U.S. patent application number 14/282165 was filed with the patent office on 2014-09-11 for use of a co-feed in the coupling of toluene with a carbon source.
This patent application is currently assigned to FINA TECHNOLOGY, INC.. The applicant listed for this patent is FINA TECHNOLOGY, INC.. Invention is credited to James R. Butler, Sivadinarayana Chinta, Joseph L. Thorman.
Application Number | 20140257004 14/282165 |
Document ID | / |
Family ID | 47175427 |
Filed Date | 2014-09-11 |
United States Patent
Application |
20140257004 |
Kind Code |
A1 |
Chinta; Sivadinarayana ; et
al. |
September 11, 2014 |
USE OF A CO-FEED IN THE COUPLING OF TOLUENE WITH A CARBON
SOURCE
Abstract
A process for making styrene is disclosed that includes
providing toluene, a co-feed, and a C.sub.1 source to a reactor
containing a catalyst, reacting toluene with the C.sub.1 source in
the presence of the catalyst and the co-feed to form a product
stream containing ethylbenzene and styrene. The co-feed can be
selected from the group of water, carbon monoxide, hydrogen, and
combinations thereof.
Inventors: |
Chinta; Sivadinarayana;
(Sugar Land, TX) ; Thorman; Joseph L.; (Helsinki,
FI) ; Butler; James R.; (Spicewood, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FINA TECHNOLOGY, INC. |
Houston |
TX |
US |
|
|
Assignee: |
FINA TECHNOLOGY, INC.
Houston
TX
|
Family ID: |
47175427 |
Appl. No.: |
14/282165 |
Filed: |
May 20, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13457500 |
Apr 27, 2012 |
8785705 |
|
|
14282165 |
|
|
|
|
61488772 |
May 22, 2011 |
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Current U.S.
Class: |
585/437 |
Current CPC
Class: |
C07C 15/46 20130101;
C07C 15/073 20130101; C07C 2529/08 20130101; C07C 2/864 20130101;
C07C 2521/02 20130101; C07C 2529/06 20130101; C07C 2/864 20130101;
C07C 2/864 20130101; C07C 2/862 20130101 |
Class at
Publication: |
585/437 |
International
Class: |
C07C 2/86 20060101
C07C002/86 |
Claims
1. A process for making styrene comprising: providing toluene, a
co-feed, and a C.sub.1 source to a reactor comprising a catalyst;
and reacting toluene with the C.sub.1 source in the presence of the
catalyst and the co-feed to form a product stream comprising
ethylbenzene and styrene; wherein the co-feed includes water.
2. The process of claim 1, wherein the C.sub.1 source is selected
from the group consisting of methanol, formaldehyde, formalin,
trioxane, methylformcel, paraformaldehyde, methylal, dimethyl
ether, and combinations thereof.
3. The process of claim 1, wherein the catalyst comprises at least
one promoter on a support material.
4. The process of claim 3, wherein the at least one promoter is
selected from the group consisting of Co, Mn, Ti, Zr, V, Nb, K, Cs,
Ga, B, P, Rb, Ag, Na, Cu, Mg, Fe, Mo, Ce, and combinations
thereof.
5. The process of claim 3, wherein the at least one promoter is
selected from the group consisting of Ce, Cu, P, Cs, B, Co, Ga, and
combinations thereof.
6. The process of claim 3, wherein the support material comprises a
zeolite.
7. The process of claim 1, wherein the catalyst comprises B and Cs
supported on a zeolite.
8. The process of claim 1, wherein the co-feed is simultaneously
fed to the reactor with the toluene and the C.sub.1 source.
9. The process of claim 1, wherein the co-feed is present in
amounts of 0.0001 to 15 wt % of the combined feed of the toluene,
co-feed and C.sub.1 source.
10. The process of claim 1, resulting in a toluene conversion from
2 to 50%.
11. The process of claim 1, having a selectivity to styrene from 15
to 80%.
12. The process of claim 1, having a selectivity to ethylbenzene
from 15 to 80%.
13. A method of making styrene, comprising: providing a reactor
comprising a catalyst; providing a reactant feed stream comprising
toluene and a C.sub.1 source; providing a co-feed including water;
and reacting the toluene with the C.sub.1 source in the presence of
the co-feed and the catalyst to form a product stream comprising
ethylbenzene and styrene.
14. The method of claim 13, wherein the co-feed further includes
carbon monoxide, hydrogen, or a combination thereof.
15. The method of claim 13, wherein the catalyst comprises at least
one promoter supported on a zeolite, wherein the at least one
promoter is selected from the group consisting of Co, Mn, Ti, Zr,
V, Nb, K, Cs, Ga, B, P, Rb, Ag, Na, Cu, Mg, Fe, Mo, Ce, and
combinations thereof.
16. The method of claim 13, resulting in a toluene conversion of
from 2 to 50%.
17. The method of claim 13, having a selectivity to styrene from 15
to 80%.
18. The method of claim 13, having a selectivity to ethylbenzene
from 15 to 80%.
19. A method of producing styrene comprising: providing toluene, a
co-feed, and a C.sub.1 source to a reactor comprising a catalyst;
and reacting toluene with the C.sub.1 source in the presence of the
catalyst and the co-feed to form a product stream comprising
ethylbenzene and styrene; wherein the C.sub.1 source is selected
from the group consisting of methanol, formaldehyde, formalin,
trioxane, methylformcel, paraformaldehyde, methylal, dimethyl
ether, and combinations thereof; wherein the catalyst comprises
boron and cesium supported on an X-type zeolite; wherein the
co-feed includes water; wherein the reaction gives a toluene
conversion of from 2 to 50%, a selectivity to styrene from 15 to
80%, and a selectivity to ethylbenzene from 15 to 80%.
20. The method of claim 19, wherein the catalyst further comprises
at least one promoter selected from the group consisting of Co, Mn,
Ti, Zr, V, Nb, K, Cs, Ga, B, P, Rb, Ag, Na, Cu, Mg, Fe, Mo, Ce, and
combinations thereof.
21. The process of claim 1, wherein the co-feed only includes
water.
22. The process of claim 1, wherein the co-feed further includes
carbon monoxide, hydrogen, or a combination thereof.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Patent
No. 61/488,772 filed on May 22, 2011.
FIELD
[0002] The present invention relates to a method for the production
of styrene and ethylbenzene. More specifically, the invention
relates to the alkylation of toluene with a carbon source (herein
referred to as a C.sub.1 source) such as methanol and/or
formaldehyde, to produce styrene and ethylbenzene.
