsorb a plurality of said bulky N-containing organic molecules onto at least a portion of the outer surface of the zeolite within the precursor catalyst.
  • Adsorptive modification of the precursor catalyst may be of physical nature (e.g., physisorption), of chemical nature (e.g., chemisorption), or a combination thereof.
  • the kinetic diameter of the bulky N-containing organic molecules that are used to modify the precursor catalyst are larger than the MWW framework pore diameter, in order to avoid entry of said molecules into the zeolite pores.
  • Examples of bulky N-containing organic molecules may include, but are not limited to, 2,4-dimethylquinoline, collidine, di-tert-butyl-pyridine, the like, and any combination thereof.
  • Bulky N-containing organic molecules may comprise N, C, H, and optionally O, and may have a molecular weight ⁇ 100 g/mol (e.g., from 100 g/mol to 500 g/mol).
  • Adsorption of the bulky N-containing organic molecules may include contacting a precursor catalyst with the bulky N-containing organic molecules at temperatures ranging from 200 °C to 400 °C (e.g., from 200 °C to 350 °C, from 250 °C to 400 °C).
  • Exposure of the precursor catalyst to the bulky N-containing organic molecules may be for 1 hour to 24 hours (e.g., from 2 hours to 6 hours).
  • the modification procedure which may be repeated multiple times, partially passivates the catalytic active sites of the methylation catalyst and may increase the o-xylene yield.
  • the precursor catalyst may be modified to include bulky N-containing organic molecules adsorbed to at least a portion of the zeolite surface (a) before introduction into the methylation reactor (ex-situ), (b) in-situ of the methylation reactor before the methylation reaction takes place, (c) in-situ of the methylation reactor during the methylation reaction, or (d) any combination thereof.
  • the precursor catalyst may be contacted with bulky N-containing organic molecules under suitable adsorption conditions.
  • the adsorption of bulky N-containing organic molecules may multiple times to achieve a desired amount of adsorbed bulky N-containing organic molecules on a surface of the zeolite.
  • the methylation catalyst having bulky N-containing organic molecules adsorbed on a surface of the zeolite of MWW framework type may be introduced into (or otherwise placed in) a methylation reactor followed by exposing the methylation catalyst to methylation reaction conditions (described further herein) in the presence of an aromatic hydrocarbon feed and a methylating agent feed.
  • the precursor catalyst having bulky N-containing organic molecules adsorbed on a surface of the zeolite of MWW framework type may be introduced into (or otherwise placed in) a methylation reactor. Once in the methylation reactor, further bulky N-containing organic molecule adsorption may occur before and/or during exposure to methylation reaction conditions in the presence of an aromatic hydrocarbon feed and a methylating agent feed.
  • the precursor catalyst in an in-situ process, may be introduced into (or otherwise placed in) a methylation reactor.
  • the precursor catalyst may be contacted with bulky N-containing organic molecules under adsorption conditions to cause the bulky N-containing organic molecules to adsorb on a surface of the zeolite of the precursor catalyst. Said bulky N-containing organic molecule-modification may occur before and/or during the methylation reaction.
  • the bulky N-containing organic molecules may be present at 1 vol% to 10 vol%, or 1 vol% to 5 vol%, or 3 vol% to 10 vol%, based on a total volume of the combined aromatic hydrocarbon feed, methylating agent feed, and bulky N-containing organic molecules.
  • Steam modification typically involves contacting the catalyst with steam. Contacting may be at temperature of at least 200 °C, preferably 200 °C to 600 °C, and most preferably 200 °C to 400 °C, and for time period of from 10 minutes to 10 hours or longer, preferably from 30 minutes to 5 hours, such as 30 minutes to 2 hours.
  • Steam partial pressures may be at least 12 psia (83 kPaa), such as about 15 psia (about 104 kPaa) or higher.
  • the steam may be in a carrier gas (e.g., hydrogen).
  • Exposure rates of steam may be 1 gram/hour (g/h) to 15 g/h, preferably 2 g/h to 10 g/h, and most preferably 4 g/h to 8 g/h.
  • the precursor catalyst may be modified with steam either (a) before introduction into the methylation reactor (ex-situ) and/or (b) in-situ of the methylation reactor before the methylation reaction takes place.
  • the precursor catalyst in an ex-situ process, may be contacted with steam under steaming conditions. Then, the methylation catalyst (the precursor catalyst modified by steam) may be introduced into (or otherwise placed in) a methylation reactor followed by exposing the methylation catalyst to methylation reaction conditions (described further herein) in the presence of an aromatic hydrocarbon feed and a methylating agent feed.
  • the precursor catalyst in another example, in an in-situ process, the precursor catalyst may be introduced into (or otherwise placed in) a methylation reactor. In the methylation reactor, the precursor catalyst may be contacted with steam under steaming conditions. This process results in a methylation catalyst (a steam-modified precursor catalyst, in this instance).
  • the methylation catalyst While still in the methylation reactor, the methylation catalyst may be exposed to methylation reaction conditions in the presence of an aromatic hydrocarbon feed and a methylating agent feed.
  • an aromatic hydrocarbon feed comprising benzene and/or toluene
  • a methylating agent feed comprising one or more of methanol and dimethyl ether.
  • the aromatic hydrocarbon feed comprises toluene at a concentration ⁇ 90 wt% (e.g., ⁇ 92 wt%, ⁇ 94 wt%, ⁇ 95 wt%, ⁇ 96 wt%, ⁇ 98 wt%, or even ⁇ 99 wt%), based on the total weight of the aromatic hydrocarbon feed.
  • the aromatic hydrocarbon feed may be pre-treated to remove catalyst poisons, such as nitrogen and sulfur-compounds.
  • the aromatic hydrocarbon feed may be fed as a single or multiple streams with the same or different compositions into the methylation reactor via one or more feed inlets.
