Claims
- 1. A process for converting hydrocarbons comprising contacting a hydrocarbon feedstream under hydrocarbon conversion conditions with a catalyst containing:
at least one macrostructure having a three dimensional network of self supporting and self bound particles comprising porous inorganic material, said particles (a) having an average particle size of less than about 2 microns; (b) occupying less than 75% of the total volume of said at least one macrostructure; and (c) being joined together to form a three-dimensional interconnected network comprised of pores having diameters greater than about 20 Å.
- 2. The process recited in claim 1, wherein the hydrocarbon conversion is carried out at conditions comprising a temperature of from 100° C. to 760° C. and/or a pressure of from 10.1 kPag to 10.1 MPag (0.1 to 100 atmospheres) and/or a weight hourly space velocity of from 0.08 hr−1 to 200 hr−1.
- 3. The process recited in claim 2, wherein said porous inorganic material is comprised of molecular sieve.
- 4. The process recited in claim 3, wherein the hydrocarbon conversion is selected from the group consisting of cracking of hydrocarbons, isomerization of alkyl aromatics, disproportionation of toluene, disproportionation of cumene, disproportionation of ethylbenzene, transalkylation of aromatics, alkylation of aromatics, reforming of naphtha to aromatics, conversion of paraffins and/or olefins to aromatics, cracking of naphtha to light olefins, alkylation of naphthalene and alkyl-naphthalene to 2,6-dialkyl-naphthalene, and dewaxing of hydrocarbons.
- 5. The process recited in claim 4, wherein said porous inorganic material is a large pore or intermediate pore size molecular sieve.
- 6. The process recited in claim 5, wherein the structure type of said molecular sieve is selected from the group consisting of LTL, FAU, MOR, *BEA, MFI, MEL, MTW, MTT, MFS, FER, and TON.
- 7. The process recited in claim 5, wherein said macrostructure does not contain significant amounts of amorphous materials.
- 8. The process recited in claim 3, wherein said at least one macrostructure has a density of less than 0.50 g/cc.
- 9. The process recited in claim 3, wherein said particles have an average particle size of less than 500 nm.
- 10. The process recited in claim 3, wherein said particles are joined together by means other than by physical binding of the particles.
- 11. The process recited in claim 4, wherein said at least one macrostructure has at least one dimension greater than about 0.1 mm.
- 12. The process recited in claim 12, wherein said at least one macrostructure is spherical or cylindrical.
- 13. The process recited in claim 10, wherein said particles are joined together as a result of the synthesis of the at least one macrostructure.
- 14. The process recited in claim 3, wherein said particles have an average particle size of less than 200 nm.
- 15. The process recited in claim 3, wherein the particular occupy less than 50% of the total volume of the macrostructure.
- 16. The process recited in claim 2, wherein said porous inorganic material is mesoporous inorganic material.
- 17. The process recited in claim 16, wherein said mesoporous inorganic material is selected from the group consisting of silica, aluminum silicate, alumina, MCM-41, and MCM-48.
- 18. The process recited in claim 2, wherein said at least one macrostructure is made by a process which comprises:
(a) providing an admixture comprising a porous organic ion exchanger and a synthesis mixture capable of forming said porous inorganic material and which occupy at least a portion of the pore space of said porous organic ion exchanger; (b) converting said synthesis mixture to form said porous inorganic material; and, (c) removing said porous organic ion exchanger from said composite material.
- 19. The process recited in claim 18, wherein said organic ion exchanger is a macroreticular ion exchanger.
- 20. The process recited in claim 19, wherein said porous inorganic material is comprised of molecular sieve.
- 21. The process recited in claim 20, wherein said porous inorganic material is a large pore or intermediate pore size molecular sieve.
- 22. The process recited in claim 21, wherein the structure type of said molecular sieve is selected from the group consisting of LTL, FAU, MOR, *BEA, MFI, MEL, MTW, MTT, MFS, FER, and TON.
- 23. The process recited in claim 21, wherein said at least one macrostructure has a density of less than 0.50 g/cc.
- 24. The process recited in claim 21, wherein said particles have an average particle size of less than 500 nm.
- 25. The process recited in claim 18, wherein said synthesis mixture is converted to said porous inorganic material under hydrothermal conditions which comprise an initial temperature greater than 90° C. and a final temperature greater than the first temperature.
- 26. The process recited in claim 18, wherein said at least one macrostructure has at least one dimension greater than about 1.0 mm.