BACKGROUND
[0003] Styrene is a monomer used in the manufacture of many
plastics. Styrene is commonly produced by making ethylbenzene,
which is then dehydrogenated to produce styrene. Ethylbenzene is
typically formed by one or more aromatic conversion processes
involving the alkylation of benzene.
[0004] Aromatic conversion processes, which are typically carried
out utilizing a molecular sieve type catalyst, are well known in
the chemical processing industry. Such aromatic conversion
processes include the alkylation of aromatic compounds such as
benzene with ethylene to produce alkyl aromatics such as
ethylbenzene. Typically an alkylation reactor, which can produce a
mixture of monoalkyl and polyalkyl benzenes, will be coupled with a
transalkylation reactor for the conversion of polyalkyl benzenes to
monoalkyl benzenes. The transalkylation process is operated under
conditions to cause disproportionation of the polyalkylated
aromatic fraction, which can produce a product having an enhanced
ethylbenzene content and reduced polyalkylated content. When both
alkylation and transalkylation processes are used, two separate
reactors, each with its own catalyst, can be employed for each of
the processes.
[0005] Ethylene is obtained predominantly from the thermal cracking
of hydrocarbons, such as ethane, propane, butane, or naphtha.
Ethylene can also be produced and recovered from various refinery
processes. Thermal cracking and separation technologies for the
production of relatively pure ethylene can account for a
significant portion of the total ethylbenzene production costs.
[0006] Benzene can be obtained from the hydrodealkylation of
toluene that involves heating a mixture of toluene with excess
hydrogen to elevated temperatures (for example 500.degree. C. to
600.degree. C.) in the presence of a catalyst. Under these
conditions, toluene can undergo dealkylation according to the
chemical equation:
C.sub.6H.sub.5CH.sub.3+H.sub.2.fwdarw.C.sub.6H.sub.6+CH.sub.4 This
reaction requires energy input and as can be seen from the above
equation, produces methane as a byproduct, which is typically
separated and may be used as heating fuel for the process.
[0007] Another known process includes the alkylation of toluene to
produce styrene and ethylbenzene. In this alkylation process,
various aluminosilicate catalysts are utilized to react methanol
and toluene to produce styrene and ethylbenzene. However, such
processes have been characterized by having very low yields in
addition to having very low selectivity to styrene and
ethylbenzene.
[0008] Also, the aluminosilicate catalysts are typically prepared
using solutions of acetone and other highly flammable organic
substances, which can be hazardous and require additional drying
steps. For instance a typical aluminosilicate catalyst can include
various promoters supported on a zeolitic substrate. These
catalysts can be prepared by subjecting the zeolite to an
ion-exchange in an aqueous solution followed by a promoter metal
impregnation using acetone. This method requires an intermediate
drying step after the ion-exchange to remove all water prior to the
promoter metal impregnation with acetone. After the promoter metal
impregnation the catalyst is subjected to a further drying step to
remove all acetone. This intermediate drying step typically
involves heating to at least 150.degree. C., which results in
increased costs.
[0009] In view of the above, it would be desirable to have a
process of producing styrene and/or ethylbenzene that does not rely
on thermal crackers and expensive separation technologies as a
source of ethylene. It would further be desirable to avoid the
process of converting toluene to benzene with its inherent expense
and loss of a carbon atom to form methane. It would be desirable to
produce styrene without the use of benzene and ethylene as
feedstreams. It would also be desirable to produce styrene and/or
ethylbenzene in one reactor without the need for separate reactors
requiring additional separation steps. Furthermore, it is desirable
to achieve a process having a high yield and selectivity to styrene
and ethylbenzene. Even further, it is desirable to achieve a
process having a high yield and selectivity to styrene such that
the step of dehydrogenation of ethylbenzene to produce styrene can
be reduced. It is further desirable to be able to produce a
catalyst having the properties desired without involving flammable
materials and/or intermediate drying steps.
SUMMARY
[0010] The present invention in its many embodiments relates to a
process of making styrene. In an embodiment of the present
invention, a process is provided for making styrene including
providing toluene, a co-feed, and a C.sub.1 source to a reactor
including a catalyst and reacting toluene with the C.sub.1 source
in the presence of the catalyst and the co-feed to form a product
stream including ethylbenzene and styrene. The co-feed is selected
from the group of water, carbon monoxide, hydrogen, and
combinations thereof.
[0011] In an embodiment, either by itself or in combination with
any other embodiment, the C.sub.1 source can be selected from the
group of methanol, formaldehyde, formalin, trioxane, methylformcel,
paraformaldehyde, methylal, dimethyl ether, and combinations
thereof.
[0012] In an embodiment, either by itself or in combination with
any other embodiment, the catalyst includes at least one promoter
on a support material. The promoter can be selected from the group
of Co, Mn, Ti, Zr, V, Nb, K, Cs, Ga, B, P, Rb, Ag, Na, Cu, Mg, Fe,
Mo, Ce, and combinations thereof. Optionally, the promoter is
selected from the group of Ce, Cu, P, Cs, B, Co, Ga, and
combinations thereof. The support material can include a zeolite.
The catalyst can include B and Cs supported on a zeolite.
[0013] In an embodiment, either by itself or in combination with
any other embodiment, the co-feed is present in amounts of 0.0001
to 15 wt % of the combined feed of the toluene, co-feed and C.sub.1
source.
[0014] In an embodiment, either by itself or in combination with
any other embodiment, the toluene conversion ranges from 2 to
50%.
[0015] In an embodiment, either by itself or in combination with
any other embodiment, the selectivity to styrene ranges from 15 to
80%.
[0016] In an embodiment, either by itself or in combination with
any other embodiment, the selectivity to ethylbenzene ranges from
15 to 80%.
[0017] Another embodiment of the present invention includes a
method of making styrene including providing a reactor including a
catalyst; contacting the catalyst with a co-feed and a reactant
feed stream including toluene and a C.sub.1 source; and reacting
the toluene with the C.sub.1 source in the presence of the catalyst
to form a product stream including ethylbenzene and styrene. The
C.sub.1 source can be selected from the group of methanol,
formaldehyde, formalin, trioxane, methylformcel, paraformaldehyde,
methylal, dimethyl ether, and combinations thereof.
[0018] The various embodiments of the present invention can be
joined in combination with other embodiments of the invention and
the listed embodiments herein are not meant to limit the invention.
All combinations of embodiments of the invention are enabled, even
if not given in a particular example herein.