  • the methylating agent feed may be fed as a single or multiple streams with the same or different compositions into the methylation reactor via one or more feed inlets.
  • at least a portion of the aromatic feed and at least a portion of the methylating agent feed may be combined and then fed into the methylation reactor as a single or multiple stream via one or more inlets.
  • a methylation process of this disclosure can be advantageously conducted at relatively low reactor (methylation reactor) temperatures, for example ⁇ 500 °C, such as ⁇ 475 °C, ⁇ 450 °C, ⁇ 425 °C, or ⁇ 400 °C.
  • a process may be conducted at temperatures of ⁇ 200 °C, such as ⁇ 250 °C, or ⁇ 300 °C in the methylation reactor which has been found to provide commercially viable methylation reaction rates. In terms of ranges, the process may be conducted at temperatures ranging from 200 °C to 500 °C, such as from 275 °C to 475 °C, from 300 °C to 450 °C, or from 250 °C to 400 °C.
  • Such low-temperature reaction can be particularly useful with the MWW framework type zeolite. Such low-temperature reaction can be particularly advantageous where a fixed bed of the methylation catalyst is present in the methylation reactor.
  • the ability of the processes of this disclosure to be operated at low temperature carries many advantages, to name a few: higher energy efficiency, longer catalyst life, fewer species of byproducts, and small quantities of byproducts that otherwise would be produced at higher temperatures, compared to conventional benzene/toluene methylation processes at temperatures higher than 500 °C.
  • Operating pressures in the methylation reactor can vary in a broad range, e.g., from ⁇ 100 kPa, such as ⁇ 1000 kPa, ⁇ 1500 kPa, ⁇ 2000 kPa, ⁇ 3000 kPa, or ⁇ 3500 kPa, to ⁇ 8500 kPa, such as ⁇ 7000 kPa, or ⁇ 6000 kPa.
  • operating pressures may range from 700 kPa to 7000 kPa, e.g., from 1000 kPa to 6000 kPa, or from 2000 kPa to 5000 kPa.
  • the combination of a high pressure e.g., a pressure from 1500 kPa to 4500 kPa or even closer to 8500 kPa
  • a low temperature e.g., a temperature from 250 °C to 500 °C
  • WHSV values based on total aromatic hydrocarbon feed and methylating agent feed can be in the range from, e.g., 0.5 hour -1 to 50 hour -1 , such as from 5 hour -1 to 15 hour -1 , from 1 hour -1 to 10 hour -1 , or from 5 hour -1 to 10 hour -1 , or from 6.7 hour -1 to 10 hour -1 .
  • at least part of the aromatic hydrocarbon feed, the methylating agent feed and/or the methylation product mixture effluent may be present in the methylation reactor in the liquid phase.
  • the methylation reaction can be conducted in a methylation reactor, which can be any suitable reactor system comprising, but not limited to, a fixed bed reactor, a moving bed reactor, a fluidized bed reactor, and/or a reactive distillation unit.
  • the reactor may include a single methylation reaction zone or multiple methylation reaction zones therein.
  • a methylation reactor may include a bed of methylation catalyst particles where the particles have insignificant motion in relation to the bed (a fixed bed).
  • the methylation reactor includes a single or a plurality of fixed bed, continuous flow-type reactors in a down flow mode, where the reactors may be arranged in series or parallel.
  • the methylation reactor may include a single or multiple catalyst beds in series and/or in parallel.
  • the methylation catalyst beds may have various configurations such as: a single bed, several horizontal beds, several parallel packed tubes, multiple beds each in its own reactor shell, or multiple beds within a single reactor shell.
  • the fixed beds provide uniform flow distribution over entire width and length of bed to utilize all of the catalyst.
  • the methylation reactor can provide heat transfer from a fixed bed to provide effective methods for controlling temperature.
  • the efficiency of a methylation reactor containing a fixed bed of methylation catalyst may be affected by the pressure drop across the fixed bed. The pressure drop depends on various factors such as the path length, the methylation catalyst particle size, and pore size. A pressure drop that is too large may cause channeling through the catalyst bed, and poor efficiency.
  • the methylation reactor has a cylindrical geometry with axial flows through the catalyst bed.
  • the various designs of the methylation reactor may accommodate control of specific process conditions, e.g., pressure, temperature, and WHSV.
  • the WHSV determines volume and residence time that may provide the desired conversion.
  • the product of the methylation reaction, the methylation product mixture effluent can comprise xylenes, benzene and/or toluene (both residual and coproduced in the process), C9+ aromatic hydrocarbons, co-produced water, and unreacted methanol and DME.
  • o-Xylene may be present in the methylation product mixture effluent at at least 27 wt% (e.g., at least 40 wt%, at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%) based on the total weight of the xylenes in the methylation product mixture effluent.
  • o-Xylene may be present in the methylation product mixture effluent at 27 wt% to 90 wt% (e.g., 30 wt% to 90 wt%, 30 wt% to 60 wt%, 40 wt% to 70 wt%, 50 wt% to 80 wt%, or 60 wt% to 90 wt%) based on the total weight of the xylenes in the methylation product mixture effluent.
  • the temperature in the methylation reactor will affect by-product formation and a temperature lower than 500 °C may decrease light gas formation.
  • the methylation product mixture effluent contains ⁇ 10 wt%, such as ⁇ wt%, ⁇ 2 wt%, ⁇ 1 wt%, or is substantially free of light gases generated by methanol decomposition to ethylene or other olefins.
  • DME, methanol, and/or toluene can be recovered through a separation subsystem.
  • the separation subsystem may include one or more separation units.
  • the separation subsystem may include any suitable method for recovery of a DME-rich stream, a methanol-rich stream, and/or a toluene-rich stream from the methylation product mixture effluent.
  • the separation subsystem includes a first recycle channel.
  • the first recycle channel is in fluid communication with the methylation agent feed or a methylation reactor inlet.