- 27. The process recited in claim 18, wherein said porous organic ion exchanger is a porous organic anionic exchanger.
- 28. The process recited in claim 21, wherein said particles have an average particle size of less than 200 nm.
- 29. The process recited in claim 21, wherein the particular occupy less than 50% of the total volume of the macrostructure.
- 30. The process recited in claim 18, wherein said porous inorganic material is mesoporous inorganic material.
- 31. The process recited in claim 30, wherein said mesoporous inorganic material is selected from the group consisting of silica, aluminum silicate, alumina, MCM-41, and MCM-48.
- 32. The process recited in claims 18, wherein said porous anionic ion-exchanger is a strongly basic anion-exchange resin containing quartenary ammonium groups.
- 33. The process recited in claims 27, wherein seeds in said synthesis mixture grow to form said porous inorganic material.
- 34. The process recited in claim 33, wherein said seeds are either formed within the pores of said porous organic ion exchanger or are introduced into said porous organic ion exchanger by either ion exchange or adsorption.
- 35. The process recited in claim 34, wherein said seeds are oligomeric anions of silicates or crystals of a molecular sieve having a size of less than 200 nm.
- 36. The process recited in claim 35, wherein said porous anionic ion-exchanger has an ion-exchange capacity greater than about 1 meg./gm of dry porous anionic ion-exchanger.
- 37. The process recited in claim 18, wherein said process is selected from the group consisting of the disproportionation of toluene, disproportionation of cumene, alkylation of aromatics, the isomerization of xylenes, the conversion of ethylbenzene, and combinations thereof.
- 38. The process recited in claim 5, wherein at least a portion of the external surface of said at least one macrostructure is coated with another molecular sieve.
- 39. The process recited in claim 5, wherein said process comprises contacting said feedstream with a second catalyst comprising a bound crystalline molecular sieve.
- 40. A catalyst suitable for hydrocarbon conversion, said catalyst comprising:
(i) at least one macrostructure having a three dimensional network of self supporting and self bound particles comprising a first porous inorganic material, said particles (a) having an average particle size of less than about 2 microns; (b) occupying less than 75% of the total volume of said at least one macrostructure; and (c) being joined together to form a three-dimensional interconnected network comprised of pores having diameters greater than about 20 Å, and (ii) a coating comprised of a second porous inorganic material and covering at least a portion of the external surface of said at least one macrostructure.
- 41. The catalyst recited in claim 40, wherein said first porous inorganic material and said second porous inorganic material are crystalline microporous molecular sieve.
- 42. The catalyst recited in claim 41, wherein said first porous inorganic material has a composition, or composition structure type that are different from said second porous inorganic material.
- 43. The catalyst recited in claim 42, wherein said first porous inorganic material and said second porous inorganic material have a large pore size or intermediate pore size.
- 44. The catalyst recited in claim 43, wherein the structure type of said first porous inorganic material and said second porous inorganic material are selected from the group consisting of MAZ, *BEA, MFI, MEL, MTW, EMT, MTT, HEU, FER, TON, EUO, and ETS-10.
- 45. The catalyst recited in claim 42, wherein said first porous inorganic material has lower acidity than said second porous inorganic material.
- 46. The catalyst recited in claim 42, wherein said first porous inorganic material has higher acidity than said second porous inorganic material.
- 47. The catalyst recited in claim 41, wherein said first porous inorganic material and said second porous inorganic material are gallosilicate or aluminosilicate.
- 48. The catalyst recited in claim 41, wherein said catalyst further comprises at least one catalytically active metal.
- 49. The catalyst recited in claim 41, wherein said coating substantially covers the external surface of said at least one macrostructure.
- 50. The catalyst recited in claim 42, wherein the structure type of said first porous inorganic material and said second porous inorganic material are MFI or MEL.
- 51. The catalyst recited in claim 42, wherein said first porous inorganic material is ZSM-5 and said second porous inorganic material is silicalite 1 or silicalite 2.
Parent Case Info
[0001] This application claims priority to U.S. Provisional Application No. 60/135,330, filed May 20, 1999, which is hereby incorporated by reference.
Provisional Applications (1)
|
Number |
Date |
Country |
|
60135330 |
May 1999 |
US |
Continuations (1)
|
Number |
Date |
Country |
Parent |
09574433 |
May 2000 |
US |
Child |
10132755 |
Apr 2002 |
US |