BRIEF DESCRIPTION OF DRAWINGS
[0019] FIG. 1 illustrates a flow chart for the production of
styrene by the reaction of formaldehyde and toluene, wherein the
formaldehyde is first produced in a separate reactor by either the
dehydrogenation or oxidation of methanol and is then reacted with
toluene to produce styrene.
[0020] FIG. 2 illustrates a flow chart for the production of
styrene by the reaction of formaldehyde and toluene, wherein
methanol and toluene are fed into a reactor, wherein the methanol
is converted to formaldehyde and the formaldehyde is reacted with
toluene to produce styrene.
DETAILED DESCRIPTION
[0021] In accordance with an embodiment of the current invention,
toluene is reacted with a carbon source capable of coupling with
toluene to form ethylbenzene or styrene, which can be referred to
as a C.sub.1 source, in the presence of a co-feed to produce
styrene and ethylbenzene. In an embodiment, the C.sub.1 source
includes methanol or formaldehyde or a mixture of the two. In an
embodiment, the co-feed includes one or more of carbon monoxide
(CO), water (H.sub.2O), or hydrogen (H.sub.2). In an alternative
embodiment, toluene is reacted with one or more of the following:
formalin (37-50% H.sub.2CO in solution of water and MeOH), trioxane
(1,3,5-trioxane), methylformcel (55% H.sub.2CO in methanol),
paraformaldehyde, methylal (dimethoxymethane), and dimethyl ether.
In a further embodiment, the C.sub.1 source is selected from the
group of methanol, formaldehyde, formalin, trioxane, methylformcel,
paraformaldehyde, methylal, dimethyl ether, and combinations
thereof.
[0022] Formaldehyde can be produced either by the oxidation or
dehydrogenation of methanol.
[0023] In an embodiment, formaldehyde is produced by the
dehydrogenation of methanol to produce formaldehyde and hydrogen
gas. This reaction step produces a dry formaldehyde stream that may
be preferred, as it would not require the separation of the water
prior to the reaction of the formaldehyde with toluene. The
dehydrogenation process is described in the equation below:
CH.sub.3OH.fwdarw.CH.sub.2O+H.sub.2
[0024] Formaldehyde can also be produced by the oxidation of
methanol to produce formaldehyde and water. The oxidation of
methanol is described in the equation below:
2CH.sub.3OH+O.sub.2.fwdarw.2CH.sub.2O+2H.sub.2O
[0025] In the case of using a separate process to obtain
formaldehyde, a separation unit may then be used in order to
separate the formaldehyde from the hydrogen gas or water from the
formaldehyde and unreacted methanol prior to reacting the
formaldehyde with toluene for the production of styrene. This
separation would inhibit the hydrogenation of the formaldehyde back
to methanol. Purified formaldehyde could then be sent to a styrene
reactor and the unreacted methanol could be recycled.
[0026] In accordance with the present invention, CO and/or H.sub.2
may be added in the presence of the coupling reaction in order to
restrict the destruction of formaldehyde. The effect of the
presence of added CO and/or H.sub.2 on preserving formaldehyde is
demonstrated in the following equations below:
CH.sub.2O.fwdarw.CO+H.sub.2
CO+H.sub.2.fwdarw.CH.sub.2O
[0027] Although the coupling reaction has a 1:1 molar ratio of
toluene and the C.sub.1 source, the ratio of the C.sub.1 source and
toluene feedstreams is not limited within the present invention and
can vary depending on operating conditions and the efficiency of
the reaction system. If excess toluene or C.sub.1 source is fed to
the reaction zone, the unreacted portion can be subsequently
separated and recycled back into the process. In one embodiment the
ratio of toluene:C.sub.1 source can range from between 100:1 to
1:100. In alternate embodiments the ratio of toluene:C.sub.1 source
can range from 50:1 to 1:50; from 20:1 to 1:20; from 10:1 to 1:10;
from 5:1 to 1:5; from 2:1 to 1:2. In a specific embodiment, the
ratio of toluene:C.sub.1 source can range from 3:1 to 1:1.
[0028] In an embodiment, the reactants, toluene and the C.sub.1
source are combined with a co-feed. In an embodiment, the co-feed
is selected from the group of hydrogen, carbon monoxide, and water,
and any combinations thereof. In another embodiment, the co-feed
may be combined with nitrogen prior to combining the co-feed with
the reactants. The co-feed may be combined with the reactants in
any desired amounts. In an embodiment, the co-feed is added in
amounts ranging from 0.0001 wt % to 15 wt % of the total feed,
optionally from 0.01 wt % to 10 wt % of the total feed, optionally
from 0.1 wt % to 5 wt % of the total feed, optionally from 0.1 wt %
to 2.5 wt % of the total feed.
[0029] In FIG. 1 there is a simplified flow chart of one embodiment
of the styrene production process described above. In this
embodiment, a first reactor (2) is either a dehydrogenation reactor
or an oxidation reactor. This reactor is designed to convert the
first methanol feed (1) into formaldehyde. The gas product (3) of
the reactor is then sent to a gas separation unit (4) where the
formaldehyde is separated from any unreacted methanol and unwanted
byproducts. Any unreacted methanol (6) can then be recycled back
into the first reactor (2). The byproducts (5) are separated from
the clean formaldehyde (7).
[0030] In one embodiment the first reactor (2) is a dehydrogenation
reactor that produces formaldehyde and hydrogen and the separation
unit (4) is a membrane capable of removing hydrogen from the
product stream (3).
[0031] In an alternate embodiment the first reactor (2) is an
oxidative reactor that produces product stream (3) comprising
formaldehyde and water. The product stream (3) comprising
formaldehyde and water can then be sent to the second reactor (9)
without a separation unit (4).
[0032] The formaldehyde feed stream (7) is then reacted with a feed
stream of toluene (8) and a co-feed stream (16) in a second reactor
(9). The toluene and formaldehyde react to produce styrene. The
product (10) of the second reactor (9) may then be sent to an
optional separation unit (11) where any unwanted byproducts (15)
such as water can separated from the styrene, unreacted
formaldehyde and unreacted toluene. Any unreacted formaldehyde (12)
and the unreacted toluene (13) can be recycled back into the
reactor (9). A styrene product stream (14) can be removed from the
separation unit (11) and subjected to further treatment or
processing if desired.
[0033] The operating conditions of the reactors and separators will
be system specific and can vary depending on the feedstream
composition and the composition of the product streams. The reactor
(9) for the reaction of toluene and formaldehyde will operate at
elevated temperatures and may contain a basic or neutral catalyst
system. The temperature can range in a non-limiting example from
250.degree. C. to 750.degree. C., optionally from 300.degree. C. to
500.degree. C., optionally from 375.degree. C. to 450.degree. C.