  • the separation subsystem includes a first separation unit, the first separation unit may separate an aqueous phase and an oil phase.
  • the separation subsystem includes a second separation unit, the second separation unit may separate a DME-rich stream from the oil phase.
  • the DME-rich stream flows through the first recycle channel which may be in fluid communication with the second separation unit and the methylation agent feed or a methylation reactor inlet.
  • the second separation unit separates an aromatics rich stream from the oil phase.
  • the separation subsystem includes a third separation unit.
  • the third separation unit may separate the aromatics-rich stream into a toluene-rich stream and a xylenes- rich stream.
  • the toluene-rich stream flows through a second recycle channel to the methylation agent feed or a methylation reactor inlet.
  • the separation subsystem includes a fourth separation unit, the fourth separation unit may separate the aqueous phase into a water-rich stream and a methanol-rich stream.
  • the methanol-rich stream flows through the third recycle channel which may be in fluid communication with the fourth separation unit and the methylation agent feed or a methylation reactor inlet.
  • the methylation product mixture effluent is separated into an aqueous phase and an oil phase in a first separation unit.
  • the method of separating the aqueous phase from the oil phase can be accomplished by a coalescing plate separator, e.g., described in U.S. Patent Nos. 4,722,800 and 5,068,035; a centrifugal separator, e.g., described in U.S. Patent Nos.4,175,040; 4,959,158; and 5,591,340; a hydrocyclone separator, e.g., described in U.S. Patent Nos. 4,428,839; 4,927,536; and 5,667,686; or other suitable methods.
  • the oil phase of the methylation product mixture effluent may contain at least 80 wt% xylenes.
  • the methylation product mixture effluent comprising an aqueous phase and an oil phase enters a first separation unit; the aqueous phase, which is denser, settles to the bottom of an upstream chamber and can be drawn from the water drain tube down below.
  • the oil phase, which is lighter, is located on top of the aqueous phase and can spill over a dividing wall to the downstream chamber where it can then be drawn from the bottom of the downstream chamber.
  • the oil phase may be fed to a second separation unit to separate a DME-rich stream, an aromatics-rich stream, and methane or other by- products.
  • the DME-rich stream may be fully or partially separated from other products and by-products to be recycled through the first recycling channel.
  • the DME-rich stream contains DME in ⁇ 50 wt%, ⁇ 60 wt%, ⁇ 70 wt%, ⁇ 80 wt%, ⁇ 90 wt%, ⁇ 95 wt%, ⁇ 98 wt%, or ⁇ 99 wt%, based on the total weight of the DME-rich stream.
  • the methylating agent feed contains DME from the DME-rich stream in ⁇ 20 wt%, ⁇ 40 wt%, ⁇ 60 wt%, ⁇ 80 wt%, ⁇ 90 wt%, ⁇ 95 wt%, ⁇ 98 wt%, or ⁇ 99 wt%, based on the total weight of the DME in the methylating agent stream. In at least one embodiment all of the DME in the methylation agent feed is obtained from the DME-rich stream.
  • the second separation unit partially or fully separates methane from other products, and by-products. In at least one embodiment, the methane is used as fuel gas.
  • the second separation unit produces an aromatics-rich stream comprising C6 to C9+ aromatic hydrocarbon products and by-products.
  • the second separation unit produces a stream of C9+ aromatics.
  • the stream of C9+ aromatics can be recovered for blending into the gasoline pool or transalkylated with benzene and/or toluene to make additional xylenes.
  • the second separation unit produces a aromatics-rich stream comprising xylenes in ⁇ 50 wt%, ⁇ 60 wt%, ⁇ 70 wt%, ⁇ 80 wt%, ⁇ 90 wt%, ⁇ 95 wt%, ⁇ 98 wt%, or ⁇ 99 wt%, based on the total weight of the aromatics-rich stream.
  • the aromatics- rich stream comprises o-xylene.
  • the aromatics-rich stream contains o- xylene in ⁇ 50 wt%, ⁇ 60 wt%, ⁇ 70 wt%, ⁇ 80 wt%, ⁇ 90 wt%, ⁇ 95 wt%, ⁇ 98 wt%, or ⁇ 99 wt%, based on the total weight of the aromatics-rich stream.
  • the second separation unit is a distillation system comprising one or more distillation columns.
  • the distillation system may be operated at increased pressure, such as ⁇ 400 kPag, ⁇ 500 kPag, ⁇ 600 kPag, ⁇ 700 kPag, ⁇ 800 kPag, ⁇ 900 kPag, such as from 400 kPag to 1400 kPag, from 600 kPag to 1300 kPag, from 700 kPag to 1200 kPag, from 800 kPag to 1100 kPag, or from 900 kPag to 1000 kPag.
  • the aromatics-rich stream is processed in a third separation unit and further separated into a xylenes-rich stream and a toluene-rich stream, which may comprise benzene.
  • the toluene-rich stream comprising benzene and/or toluene may contain toluene in ⁇ 50 wt%, ⁇ 60 wt%, ⁇ 70 wt%, ⁇ 80 wt%, ⁇ 90 wt%, ⁇ 95 wt%, ⁇ 98 wt%, or ⁇ 99 wt%, based on the total weight of the toluene-rich stream.
  • the toluene-rich stream comprises benzene and toluene in a combined wt% of ⁇ 50 wt%, ⁇ 60 wt%, ⁇ 70 wt%, ⁇ 80 wt%, ⁇ 90 wt%, ⁇ 95 wt%, ⁇ 98 wt%, or ⁇ 99 wt%, based on the total weight of the toluene-rich stream.
  • the xylenes-rich stream may contain o-xylene in at least 27 wt% (e.g., at least 40 wt%, at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, 27 wt% to 90 wt%, 30 wt% to 90 wt%, 30 wt% to 60 wt%, 40 wt% to 70 wt%, 50 wt% to 80 wt%, or 60 wt% to 90 wt%), based on the total weight of the xylenes-rich stream.
