Phosphorus modified zeolite catalysts

Abstract

The invention relates to a bound phosphorus-modified catalyst composition comprising a zeolite having a silica to alumina molar ratio of at least 40 and a binder having a surface area less than 200 m2 / g, wherein the bound catalyst composition exhibits a mesopore size distribution with less than 20% of mesopores having a size below 10 nm before steaming in approximately 100% steam for about 96 hours at about 1000° F. (about 538° C.) and with more than 60% of mesopores having a size at least 21 nm after steaming in approximately 100% steam for about 96 hours at about 1000° F. (about 538° C.).

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application claims the benefit of U.S. Provisional Application No. 61 / 548,057, filed on Oct. 17, 2011, the entire contents of which are hereby incorporated by reference herein.[0002]This application also claims the benefit of related U.S. Provisional Application Nos. 61 / 548,015, 61 / 548,038, 61 / 548,044, 61 / 548,052, and 61 / 548,064, each filed on Oct. 17, 2011, the entire contents of each of which are hereby also incorporated by reference herein. This application is also related to five other co-pending U.S. utility applications, each filed on even date herewith and claiming the benefit to the aforementioned provisional patent applications, and which are entitled “Process for Producing Phosphorus Modified Zeolite Catalysts”, “Process for Producing Phosphorus Modified Zeolite Catalysts”, “Phosphorus Modified Zeolite Catalysts”, “Phosphorus Modified Zeolite Catalysts”, and “Selective Dehydration of Alcohols to Dialkyl Ethers”, respectivel...

AI Technical Summary

Benefits of technology

The patent describes a catalyst that uses a type of material called zeolite. This zeolite is specifically called ZSM- 5. The use of this material can improve the efficiency and effectiveness of a catalyst in a chemical process.

Problems solved by technology

This result is surprising, because binder particles can typically be larger than the opening of the microchannels of the zeolite, and hence penetration of binder into the zeolite micropores in such situations was not anticipated.

Moreover, blockage of zeolite micropores by binder located at the pore mouth of the microchannels was not expected to occlude zeolite micropore volume in a zeolite with the three-dimensional pore structure favored for MTG reactions, such as in MFI zeolites.

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