The pressure can range in a non-limiting example from 0.1 atm to 70
atm, optionally from 0.1 atm to 35 atm, optionally from 0.1 atm to
10 atm, optionally from 0.1 atm to 5 atm.
[0034] FIG. 2 is a simplified flow chart of another embodiment of
the styrene process discussed above. A C.sub.1 source containing
feed stream (21) is fed along with a feed stream of toluene (22)
and a co-feed stream (31) in a reactor (23). Toluene and the
C.sub.1 source then react to produce styrene. The product (24) of
the reactor (23) may then be sent to an optional separation unit
(25) where any unwanted byproducts (26) can be separated from the
styrene, and any unreacted C.sub.1 source, unreacted methanol,
unreacted formaldehyde and unreacted toluene. Any unreacted
methanol (27), unreacted formaldehyde (28) and the unreacted
toluene (29) can be recycled back into the reactor (23). A product
stream (30) that can include styrene and ethylbenzene can be
removed from the separation unit (25) and subjected to further
treatment or processing if desired.
[0035] The operating conditions of the reactors and separators will
be system specific and can vary depending on the feedstream
composition and the composition of the product streams. The reactor
(23) for the reactions of methanol to formaldehyde and toluene with
a C.sub.1 source, such as formaldehyde, will operate at elevated
temperatures and pressures and may contain a basic or neutral
catalyst system. The temperature can range in a non-limiting
example from 250.degree. C. to 750.degree. C., optionally from
350.degree. C. to 550.degree. C., optionally from 375.degree. C. to
475.degree. C. The pressure can range in a non-limiting example
from 0.1 atm to 70 atm, optionally from 0.1 atm to 10 atm,
optionally from 0.1 atm to 3 atm.
[0036] Improvement in side chain alkylation selectivity may be
achieved by treating a molecular sieve zeolite catalyst with
chemical compounds to inhibit the external acidic sites and
minimize aromatic alkylation on the ring positions. Another means
of improvement of side chain alkylation selectivity can be to
inhibit overly basic sites, such as for example with the addition
of a boron compound. Another means of improvement of side chain
alkylation selectivity can be to impose restrictions on the
catalyst structure to facilitate side chain alkylation. In one
embodiment the catalyst used in an embodiment of the present
invention is a basic or neutral catalyst.
[0037] The catalytic reaction systems suitable for this invention
can include one or more of the zeolite or amorphous materials
modified for side chain alkylation selectivity. A non-limiting
example can be a zeolite promoted with one or more of the
following: Co, Mn, Ti, Zr, V, Nb, K, Cs, Ga, B, P, Rb, Ag, Na, Cu,
Mg, Fe, Mo, Ce, or combinations thereof. In an embodiment, the
zeolite can be promoted with one or more of Ce, Cu, P, Cs, B, Co,
Ga, or combinations thereof. The promoter can exchange with an
element within the zeolite or amorphous material and/or be attached
to the zeolite or amorphous material in an occluded manner. In an
embodiment the amount of promoter is determined by the amount
needed to yield less than 0.5 mol % of ring alkylated products such
as xylenes from a coupling reaction of toluene and a C.sub.1
source.
[0038] In an embodiment, the catalyst contains greater than 0.1 wt
% of at least one promoter based on the total weight of the
catalyst. In another embodiment, the catalyst contains up to 5 wt %
of at least one promoter. In a further embodiment, the catalyst
contains from 0.1 to 3 wt % of at least one promoter, optionally
from 0.1 to 1 wt % of at least one promoter. In an embodiment, the
at least one promoter is boron.
[0039] Zeolite materials suitable for this invention may include
silicate-based zeolites and amorphous compounds such as faujasites,
mordenites, etc. Silicate-based zeolites are made of alternating
SiO.sub.4.sup.- and MO.sub.X tetrahedra, where M is an element
selected from the Groups 1 through 16 of the Periodic Table (new
IUPAC). These types of zeolites have 4, 6, 8, 10, or 12-membered
oxygen ring channels. An example of zeolites of this invention can
include faujasites, such as an X-type or Y-type zeolite and zeolite
beta. Zeolite-like materials can also be an effective substrate.
Alternate molecular sieves also contemplated are zeolite-like
materials such as the crystalline silicoaluminophosphates (SAPO)
and the aluminophosphates (ALPO) and the like.
[0040] In an embodiment, the zeolite materials suitable for this
invention are characterized by silica to alumina ratio (Si/Al) of
less than 1.5. In another embodiment, the zeolite materials are
characterized by a Si/Al ratio ranging from 1.0 to 200, optionally
from 1.0 to 100, optionally from 1.0 to 50, optionally from 1.0 to
10, optionally from 1.0 to 2.0, optionally from 1.0 to 1.5.
[0041] The present catalyst is adaptable to use in the various
physical forms in which catalysts are commonly used. The catalyst
of the invention may be used as a particulate material in a contact
bed or as a coating material on structures having a high surface
area. If desired, the catalyst can be deposited with various
catalyst binder and/or support materials.
[0042] A catalyst comprising a substrate that supports a promoting
metal or a combination of metals can be used to catalyze the
reaction of hydrocarbons. The method of preparing the catalyst,
pretreatment of the catalyst, and reaction conditions can influence
the conversion, selectivity, and yield of the reactions.
[0043] The various elements that make up the catalyst can be
derived from any suitable source, such as in their elemental form,
or in compounds or coordination complexes of an organic or
inorganic nature, such as carbonates, oxides, hydroxides, nitrates,
acetates, chlorides, phosphates, sulfides and sulfonates. The
elements and/or compounds can be prepared by any suitable method,
known in the art, for the preparation of such materials.
[0044] The term "substrate" as used herein is not meant to indicate
that this component is necessarily inactive, while the other metals
and/or promoters are the active species. On the contrary, the
substrate can be an active part of the catalyst. The term
"substrate" would merely imply that the substrate makes up a
significant quantity, generally 10% or more by weight, of the
entire catalyst. The promoters individually can range from 0.01% to
60% by weight of the catalyst, optionally from 0.01% to 50%,
optionally from 0.01% to 40%, optionally from 0.01% to 30%,
optionally from 0.01% to 20%, optionally from 0.01% to 10%,
optionally from 0.01% to 5%. If more than one promoter is combined,
they together generally can range from 0.01% up to 70% by weight of
the catalyst, optionally from 0.01% to 50%, optionally from 0.01%
to 30%, optionally from 0.01% to 15%, optionally from 0.01% to 5%.