  • 27 wt% e.g., at least 40 wt%, at least 50 wt%, at least 60 wt%, at least 70 wt%, at least 80 wt%, 27 wt% to 90 wt%, 30 wt% to 90 wt%, 30 wt% to 60 wt%, 40 wt
  • the aqueous phase is transferred to a fourth separation unit to separate a methanol-rich stream from a water-rich stream.
  • the methanol- rich stream to be recycled through the third recycling channel contains methanol at ⁇ 50 wt%, ⁇ 60 wt%, ⁇ 70 wt%, ⁇ 80 wt%, ⁇ 90 wt%, ⁇ 95 wt%, ⁇ 98 wt%, or ⁇ 99 wt%, based on the overall weight of the methanol-rich stream.
  • the fourth separation unit is a distillation system, an example system is described in U.S. Patent Nos. 3,293,154 and 4,210,495.
  • the separation system employed is a membrane separation system or pervaporation separation system.
  • the DME-rich stream is combined with the methanol-rich stream to form a single recycle stream.
  • the toluene-rich stream, the DME-rich stream, and the methanol-rich stream are combined to form a single recycle stream.
  • FIG. 1 schematically illustrates a process for converting benzene and/or toluene via methylation with methanol and/or DME to produce o-xylene according to one embodiment of this disclosure.
  • Methylating agent feed 101 comprising methanol and/or DME is combined with aromatic hydrocarbon feed 103 comprising toluene and/or benzene in fluid transfer line 105.
  • Fluid transfer line 105 may contain an agitator or other mixing device (not shown) in order to combine methylating agent feed 101 and aromatic hydrocarbon feed 103 to form a combined feed.
  • the combined feed is fed by line 107 to heat exchanger 109 to pre-heat the combined feed.
  • the heated combined feed comprising a mixture of feed 101 and feed 103 is fed through line 111 to heat exchanger 113. Heat exchanger 113 may be used to heat or cool the combined feed as necessary.
  • the combined feed is then passed through line 115, through inlet 117 to methylation reactor 119.
  • Line 115 may also include a pump or series of pumps (not shown) in order to maintain sufficient pressure and WHSV in methylation reactor 119.
  • Inlet 117 may accept one or more feeds or streams comprising one or more recycle streams.
  • Methylation reactor 119 can be a fixed or fluid bed reactor containing the methylation catalyst (not shown) and is operated at methylation reaction conditions, which may include a temperature lower than 500 °C and an absolute pressure ⁇ 100 kPa. Methylation reactor 119 may have one or more methylation reactors (not shown) where the methylation catalyst is present.
  • the product of the methylation conditions in the methylation reactor (the methylation product mixture effluent) can be a mixture of xylenes, water, methanol, dimethyl ether, and by-products and is fed from methylation reactor 119 through outlet 121 to line 123 and ultimately to heat exchanger 109 to be cooled.
  • the cooled methylation product mixture effluent is passed through line 125 to heat exchanger 127 to be either heated or cooled as necessary to arrive at the desired temperature for separation, then through line 129 to separation subsystem 131.
  • Separation subsystem 131 may contain one or more separation units (not shown).
  • Separation subsystem 131 may separate methane or other light gases which can be removed via line 133 and may lead be used as fuel gas (not shown). [0095] Separation subsystem 131 may further separate a dimethyl ether-rich stream which is then provided to line 135, which can be recycled into methylating agent feed 101 or methylation reactor inlet 117.
  • Line 135 may include pumps or compressors so that the DME-rich stream may enter the methylation agent feed or methylation reactor at a desired pressure, the combination of lines and pumps or compressors is a first recycling channel.
  • the first recycling channel may contain other combinations of lines and pumps or compressors (not shown) suitable to recycle DME to methylation reactor 119.
  • Separation subsystem 131 may further separate toluene-rich stream 137, which may contain benzene and can be recycled into aromatic hydrocarbon feed 103 or methylation reactor inlet 117.
  • Line 137 may include pumps or compressors so that the toluene-rich stream may enter the aromatic hydrocarbon feed or methylation reactor at a desired pressure; the combination of lines and pumps or compressors is a second recycling channel.
  • the separation may yield a xylenes-rich stream which is sent out of line 139, and line 139 may be connected to other systems for further processing (not shown).
  • the xylenes-rich stream can be fed to a separation system such as a crystallizer or a simulated moving bed adsorption chromatography to recover a high-purity p-xylene product and produce a o-xylene-rich stream (which may further comprise m-xylene).
  • Separation subsystem 131 may further separate a methanol-rich stream which is then provided to line 141, which can be recycled into methylating agent feed 101 or methylation reactor inlet 117.
  • Line 141 may include pumps or compressors so that the methanol-rich stream may enter the methylation agent feed or methylation reactor at a desired pressure; the combination of lines and pumps or compressors is a third recycling channel.
  • the third recycling channel may contain other combinations of lines and pumps or compressors (not shown) suitable to recycle methanol to methylation reactor 119. Furthermore, the separation may yield a water-rich stream which is sent out of line 143, and line 143 may be connected to other systems for further processing (not shown), comprising wastewater purification systems (not shown).
  • FIG. 2 schematically illustrates a process for converting benzene/toluene via methylation with methanol/dimethyl ether to produce o-xylene according to an embodiment of this disclosure.
  • Methylating agent feed 201 comprising methanol and/or DME, is combined with aromatic hydrocarbon feed 203 comprising toluene and/or benzene in fluid transfer line 205.
  • Fluid transfer line 205 may contain an agitator or other mixing device (not shown) in order to fully combine methylating agent feed 201 and aromatic hydrocarbon feed 203.
  • the combined feed is transferred by line 207 to heat exchanger 209 to pre-heat the combined feed.
