Methods addressing aging in flocculated molecular sieve catalysts for hydrocarbon conversion processes
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
C08F-002/00
B01J-029/06
C08F-010/00
출원번호
UP-0021918
(2008-01-29)
등록번호
US-7732537
(2010-06-29)
발명자
/ 주소
Chang, Yun-feng
Martens, Luc R. M.
Mertens, Machteld Maria
Vaughn, Stephen N.
출원인 / 주소
ExxonMobil Chemical Patents Inc.
대리인 / 주소
Faulkner, Kevin M.
인용정보
피인용 횟수 :
1인용 특허 :
25
초록▼
One aspect of the invention relates to a method for formulating a molecular sieve catalyst composition, the method comprising the steps of: (a) providing a synthesized molecular sieve having been recovered in the presence of a flocculant; (b) thermally treating the synthesized molecular sieve at a t
One aspect of the invention relates to a method for formulating a molecular sieve catalyst composition, the method comprising the steps of: (a) providing a synthesized molecular sieve having been recovered in the presence of a flocculant; (b) thermally treating the synthesized molecular sieve at a temperature from about 50° C. to about 250° C. and under other conditions sufficient to form a thermally treated synthesized molecular sieve having a first LOI less than 26% and a first micropore surface area; (c) aging the thermally treated synthesized molecular sieve for at least one year; (d) analyzing the aged, thermally treated molecular sieve to determine a second micropore surface area, wherein the second micropore surface area is 3% or less lower than the first micropore surface area; and (e) combining the aged, thermally treated synthesized molecular sieve, a binder, and optionally a matrix material to produce an aged, formulated molecular sieve catalyst composition.
대표청구항▼
What is claimed is: 1. A method for formulating a molecular sieve catalyst composition, the method comprising the steps of: (a) providing a synthesized molecular sieve having been recovered in the presence of a flocculant; (b) thermally treating the synthesized molecular sieve at a temperature from
What is claimed is: 1. A method for formulating a molecular sieve catalyst composition, the method comprising the steps of: (a) providing a synthesized molecular sieve having been recovered in the presence of a flocculant; (b) thermally treating the synthesized molecular sieve at a temperature from about 50° C. to about 250° C. and under other conditions sufficient to form a thermally treated synthesized molecular sieve having a first LOI less than 26% and a first micropore surface area; (c) aging the thermally treated synthesized molecular sieve for at least three months; (d) analyzing the aged, thermally treated molecular sieve to determine a second micropore surface area, wherein the second micropore surface area is not more than 3% lower than the first micropore surface area; and (e) combining the aged, thermally treated synthesized molecular sieve, a binder, and optionally a matrix material to produce an aged, formulated molecular sieve catalyst composition. 2. The method of claim 1, wherein the providing in step (a) comprises: (i) crystallizing a molecular sieve in a slurry in a reaction vessel, the slurry comprising at least two of a silicon source, an aluminum source, and a phosphorous source; (ii) settling the molecular sieve in a reaction vessel by introducing the flocculant to the slurry; and (iii) recovering the molecular sieve to form the synthesized molecular sieve. 3. The method of claim 1, wherein the synthesized molecular sieve is synthesized from a synthesis mixture comprising a silicon source, a phosphorous source, and an aluminum source, optionally in the presence of a templating agent. 4. The method of claim 1, wherein the combining in step (e) comprises forming a slurry containing said ingredients and spray drying the slurry to form a spray dried formulated molecular sieve catalyst composition. 5. The method of claim 4, wherein the spray dried formulated molecular sieve catalyst composition is further calcined. 6. The method of claim 1, wherein the synthesized molecular sieve is selected from one or more of the group consisting of a metalloaluminophosphate, an aluminophosphate, a CHA framework-type molecular sieve, an AEI framework-type molecular sieve, and a CHA and AEI intergrowth or mixed framework-type molecular sieve. 7. The method of claim 1, wherein the amount of synthesized molecular sieve in step (a) is greater than 250 Kg. 8. The method of claim 1, wherein, in step (b), the synthesized molecular sieve is thermally treated at a temperature from 80° C. to 150° C. 9. The method of claim 1, wherein the thermally treated molecular sieve has a LOI no less than 25%. 10. The method of claim 1, wherein the thermally treated molecular sieve has a LOI in the range from 10% to 20%. 11. The method of claim 2, wherein, in step (iii), the molecular sieve is recovered by filtration. 12. The method of claim 2, wherein, prior to step (iii), a portion of a liquid in the synthesis mixture is separated from the molecular sieve, and additional flocculant, additional liquid, or both is(are) introduced to the synthesis mixture. 13. The process of claim 1, wherein the flocculant is anionic or cationic. 14. A process for producing one or more olefins, the process comprising the steps of: (A) formulating a molecular sieve catalyst composition according to the method of claim 1; (B) introducing a feedstock to a reactor system in the presence of the formulated molecular sieve catalyst composition; (C) withdrawing from the reactor system an effluent stream; and (D) passing the effluent gas through a recovery system recovering at least the one or more olefins. 15. The process of claim 14, wherein the feedstock comprises one or more oxygenates. 16. The process of claim 15, wherein the molecular sieve catalyst composition has an ARI in the range from about 0.01 wt %/hr to about 1.0 wt %/hr. 17. A process for polymerizing one or more olefins to form a polymer, the process comprising: (1) producing one or more olefins according to the process of claim 15; (2) contacting at least one of the one or more olefins with a polymerization catalyst under conditions sufficient to an olefin-containing polymer. 18. The process of claim 17, wherein the one or more oxygenates comprises methanol, wherein the olefins comprise ethylene, propylene, or both, and wherein the molecular sieve catalyst composition comprises a silicoaluminophosphate molecular sieve. 19. The process of claim 18, wherein the olefin-containing polymer is a polyolefin. 20. A method for formulating a molecular sieve catalyst composition, the method comprising the steps of: (a) providing a synthesized molecular sieve having been recovered in the presence of a flocculant; (b) thermally treating the synthesized molecular sieve at a temperature from about 50° C. to about 250° C. and under other conditions sufficient to form a thermally treated synthesized molecular sieve having a first LOI less than 26%; (c) combining the thermally treated synthesized molecular sieve, a binder, and optionally a matrix material to produce an formulated molecular sieve catalyst composition having a first micropore surface area; (d) aging the formulated molecular sieve catalyst composition for at least three months; and (e) analyzing the aged, formulated molecular sieve catalyst composition to determine a second micropore surface area, wherein the second micropore surface area is not more than 3% lower than the first micropore surface area. 21. A method for formulating a molecular sieve catalyst composition, the method comprising the steps of: (a) providing a synthesized molecular sieve having been recovered in the presence of a flocculant; (b) thermally treating the synthesized molecular sieve at a temperature from about 50° C. to about 250° C. and under other conditions sufficient to form a thermally treated synthesized molecular sieve having a first LOI less than 26% and a first micropore surface area; (c) aging the thermally treated synthesized molecular sieve for at least two months; (d) analyzing the aged, thermally treated molecular sieve to determine a second micropore surface area, wherein the second micropore surface area is not more than 3% lower than the first micropore surface area; (e) combining the aged, thermally treated synthesized molecular sieve, a binder, and optionally a matrix material to produce an aged, formulated molecular sieve catalyst composition having a third micropore surface area; (f) further aging the aged, formulated molecular sieve catalyst composition for at least two months; and (g) analyzing the further aged, formulated molecular sieve catalyst composition to determine a fourth micropore surface area, wherein the fourth micropore surface area is not more than 3% lower than the third micropore surface area.
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이 특허에 인용된 특허 (25)
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