The elements of the catalyst composition can be provided from any
suitable source, such as in its elemental form, as a salt, as a
coordination compound, etc.
[0045] The addition of a support material to improve the catalyst
physical properties is possible within the present invention.
Binder material, extrusion aids or other additives can be added to
the catalyst composition or the final catalyst composition can be
added to a structured material that provides a support structure.
For example, the final catalyst composition can include an alumina
or aluminate framework as a support. Upon calcination these
elements can be altered, such as through oxidation which would
increase the relative content of oxygen within the final catalyst
structure. The combination of the catalyst of the present invention
combined with additional elements such as a binder, extrusion aid,
structured material, or other additives, and their respective
calcination products, are included within the scope of the
invention.
[0046] In one embodiment, the catalyst can be prepared by combining
a substrate with at least one promoter element. Embodiments of a
substrate can be a molecular sieve, from either natural or
synthetic sources. Zeolites and zeolite-like materials can be an
effective substrate. Alternate molecular sieves also contemplated
are zeolite-like materials such as the crystalline
silicoaluminophosphates (SAPO) and the aluminophosphates
(ALPO).
[0047] The present invention is not limited by the method of
catalyst preparation, and all suitable methods should be considered
to fall within the scope herein. Particularly effective techniques
are those utilized for the preparation of solid catalysts.
Conventional methods include co-precipitation from an aqueous, an
organic or a combination solution-dispersion, impregnation, dry
mixing, wet mixing or the like, alone or in various combinations.
In general, any method can be used which provides compositions of
matter containing the prescribed components in effective amounts.
According to an embodiment the substrate is charged with promoter
via an incipient wetness impregnation. Other impregnation
techniques such as by soaking, pore volume impregnation, or
percolation can optionally be used. Alternate methods such as ion
exchange, wash coat, precipitation, and gel formation can also be
used. Various methods and procedures for catalyst preparation are
listed in the technical report Manual of Methods and Procedures for
Catalyst Characterization by J. Haber, J. H. Block and B. Dolmon,
published in the International Union of Pure and Applied Chemistry,
Volume 67, Nos 8/9, pp. 1257-1306, 1995, incorporated herein in its
entirety.
[0048] The promoter elements can be added to or incorporated into
the substrate in any appropriate form. In an embodiment, the
promoter elements are added to the substrate by mechanical mixing,
by impregnation in the form of solutions or suspensions in an
appropriate liquid, or by ion exchange. In a more specific
embodiment, the promoter elements are added to the substrate by
impregnation in the form of solutions or suspensions in a liquid
selected from the group of acetone, anhydrous (or dry) acetone,
methanol, and aqueous solutions.
[0049] In another more specific embodiment, the promoter is added
to the substrate by ion exchange. Ion exchange may be performed by
conventional ion exchange methods in which sodium, hydrogen, or
other inorganic cations that may be typically present in a
substrate are at least partially replaced via a fluid solution. In
an embodiment, the fluid solution can include any medium that will
solubilize the cation without adversely affecting the substrate. In
an embodiment, the ion exchange is performed by heating a solution
containing any promoter selected from the group of Co, Mn, Ti, Zr,
V, Nb, K, Cs, Ga, B, P, Rb, Ag, Na, Cu, Mg, Fe, Mo, Ce, and any
combinations thereof in which the promoter(s) is(are) solubilized
in the solution, which may be heated, and contacting the solution
with the substrate. In another embodiment, the ion exchange
includes heating a solution containing any one selected from the
group of Ce, Cu, P, Cs, B, Co, Ga, and any combinations thereof. In
an embodiment, the solution is heated to temperatures ranging from
50 to 120.degree. C. In another embodiment, the solution is heated
to temperatures ranging from 80 to 100.degree. C.
[0050] The solution for use in the ion exchange method may include
any fluid medium. A non-fluid ion exchange is also possible and
within the scope of the present invention. In an embodiment, the
solution for use in the ion exchange method includes an aqueous
medium or an organic medium. In a more specific embodiment, the
solution for use in the ion exchange method includes water.
[0051] The promoters may be incorporated into the substrate in any
order or arrangement. In an embodiment, all of the promoters are
simultaneously incorporated into the substrate. In more specific
embodiment, each promoter is in an aqueous solution for
ion-exchange with and/or impregnation to the substrate. In another
embodiment, each promoter is in a separate aqueous solution,
wherein each solution is simultaneously contacted with the
substrate for ion-exchange with and/or impregnation to the
substrate. In a further embodiment, each promoter is in a separate
aqueous solution, wherein each solution is separately contacted
with the substrate for ion-exchange with and/or impregnation to the
substrate.
[0052] In an embodiment, the at least one promoter includes boron.
In an embodiment, the catalyst contains greater than 0.1 wt % boron
based on the total weight of the catalyst. In another embodiment,
the catalyst contains from 0.1 to 3 wt % boron, optionally from 0.1
to 1 wt % boron.
[0053] The boron promoter can be added to the catalyst by
contacting the substrate, impregnation, or any other method, with
any known boron source. In an embodiment, the boron source is
selected from the group of boric acid, boron phosphate,
methoxyboroxine, methylboroxine, and trimethoxyboroxine and
combinations thereof. In another embodiment, the boron source
contains boroxines. In a further embodiment, the boron source is
selected from the group of methoxyboroxine, methylboroxine, and
trimethoxyboroxine and combinations thereof.
[0054] In an embodiment, a substrate may be previously treated with
a boron source prior to an addition of at least one promoter,
wherein the at least one promoter includes boron. In another
embodiment, a boron treated zeolite may be combined with at least
one promoter, wherein the at least one promoter includes boron. In
a further embodiment, boron may be added to the catalyst system by
adding at least one promoter containing boron as a co-feed with
toluene and methanol. In an even further embodiment, boron may be
added to the catalyst system by adding boroxines as a co-feed with
toluene and methanol. The boroxines can include, methoxyboroxine,
methylboroxine, and trimethoxyboroxine, and combinations thereof.
The boron treated zeolite further combined with at least one
promoter including boron may be used in preparing a supported
catalyst such as extrudates and tablets.
[0055] When slurries, precipitates or the like are prepared, they
may be dried, usually at a temperature sufficient to volatilize the
water or other carrier, such as from 100.degree. C. to 250.degree.
C., with or without vacuum. Irrespective of how the components are
combined and irrespective of the source of the components, the
dried composition is generally calcined in the presence of an
oxygen-containing gas, usually at temperatures between about
300.degree. C. and about 900.degree. C. for from 1 to 24 hours. The
calcination can be in an oxygen-containing atmosphere, or
alternately in a reducing or inert atmosphere.