  • the heated combined feed comprising a mixture of feed 201 and feed 203 is fed through line 211 to heat exchanger 213.
  • Heat exchanger 213 may be used to heat or cool the combined feed as necessary.
  • the combined feed is then passed through line 215, through inlet 217, to methylation reactor 219.
  • Line 215 may also include a pump or series of pumps (not shown) in order to maintain sufficient pressure and WHSV in methylation reactor 219.
  • Inlet 217 may accept one or more feeds or streams comprising one or more recycle streams.
  • Methylation reactor 219 can be a fixed or fluid bed reactor containing the methylation catalyst (not shown) and is operated at methylation reaction conditions, which may include a temperatures ⁇ 500 °C and pressures ⁇ 100 kPa. Methylation reactor 219 may have one or more methylation reactors (not shown) where the methylation catalyst is present.
  • the product of the methylation conditions in the methylation reactor (the methylation product mixture effluent) can be a mixture of xylenes, water, methanol, dimethyl ether, and by-products.
  • First separation unit 233 separates the aqueous phase (a water/methanol mixture) of the methylation product mixture effluent from the oil phase (a hydrocarbon portion of the methylation product mixture effluent) of the methylation product mixture effluent.
  • First separation unit 233 may function through any suitable method of separating aqueous and oil phases, including simple phase separation, hydrocyclonic separation, or other suitable methods.
  • the oil phase of the methylation product mixture effluent may contain xylenes, methane, dimethyl ether, unreacted benzene or toluene, and other by-products.
  • the hydrocarbon portion of the methylation product mixture effluent is passed through outlet 235 through line 237 to inlet 239 of second separation unit 241.
  • the aqueous phase is passed through outlet 269 to line 271.
  • Second separation unit 248 separates the oil phase into (i) a light gas portion comprising methane, which can be vented to fuel gas through line 243; (ii) a dimethyl ether- rich stream, which is passed through outlet 245 through line 247 to pump 249, through line 251 and is recycled into methylating agent feed 201 or methylation reactor inlet 217; the combination of lines and pumps or compressors is a first recycling channel; and (iii) a aromatics-rich stream comprising o-xylene, p-xylene, and m-xylene, which can be removed for further processing through outlet 253 and line 255.
  • Second separation unit 241 can be a distillation column run at sufficient pressure to allow dimethyl ether to be separated as a liquid while not requiring a bottoms temperature sufficiently high so as to cause decomposition of portions of the methylation product mixture effluent.
  • the aromatics-rich stream passed though line 255 may be introduced to inlet 257 and into third separation unit 259 where it can be separated. The separation may yield a toluene- rich stream which is sent out of outlet 261 through line 263 and may be recycled to aromatic hydrocarbon feed 203 or methylation reactor inlet 217.
  • Line 263 may include pumps or compressors so that the toluene-rich stream may enter the aromatic hydrocarbon feed or methylation reactor at a desired pressure, the combination of lines and pumps or compressors is a second recycling channel. Furthermore, the separation may yield a xylenes-rich stream which is sent out of outlet 265 through line 267, and line 267 may be connected to other systems for further processing (not shown). [0102]
  • the aqueous phase from first separation unit 233 can be passed through outlet 269 and through line 271 to inlet 273 of fourth separation unit 275.
  • Fourth separation unit 275 separates a water-rich stream and a methanol-rich stream.
  • Fourth separation unit 275 can function through any suitable method of separating methanol and water, including distillation, pervaporation, membrane separation, or other suitable methods.
  • the water rich stream may be passed through outlet 277 and line 279 for further processing or disposal.
  • the methanol rich stream can be sent out of outlet 281 to line 283 and to pump 285.
  • the methanol rich stream may then be passed through line 289 and introduced to methylating agent feed 201 or methylation reactor inlet 217 (not shown).
  • Lines 283 and 289 may contain additional pumps (additional to pump 285) or compressors to return the methanol-rich stream at a desired pressure to either methylation agent feed 201 or methylation reactor inlet 217; the combination of lines and pumps are a third recycle channel.
  • Example 1 An exemplary process for converting an aromatic feed via methylation with a methylating feed to produce o-xylene with higher than equilibrium selectivity in the presence of a methylation catalyst modified ex-situ was performed. First, the MCM-49 based precursor catalyst of Example C1 was modified with a 20 wt% SiO 2 coating.
  • This catalyst was prepared by mixing tetraethylorthosilicate (TEOS; 4.1wt% SiO2; > 99.0 wt% purity, Sigma Aldrich) at 80°C under stirring for 1 hour in n-hexane (97 wt% purity, Sigma Aldrich). This procedure was repeated for multiple times, leading to a total concentration of 20 wt% added SiO 2 in the methylation catalyst.
  • the methylation catalyst was then loaded into a reactor, where the methylation reaction took place at 600 psig, 350°C and 6.4 hour -1 WHSV, and with a 1:3 molar ratio of methanol to toluene feed.
  • FIG. 3A shows the toluene conversion
  • FIG. 3A shows the toluene conversion
  • Example 3B shows the xylene isomers selectivities based on the total weight of xylenes produced. As seen in FIG. 3B, the selectivity of o-xylene within the methylation product mixture effluent surpassed the 40% mark, which is significantly superior to that in Comparative Example C1.
  • Example 2 An exemplary process for converting an aromatic feed via methylation with a methylating feed to produce o-xylene with higher than equilibrium selectivity in the presence of a methylation catalyst modified in-situ was performed. First, the MCM-49 based precursor catalyst of Example C1 was loaded into a reactor and modified by contacting the precursor catalyst with 2,4-dimethyl quinolone at 350°C forming the methylation catalyst.
  • the methylation catalyst was then used for methylation reaction with a toluene feed and a methanol feed at 600 psig, 350°C and 15.5 hour -1 WHSV, and with a 1:3 molar ratio of methanol to toluene.