[0056] The prepared catalyst can be ground, pressed, sieved, shaped
and/or otherwise processed into a form suitable for loading into a
reactor. The reactor can be any type known in the art such as a
fixed bed, fluidized bed, or swing bed reactor. Optionally an inert
material can be used to support the catalyst bed and to place the
catalyst within the bed. Depending on the catalyst, a pretreatment
of the catalyst may, or may not, be necessary. For the
pretreatment, the reactor can be heated to elevated temperatures,
such as 200.degree. C. to 900.degree. C. with an air flow, such as
100 mL/min, and held at these conditions for a length of time, such
as 1 to 3 hours. Then, the reactor can be brought to the operating
temperature of the reactor, for example 300.degree. C. to
550.degree. C., or optionally down to any desired temperature, for
instance down to ambient temperature to remain under a purge until
it is ready to be put in service. The reactor can be kept under an
inert purge, such as under a nitrogen or helium purge.
[0057] Embodiments of reactors that can be used with the present
invention can include, by non-limiting examples: fixed bed
reactors; fluid bed reactors; moving bed reactors; and entrained
bed reactors. Reactors capable of the elevated temperature and
pressure as described herein, and capable of enabling contact of
the reactants with the catalyst, can be considered within the scope
of the present invention. Embodiments of the particular reactor
system may be determined based on the particular design conditions
and throughput, as by one of ordinary skill in the art, and are not
meant to be limiting on the scope of the present invention. An
example of a suitable reactor can be a fluid bed reactor having
catalyst regeneration capabilities. This type of reactor system
employing a riser can be modified as needed, for example by
insulating or heating the riser if thermal input is needed, or by
jacketing the riser with cooling water if thermal dissipation is
required. These designs can also be used to replace catalyst while
the process is in operation, by withdrawing catalyst from the
regeneration vessel from an exit line or adding new catalyst into
the system while in operation.
[0058] In another embodiment, the one or more reactors may include
one or more catalyst beds. In the event of multiple beds, an inert
material layer can separate each bed. The inert material can
comprise any type of inert substance. In an embodiment, a reactor
includes between 1 and 25 catalyst beds. In a further embodiment, a
reactor includes between 2 and 10 catalyst beds. In a further
embodiment, a reactor includes between 2 and 5 catalyst beds. In
addition, the co-feed, the C.sub.1 source and/or toluene may be
injected into a catalyst bed, an inert material layer, or both. In
a further embodiment, the toluene feed is injected prior to the
first catalyst bed while at least a portion of the C.sub.1 source
and/or at least a portion of the co-feed are injected into one or
more catalyst bed(s) along the reactor to control the toluene:
C.sub.1 source in each catalyst bed.
[0059] In an alternate embodiment, the entire C.sub.1 source is
injected into a catalyst bed(s), all of the toluene feed is
injected into an inert material layer(s) and all of the co-feed is
injected into one of: the catalyst bed(s), the inert material
layer(s), or any combination thereof. In another embodiment, at
least a portion of the toluene feed is injected into a catalyst
bed(s), at least a portion of the co-feed is injected into a
catalyst bed(s), and at least a portion the C.sub.1 source is
injected into an inert material layer(s). In a further embodiment,
all of the toluene feed and all of the co-feed are injected into a
catalyst bed(s) and the entire C.sub.1 source is injected into an
inert material layer(s).
[0060] The toluene and C.sub.1 source coupling reaction may have a
toluene conversion percent greater than 0.01 mol %. In an
embodiment the toluene and C.sub.1 source coupling reaction is
capable of having a toluene conversion percent in the range of from
0.05 mol % to 40 mol %. In a further embodiment the toluene and
C.sub.1 source coupling reaction is capable of having a toluene
conversion in the range of from 2 mol % to 40 mol %, optionally
from 5 mol % to 35 mol %, optionally from 10 mol % to 30 mol %.
[0061] In an embodiment the toluene and C.sub.1 source coupling
reaction is capable of selectivity to styrene greater than 1 mol %.
In another embodiment, the toluene and C.sub.1 source coupling
reaction is capable of selectivity to styrene in the range of from
1 mol % to 99 mol %. In an embodiment the toluene to a C.sub.1
source coupling reaction is capable of selectivity to ethylbenzene
greater than 1 mol %. In another embodiment, the toluene and
C.sub.1 source coupling reaction is capable of selectivity to
ethylbenzene and styrene in the range of from 1 mol % to 99 mol %.
In an embodiment the toluene and C.sub.1 source coupling reaction
is capable of yielding less than 0.5 mol % of undesirable ring
alkylated products such as xylenes.
EXAMPLES
[0062] The alkylation of toluene with a carbon source over a
catalyst, such as a basic zeolite catalyst, may yield ethylbenzene
and styrene as major products as well as other by-products and
unreacted reactants. It is desirable to optimize styrene
selectivity in order to improve the economics of styrene
production. The following examples demonstrate that styrene
selectivity can be improved by adding a co-feed, such as carbon
monoxide, hydrogen, or water, along with the reactant feed to the
reactor.
Comparative Example
[0063] The examples herein used a X-type zeolite promoted with
cesium and boron, labeled as (Cs, B)/X. The procedure used to
produce the cesium ion-exchanged zeolite material used a glass
cylinder (2'' inside diameter), fitted with a sintered glass disk
and stopcock at the lower end, that was charged with 544-HP zeolite
(100 g, W. R. Grace) and CsOH (400 mL, 1.0 M in water). The mixture
was then brought to 90.degree. C. and allowed to stand for 4 hours.
The liquid was drained from the zeolite material and another
aliquot of CsOH (400 mL of 1.0 M solution in water) was added and
allowed to stand for 3 hours at 90.degree. C. The liquid was
drained from the zeolite material and another aliquot of CsOH (400
mL of 1.0 M solution in water) was added and allowed to stand for
15 hours at 90.degree. C. The liquid was drained from the zeolite
material and dried at 150.degree. C. for 1.5 hours.
[0064] A deposition of 1.4 wt % boron (by weight of final zeolite
material) onto the cesium ion-exchanged zeolite material was then
performed. The cesium ion-exchanged zeolite material (35 g) was
treated with a solution of boric acid (2.8 g) dissolved in acetone
(500 mL) at room temperature for 2 hours. The (Cs, B)/X material
was then dried at 110.degree. C. for 20 hours.
[0065] Stainless steel reactor details: A stainless steel tube with
0.5-inch outer diameter and 0.465 inch internal diameter was filled
with crushed quartz of 850-2000 .mu.m size (to a height of about 10
inches, 29.2 mL), then the catalyst (to a height of 3.0 inches; 6.6
mL, 3.35 g) at sizes ranging from 250-425 .mu.m, and then more
crushed quartz of 850-2000 .mu.m size (to a height of about 17
inches, 37.2 mL) such that a 0.125 inch stainless steel thermowell
was positioned in the middle of the catalyst bed. The reactor was
installed in a 3-zone furnace and heated to 500.degree. C. and held
for 2 hours while passing nitrogen through it at 150 cc/min. The
reactor was then cooled to the reaction temperature of 420.degree.
C.
[0066] The feed consisted of toluene and methanol in a 4:1 molar
ratio to conduct a "normal" alkylation reaction. Reaction
conditions used were a temperature of 420.degree. C. and a pressure
of 15 psig. The flow rates were corrected for temperature. The
effluent was monitored by an on-line gas chromatograph. The results
are shown in Table 1.
TABLE-US-00001 TABLE 1 Contact Time Time On Stream Catalyst (sec)
(hh:mm) X.sub.Tol S.sub.Bz S.sub.Xyl S.sub.EB S.sub.Sty X.sub.MeOH
Cs, B/X 2.6 1:50 3.5 1.2 0.5 80.9 16.4 60.5 Cs, B/X 2.6 2:35 3.6
1.1 0.4 80.9 16.9 57.0 Cs, B/X 2.6 4:45 2.0 1.8 0.5 83.7 13.7 37.6
Cs, B/X 2.6 5:50 2.0 1.8 0.5 84.5 12.9 60.0
Example 1
[0067] The influence of water on improving catalyst lifetime and
functionality was examined. This example involved adding water to
the catalyst bed to simulate the amount of water present during 4
mol % conversion of toluene. In the alkylation of toluene with a
C.sub.1 source, one mole of water is a co-product with each mole of
styrene produced. Thus, if water caused the destruction of active
sites we would observe a low toluene conversion upon adding the
toluene and methanol. The catalyst was a X-type zeolite promoted
with cesium and boron, labeled as (Cs, B)/X and is the same
catalyst as used in the comparative example above. The same reactor
was used with a temperature of 420.degree. C. and pressure of 15
psig
[0068] The catalyst was subjected to the flow of water at a rate of
0.004 mL/min with nitrogen at a rate of 115 mL/min to simulate 4%
toluene conversion coming from a preceding bed at a 2.5 second
contact time for 4 hours. Then the feed was switched to toluene and
methanol in a 4:1 molar ratio to conduct a "normal" alkylation
reaction. Reaction conditions used were a temperature of
420.degree. C. and pressure of 15 psig. As shown in Table 2,
toluene conversion, selectivity to benzene and selectivity to
xylene were essentially uninfluenced by the pretreatment with
water. The selectivity to EB decreased substantially as compared to
the comparative example without pretreatment. The selectivity to
styrene increased substantially as compared to the comparative
example without pretreatment. The selectivity to EB and styrene
remained consistent with time on stream.
TABLE-US-00002 TABLE 2 The Effect of Water Added to the Catalyst
Bed of an ATM Process. Contact Time Time On Stream Catalyst (sec)
(hh:mm) X.sub.Tol S.sub.Bz S.sub.Xyl S.sub.EB S.sub.Sty X.sub.MeOH
Cs, B/X 2.6 2:00 3.6 1.5 0.4 23.5 55.3 100 Cs, B/X 2.6 2:45 4.2 1.1
0.3 22.8 57.6 100 Cs, B/X 2.6 3:50 3.9 1.1 0.3 23.4 56.1 100 4 hr
steaming 0.004 mL/min 4:15 3.7 1.1 0.3 24.2 55.3 100 H.sub.2O and
115 mL/min N.sub.2 prior to ATM reaction
Example 2
[0069] The next example was carried out with toluene, methanol, and
water as a combined feed stream to determine if water was competing
with the active sites of the catalyst. This experiment had
conditions equivalent to Example 1, except the water was added with
the toluene and methanol feed in an amount of 0.00022 moles of
water for every 1 mole of methanol. Reaction conditions used were a
temperature of 420.degree. C., pressure of 15 psig and a molar
ratio of toluene to methanol of 4:1. Again, as shown in Table 3,
the toluene conversion was essentially uninfluenced by the presence
of water as compared to the comparative example. Over the 4-5 hours
of use, the catalyst did not deactivate as quickly as when water
was absent. The selectivity to EB increased with time on stream
while the selectivity to styrene decreased with time on stream.
Toluene conversion, selectivity to benzene and selectivity to
xylene were essentially uninfluenced by the addition of water in
the feed. The selectivity to EB decreased substantially while the
selectivity to styrene increased substantially as compared to the
comparative example without the addition of water in the feed.
TABLE-US-00003 TABLE 3 The Effect of Water Added as a co-Feed with
Toluene and C.sub.1 source in an ATM process. Contact Time Time On
Stream Catalyst (sec) (hh:mm) X.sub.Tol S.sub.Bz S.sub.Xyl S.sub.EB
S.sub.Sty X.sub.MeOH Cs, B/X 2.6 2:29 3.4 1.4 0.3 33 66 100.0 Cs,
B/X 2.6 3:01 3.3 1.5 0.3 36 62 100.0 Cs, B/X 2.6 4:15 3.2 1.4 0.3
38 61 100.0 0.004 mL/min H.sub.2O co-feed 4:55 2.8 1.7 0.3 39 59
100.0
Example 3
[0070] In this example, the influence of hydrogen as a co-feed with
toluene and methanol was investigated. An experiment was conducted
on the (Cs, B)/X catalyst of the comparative example using 33
mL/min hydrogen as a co-feed to further investigate potential
active site poisons. Reaction conditions used were a temperature of
420.degree. C. pressure of 15 psig and a molar ratio of toluene to
methanol of 4:1. Hydrogen as a co-feed was added in an amount of
0.115 moles of hydrogen for every mole of methanol.
TABLE-US-00004 TABLE 4 The Effect of Hydrogen Added as a co-Feed
with Toluene and C.sub.1 source in an ATM process. Contact Time
Time On Stream Catalyst (sec) (hh:mm) X.sub.Tol S.sub.Bz S.sub.Xyl
S.sub.EB S.sub.Sty X.sub.MeOH Cs, B/X 2.5 2:45 2.3 1.5 0.5 43 55
87.4 Cs, B/X 2.5 3:46 2.2 1.4 0.6 45 53 100.0 Cs, B/X 2.5 5:57 1.9
1.5 0.7 48 50 93.0 33 mL/min H.sub.2 co-feed 6:54 1.7 1.6 0.7 50 48
91.7
[0071] According to the results in Table 4, the addition of
hydrogen increased selectivity to EB with time on stream while the
selectivity to styrene decreased with time on stream. Toluene
conversion, selectivity to benzene and selectivity to xylene were
essentially uninfluenced by the addition of hydrogen in the feed.