  • FIG. 4A shows the toluene conversion
  • FIG. 4B shows the xylene isomers selectivities based on the total weight of xylenes produced. As seen in FIG.4B, the selectivity of o-xylene within the methylation product mixture effluent surpassed the 70% mark, which is significantly superior to that in Comparative Example C1. [0107] Example 3.
  • Non-limiting Example Embodiments [0108] This disclosure can further include the following non-limiting embodiments: [0109] A1.
  • a process comprising: contacting an aromatic hydrocarbon feed with a methylating agent feed in the presence of a methylation catalyst in a methylation reactor under methylation reaction conditions to produce a methylation product mixture effluent exiting the methylation reactor, wherein the aromatic hydrocarbon feed comprises benzene and/or toluene, the methylating agent feed comprises methanol and/or dimethyl ether, the methylation catalyst comprises a modified zeolite comprising (a) a zeolite of MWW framework type and (b) a surface modification agent on at least a portion of an outer surface of the zeolite, and the methylation product mixture effluent comprises o-xylene at a concentration of at least 27 wt%, based on a total weight of the xylenes in the methylation product mixture effluent.
  • the aromatic hydrocarbon feed comprises benzene and/or toluene
  • the methylating agent feed comprises methanol and/or dimethyl
  • A2 The process of A1, wherein the methylation product mixture effluent comprises the o-xylene at a concentration of at least 30 wt%, based on a total weight of the xylenes in the methylation product mixture effluent.
  • A3. The process of A1 or A2, wherein the surface modification agent comprise: silica, a bulky N-containing organic molecule, coke, or any combination thereof.
  • A4. The process of any of A1 to A3, wherein the surface modification agent at least partially passivates a plurality of acid sites on the outer surface of the zeolite.
  • A5. The process of any of A1 to A4, wherein the surface modification agent comprises silica.
  • A6 The process of A5, wherein the methylation catalyst is produced by a method comprising: providing a precursor catalyst comprising the zeolite; and subjecting the precursor catalyst to one or more treatments comprising contacting the precursor catalyst with an organosilicon compound, wherein each treatment is followed by calcining the precursor catalyst to produce the methylation catalyst.
  • A7 The process of A6, wherein the organosilicon compound comprise a silicone, a siloxane, and/or a silane.
  • the organosilicon compound comprise at least one of: dimethyl silicone, diethyl silicone, phenylmethyl silicone, methylhydrogen silicone, ethylhydrogen silicone, phenylhydrogen silicone, methylethyl silicone, phenylethyl silicone, diphenyl silicone, methyltrifluoropropyl silicone, ethyltrifluoropropyl silicone, polydimethyl silicone, tetrachlorophenylmethyl silicone, tetrachlorophenylethyl silicone, tetrachlorophenylhydrogen silicone, tetrachlorophenylphenyl silicone, methylvinyl silicone, and ethylvinyl silicone.
  • A9 The process of any of A1 to A8, wherein the surface modification agent comprises a bulky N-containing organic molecule.
  • A10 The process of A9, wherein the bulky N-containing organic molecule comprises 2,4-dimethylquinoline, collidines, and/or di-tert-butyl-pyridine.
  • A11 The process of A9, further comprising: providing a precursor catalyst comprising the zeolite in the methylation reactor; and contacting the precursor catalyst with the bulky N-containing organic molecule to produce the methylation catalyst.
  • A11 The process of A11, wherein the contacting of the precursor catalyst with the bulky N-containing organic molecule occurs during at least a portion of the contacting of the aromatic hydrocarbon feed with the methylating agent feed.
  • A13 The process of A11, wherein the contacting of the precursor catalyst with the bulky N-containing organic molecule occurs before the contacting of the aromatic hydrocarbon feed with the methylating agent feed and, optionally, during at least a portion of the contacting of the aromatic hydrocarbon feed with the methylating agent feed.
  • A14 The process of any of A1 to A13, wherein the surface modification agent is coke. [0123] A15.
  • the process of A14 further comprising: providing a precursor catalyst comprising the zeolite; and contacting the precursor catalyst with a thermally decomposable organic compound at an elevated temperature at or above a decomposition temperature of the thermally decomposable organic compound to deposit coke on the surface of the zeolite and produce the methylation catalyst.
  • A16 The process of A15, wherein the precursor catalyst is provided in the methylation reactor before the contacting of the precursor catalyst with the thermally decomposable organic compound.
  • A17 further comprising: adding the precursor catalyst to the methylation reactor before the contacting of the aromatic hydrocarbon feed with the methylating agent feed in the presence of the methylation catalyst.
  • any of A1 to A17, wherein the methylation reaction conditions comprise a temperature in a range from 200 °C to 500 °C and an absolute pressure in a range from 700 kPa to 8,500 kPa.
  • A19 The process of A18, wherein the methylation reaction conditions comprises the temperature from 250 °C to 450 °C.
  • A20 The process of A18, wherein the methylation reaction conditions comprises the absolute pressure in a range from 1,500 kPa to 6,000 kPa.
  • the process of A18, wherein the methylation reaction conditions comprises conditions that cause the methylation reaction to occur in a supercritical phase. [0130] A22.
  • any of A1 to A21 wherein the zeolite comprises MCM-22, PSH- 3, SSZ-25, ERB-1, ITQ-1, ITQ-2, MCM-36, MCM-49, MCM-56, EMM-10, EMM-12, EMM- 13, UZM-8, UZM-8HS, UZM-37, UCB-3, or a mixture of two or more thereof.
  • A23 The process of any of A1 to A22, further comprising: separating via fractionation an o-xylene stream rich in o-xylene from the methylation product mixture effluent.
  • A24 The process of any of A1 to A21, wherein the zeolite comprises MCM-22, PSH- 3, SSZ-25, ERB-1, ITQ-1, ITQ-2, MCM-36, MCM-49, MCM-56, EMM-10, EMM-12, EMM- 13, UZM-8, UZM-8HS, UZM-37, UCB-3, or a mixture of two
  • a process comprising: providing a precursor catalyst comprising a zeolite of the MWW framework structure; loading the precursor catalyst in a methylation reactor; contacting the precursor catalyst in the methylation reactor with a surface modification agent to produce a methylation catalyst comprising a modified zeolite comprising the surface modification agent on at least a portion of an outer surface of the zeolite; and contacting the methylation catalyst in the methylation reactor with an aromatic hydrocarbon feed and a methylating agent feed under methylation reaction conditions to produce a methylation product mixture effluent, wherein the aromatic hydrocarbon feed comprises benzene and/or toluene, the methylating agent feed comprises methanol and/or dimethyl ether, and the methylation product mixture effluent comprises o-xylene
  • B2 The process of B1, wherein the surface modification agent comprises a bulky N-containing compound, and wherein the contacting of the surface modification agent with the precursor catalyst occurs before and optionally during the contacting of the methylation catalyst with the aromatic hydrocarbon feed and the methylating agent feed.
  • B3 The process of B2, wherein the bulky N-containing organic molecule comprises 2,4-dimethylquinoline, collidines, and/or di-tert-butyl-pyridine.
  • any of B1 to B3 wherein the surface modification agent comprises coke
  • the method further comprises contacting the precursor catalyst with a thermally decomposable organic compound at an elevated temperature at or above a decomposition temperature of the thermally decomposable organic compound to deposit the coke on the surface of the zeolite and produce the methylation catalyst.
  • B5. The process of any of B1 to B4, wherein the methylation product mixture effluent comprises the o-xylene at a concentration of at least 40 wt%, based on the total weight of the xylenes in the methylation product mixture effluent.
  • B6 wherein the methylation product mixture effluent comprises the o-xylene at a concentration of at least 40 wt%, based on the total weight of the xylenes in the methylation product mixture effluent.
  • B7 The process of any of B1 to B5, wherein the surface modification agent at least partially passivates a plurality of acid sites on the outer surface of the zeolite.
  • B7 The process of any of B1 to B6, wherein the methylation reaction conditions comprise a temperature in a range from 200 °C to 500 °C and an absolute pressure in a range from 700 kPa to 8,500 kPa.
  • B8 The process of B7, wherein the methylation reaction conditions comprises the temperature from 250 °C to 450 °C.
  • B9 The process of B7, wherein the methylation reaction conditions comprises the absolute pressure in a range from 1,500 kPa to 6,000 kPa.
  • B7 wherein the methylation reaction conditions comprises conditions that cause the methylation reaction to occur in a supercritical phase.
  • B11 The process of any of B1 to B10, wherein the zeolite comprises MCM-22, PSH- 3, SSZ-25, ERB-1, ITQ-1, ITQ-2, MCM-36, MCM-49, MCM-56, EMM-10, EMM-12, EMM- 13, UZM-8, UZM-8HS, UZM-37, UCB-3, or a mixture of two or more thereof.
  • a process comprising: providing a precursor catalyst comprising a zeolite of the MWW framework structure; loading the precursor catalyst in a methylation reactor; contacting the precursor catalyst in the methylation reactor with water to produce a methylation catalyst comprising a modified zeolite comprising neutralized acid groups on at least a portion of an outer surface of the zeolite; and contacting the methylation catalyst in the methylation reactor with an aromatic hydrocarbon feed and a methylating agent feed under methylation reaction conditions to produce a methylation product mixture effluent, wherein the aromatic hydrocarbon feed comprises benzene and/or toluene, the methylating agent feed comprises methanol and/or dimethyl ether, and the methylation product mixture effluent comprises o- xylene at a concentration of at least 27 wt%, based on a total weight of the xylenes in the methylation product mixture effluent.
  • C2 The process of C1, wherein the methylation product mixture effluent comprises the o-xylene at a concentration of at least 30 wt%, based on a total weight of the xylenes in the methylation product mixture effluent.
  • C3 The process of C1 or C2, wherein the methylation reaction conditions comprise a temperature in a range from 200 °C to 500 °C and an absolute pressure in a range from 700 kPa to 8,500 kPa.
  • C4 The process of C3, wherein the methylation reaction conditions comprises the temperature from 250 °C to 450 °C.
  • C3 wherein the methylation reaction conditions comprises the absolute pressure in a range from 1,500 kPa to 6,000 kPa.
  • C6 The process of C3, wherein the methylation reaction conditions comprises conditions that cause the methylation reaction to occur in a supercritical phase.
  • C7 The process of any of C1 to C6, wherein the zeolite comprises MCM-22, PSH- 3, SSZ-25, ERB-1, ITQ-1, ITQ-2, MCM-36, MCM-49, MCM-56, EMM-10, EMM-12, EMM- 13, UZM-8, UZM-8HS, UZM-37, UCB-3, or a mixture of two or more thereof.
  • C8 The process of C3 to C6, wherein the zeolite comprises MCM-22, PSH- 3, SSZ-25, ERB-1, ITQ-1, ITQ-2, MCM-36, MCM-49, MCM-56, EMM-10, EMM-12, EMM- 13, UZM-8, UZM
  • a process comprising: providing a precursor catalyst comprising a zeolite of the MWW framework structure; subjecting the precursor catalyst to one or more treatments comprising contacting the precursor catalyst with an organosilicon compound, wherein each treatment is followed by calcining the precursor catalyst to produce the methylation catalyst, wherein the surface modification agent is silica; loading the methylation catalyst in a methylation reactor; and contacting the methylation catalyst in the methylation reactor with an aromatic hydrocarbon feed and a methylating agent feed under methylation reaction conditions to produce a methylation product mixture effluent, wherein the aromatic hydrocarbon feed comprises benzene and/or toluene, the methylating agent feed comprises methanol and/or dimethyl ether, and the methylation product mixture effluent comprises o-xylene at a concentration of at least 27 wt%, based on a total weight of the xylenes in the methylation product mixture effluent.