The selectivity to EB decreased substantially as compared to the
comparative example. The selectivity to styrene increased
substantially as compared to the comparative example without the
addition of hydrogen in the feed.
Example 4
[0072] In this example, the influence of CO as a co-feed with
toluene and a C.sub.1 source was investigated. An ATM experiment
was conducted on the (Cs, B)/X catalyst as used in the other
examples herein, using 23 mL/min CO as a co-feed to further
investigate potential active site poisons. Normal reaction
conditions were used of a molar ratio of toluene to methanol of
4:1, temperature of 420.degree. C., and pressure of 15 psig. Carbon
monoxide as a co-feed was added in an amount of 0.001 moles of CO
for every 4 moles of toluene and for every 1 mole of methanol.
TABLE-US-00005 TABLE 5 The Effect of CO Added as a co-Feed with
Toluene and C.sub.1 source in an ATM process. Contact Time Time On
Stream Catalyst (sec) (hh:mm) X.sub.Tol S.sub.Bz S.sub.Xyl S.sub.EB
S.sub.Sty X.sub.MeOH Cs, B/X 2.7 2:39 3.5 1.7 0.3 34 64 100.0 Cs,
B/X 2.7 3:30 3.1 1.8 0.4 36 62 100.0 Cs, B/X 2.7 4:38 2.8 1.9 0.4
38 60 100.0 23 mL/min CO co-feed 5:15 2.6 1.9 0.4 40 58 100.0
[0073] The results in Table 5 show that an improvement in styrene
selectivity was obtained with CO as a co-feed. Toluene conversion,
selectivity to benzene and selectivity to xylene were essentially
uninfluenced by the addition of CO in the feed. The selectivity to
EB decreased substantially as compared to the comparative example.
The selectivity to styrene increased substantially as compared to
the comparative example without the addition of CO in the feed.
Furthermore, the use of CO as co-feed did not require the
additional energy consumption necessary to convert water to
steam.
[0074] The term "conversion" refers to the percentage of reactant
(e.g. toluene) that undergoes a chemical reaction.
X.sub.Tol=conversion of toluene (mol
%)=(Tol.sub.in-Tol.sub.out)/Tol.sub.in.times.100
X.sub.MeoH=conversion of methanol to styrene+ethylbenzene (mol
%)=(MeOH.sub.in-MeOH.sub.out)/MeOH.sub.in.times.100
[0075] The term "molecular sieve" refers to a material having a
fixed, open-network structure, usually crystalline, that may be
used to separate hydrocarbons or other mixtures by selective
occlusion of one or more of the constituents, or may be used as a
catalyst in a catalytic conversion process.
[0076] Use of the term "optionally" with respect to any element of
a claim is intended to mean that the subject element is required,
or alternatively, is not required. Both alternatives are intended
to be within the scope of the claim. Use of broader terms such as
comprises, includes, having, etc. should be understood to provide
support for narrower terms such as consisting of, consisting
essentially of, comprised substantially of, etc.
[0077] The term "regenerated catalyst" refers to a catalyst that
has regained enough activity to be efficient in a specified
process. Such efficiency is determined by individual process
parameters.
[0078] The term "selectivity" refers to the relative activity of a
catalyst in reference to a particular compound in a mixture.
Selectivity is quantified as the proportion of a particular product
relative to all other products.
S.sub.Sty=selectivity of toluene to styrene (mol
%)=Sty.sub.out/Tol.sub.converted.times.100
S.sub.Bz=selectivity of toluene to benzene (mol
%)=Benzene.sub.out/Tol.sub.converted.times.100
S.sub.EB=selectivity of toluene to ethylbenzene (mol
%)=EB.sub.out/Tol.sub.converted.times.100
S.sub.Xyl=selectivity of toluene to xylenes (mol
%)=Xylenes.sub.out/Tol.sub.converted.times.100
S.sub.Sty+EB(MeOH)=selectivity of methanol to styrene+ethylbenzene
(mol %)=(Sty.sub.out+EB.sub.out)/MeOH.sub.converted.times.100
[0079] The term "spent catalyst" refers to a catalyst that has lost
enough catalyst activity to no longer be efficient in a specified
process. Such efficiency is determined by individual process
parameters.
[0080] The term "zeolite" refers to a molecular sieve containing an
aluminosilicate lattice, usually in association with some aluminum,
boron, gallium, iron, and/or titanium, for example. In the
following discussion and throughout this disclosure, the terms
molecular sieve and zeolite will be used more or less
interchangeably. One skilled in the art will recognize that the
teachings relating to zeolites are also applicable to the more
general class of materials called molecular sieves.
[0081] The various embodiments of the present invention can be
joined in combination with other embodiments of the invention and
the listed embodiments herein are not meant to limit the invention.
All combinations of various embodiments of the invention are
enabled, even if not given in a particular example herein.
[0082] While illustrative embodiments have been depicted and
described, modifications thereof can be made by one skilled in the
art without departing from the spirit and scope of the disclosure.
Where numerical ranges or limitations are expressly stated, such
express ranges or limitations should be understood to include
iterative ranges or limitations of like magnitude falling within
the expressly stated ranges or limitations (e.g., from about 1 to
about 10 includes, 2, 3, 4, etc.; greater than 0.10 includes 0.11,
0.12, 0.13, etc.).
[0083] Depending on the context, all references herein to the
"invention" may in some cases refer to certain specific embodiments
only. In other cases it may refer to subject matter recited in one
or more, but not necessarily all, of the claims. While the
foregoing is directed to embodiments, versions and examples of the
present invention, which are included to enable a person of
ordinary skill in the art to make and use the inventions when the
information in this patent is combined with available information
and technology, the inventions are not limited to only these
particular embodiments, versions and examples. Also, it is within
the scope of this disclosure that the embodiments disclosed herein
are usable and combinable with every other embodiment disclosed
herein, and consequently, this disclosure is enabling for any and
all combinations of the embodiments disclosed herein. Other and
further embodiments, versions and examples of the invention may be
devised without departing from the basic scope thereof and the
scope thereof is determined by the claims that follow.
* * * * *