  • D2 The process of D1, wherein the methylation product mixture effluent comprises the o-xylene at a concentration of at least 30 wt%, based on a total weight of the xylenes in the methylation product mixture effluent.
  • D3 The process of D1 or D2, wherein the surface modification agent at least partially passivates a plurality of acid sites on the outer surface of the zeolite.
  • D4 The process of any of D1 to D3, wherein the organosilicon compound comprise a silicone, a siloxane, and/or a silane.
  • the organosilicon compound comprise dimethyl silicone, diethyl silicone, phenylmethyl silicone, methylhydrogen silicone, ethylhydrogen silicone, phenylhydrogen silicone, methylethyl silicone, phenylethyl silicone, diphenyl silicone, methyltrifluoropropyl silicone, ethyltrifluoropropyl silicone, polydimethyl silicone, tetrachlorophenylmethyl silicone, tetrachlorophenylethyl silicone, tetrachlorophenylhydrogen silicone, tetrachlorophenylphenyl silicone, methylvinyl silicone, and/or ethylvinyl silicone.
  • D6 The process of any of D1 to D5, wherein the methylation reaction conditions comprise a temperature in a range from 200 °C to 500 °C and an absolute pressure in a range from 700 kPa to 8,500 kPa.
  • D7 The process of D6, wherein the methylation reaction conditions comprises the temperature from 250 °C to 450 °C.
  • D8 The process of D6, wherein the methylation reaction conditions comprises the absolute pressure in a range from 1,500 kPa to 6,000 kPa.
  • D9 The process of D6, wherein the methylation reaction conditions comprises conditions that cause the methylation reaction to occur in a supercritical phase. [0164] D10.
  • any of D1 to D9 wherein the zeolite comprises MCM-22, PSH- 3, SSZ-25, ERB-1, ITQ-1, ITQ-2, MCM-36, MCM-49, MCM-56, EMM-10, EMM-12, EMM- 13, UZM-8, UZM-8HS, UZM-37, UCB-3, or a mixture of two or more thereof.
  • D11 The process of any of D1 to D10, further comprising: separating via fractionation an o-xylene stream rich in o-xylene from the methylation product mixture effluent.
  • a process comprising: providing a precursor catalyst comprising a zeolite of the MWW framework structure; contacting the precursor catalyst with a thermally decomposable organic compound at an elevated temperature at or above a decomposition temperature of the thermally decomposable organic compound to deposit the coke on the surface of the zeolite and produce a methylation catalyst; loading the methylation catalyst in a methylation reactor; and contacting the methylation catalyst in the methylation reactor with an aromatic hydrocarbon feed and a methylating agent feed under methylation reaction conditions to produce a methylation product mixture effluent, wherein the aromatic hydrocarbon feed comprises benzene and/or toluene, the methylating agent feed comprises methanol and/or dimethyl ether, and the methylation product mixture effluent
  • E2 The process of E1, wherein the methylation product mixture effluent comprises the o-xylene at a concentration of at least 30 wt%, based on a total weight of the xylenes in the methylation product mixture effluent.
  • E3. The process of E1 or E2, wherein the methylation reaction conditions comprise a temperature in a range from 200 °C to 500 °C and an absolute pressure in a range from 700 kPa to 8,500 kPa.
  • E4 The process of E3, wherein the methylation reaction conditions comprises the temperature from 250 °C to 450 °C.
  • E3 wherein the methylation reaction conditions comprises the absolute pressure in a range from 1,500 kPa to 6,000 kPa.
  • E6 The process of E3, wherein the methylation reaction conditions comprises conditions that cause the methylation reaction to occur in a supercritical phase.
  • E7 The process of any of E1 to E6, wherein the zeolite comprises MCM-22, PSH- 3, SSZ-25, ERB-1, ITQ-1, ITQ-2, MCM-36, MCM-49, MCM-56, EMM-10, EMM-12, EMM- 13, UZM-8, UZM-8HS, UZM-37, UCB-3, or a mixture of two or more thereof.
  • E8 The process of E3 to E6, wherein the zeolite comprises MCM-22, PSH- 3, SSZ-25, ERB-1, ITQ-1, ITQ-2, MCM-36, MCM-49, MCM-56, EMM-10, EMM-12, EMM- 13, UZM-8, UZM
  • compositions and methods are described herein in terms of “comprising” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps.

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Abstract

L'invention concerne des catalyseurs de méthylation contenant des zéolites à surface modifiée qui peuvent être utiles pour convertir du benzène et/ou du toluène par méthylation avec du méthanol et/ou de l'éther diméthylique pour produire des produits de xylène avec une sélectivité d'o-xylène supérieure à celle à l'équilibre. Par exemple, un procédé de méthylation peut comprendre : la mise en contact d'une charge d'hydrocarbure aromatique avec une charge d'agent de méthylation en présence d'un catalyseur de méthylation dans un réacteur de méthylation dans des conditions de réaction de méthylation pour produire un effluent de mélange de produit de méthylation sortant du réacteur de méthylation, le catalyseur de méthylation comprenant une zéolite modifiée comprenant (a) une zéolite de type à structure MWW, telle que MCM-49, et. (b) un agent de modification de surface sur au moins une partie d'une surface externe de la zéolite, et l'effluent de mélange de produit de méthylation ayant une sélectivité d'o-xylène supérieure à celle à l'équilibre.
PCT/US2022/077325 2021-10-12 2022-09-30 Catalyseur et procédés de production de produits de xylène riches en o-xylène WO2023064683A1 (fr)

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