U.S. patent application number 16/793530 was filed with the patent office on 2021-08-19 for toluene disproportionation using an enhanced uzm-44 aluminosilicate zeolite.
The applicant listed for this patent is UOP LLC. Invention is credited to Martha Leigh Abrams, Edwin P. Boldingh, Christopher P. Nicholas.
Application Number | 20210253498 16/793530 |
Document ID | / |
Family ID | 1000005750139 |
Filed Date | 2021-08-19 |
United States Patent
Application |
20210253498 |
Kind Code |
A1 |
Boldingh; Edwin P. ; et
al. |
August 19, 2021 |
TOLUENE DISPROPORTIONATION USING AN ENHANCED UZM-44 ALUMINOSILICATE
ZEOLITE
Abstract
Toluene disproportionation processes utilizing treated UZM-44
zeolites are described. The processes produce effluent streams
comprising para-xylene and benzene. The molar ratio of benzene to
xylene (Bz/X) in the effluent stream can be in a range of about
1.00 to about 1.14, the molar ratio of para-xylene to xylene (pX/X)
in the effluent stream can be in a range of about 0.80 to about
1.0, and the conversion of toluene can be about 20% to about
40%.
Inventors: |
Boldingh; Edwin P.;
(Arlington Heights, IL) ; Nicholas; Christopher P.;
(Evanston, IL) ; Abrams; Martha Leigh; (Chicago,
IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
UOP LLC |
Des Plaines |
IL |
US |
|
|
Family ID: |
1000005750139 |
Appl. No.: |
16/793530 |
Filed: |
February 18, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B01J 37/0215 20130101;
C07C 6/126 20130101; B01J 29/70 20130101; B01J 2229/36 20130101;
B01J 21/08 20130101; B01J 21/18 20130101; B01J 37/10 20130101; C07C
2529/70 20130101; B01J 2229/186 20130101 |
International
Class: |
C07C 6/12 20060101
C07C006/12; B01J 29/70 20060101 B01J029/70; B01J 21/08 20060101
B01J021/08; B01J 21/18 20060101 B01J021/18; B01J 37/02 20060101
B01J037/02; B01J 37/10 20060101 B01J037/10 |
Claims
1. A toluene disproportionation process comprising contacting a
feed comprising toluene with a catalyst comprising a microporous
crystalline zeolite at disproportionation conditions to produce an
effluent stream comprising para-xylene and benzene, wherein the
zeolite is UZM-44, wherein a molar ratio of benzene to xylene in
the effluent stream is in a range of about 1.00 to about 1.14,
wherein a molar ratio of para-xylene to xylene in the effluent
stream is in a range of about 0.80 to about 1.0, wherein a
conversion of toluene is about 20% to about 40%; and wherein the
catalyst has been enhanced with at least one enhancement treatment
step selected from treatment for deposition of carbon, treatment
for deposition of silica, or both.
2. The process of claim 1 wherein the molar ratio of benzene to
xylene is in the range of about 1.00 to about 1.08.
3. The process of claim 1 wherein the microporous crystalline
zeolite comprises a three-dimensional framework of at least
AlO.sub.2 and SiO.sub.2 tetrahedral units and an empirical
composition in hydrogen form expressed by an empirical formula of:
M1.sub.a.sup.N+Al.sub.(1-x)E.sub.xSi.sub.y'O.sub.z'' and where M1
is at least one exchangeable cation selected from the group
consisting of alkali, alkaline earth metals, rare earth metals,
zinc, ammonium ion, hydrogen ion and combinations thereof, "a" is
the mole ratio of M1 to (Al+E) and varies from about 0.05 to about
50, "N" is the weighted average valence of M1 and has a value of
about +1 to about +3, E is an element selected from the group
consisting of gallium, iron, boron, and combinations thereof, "x"
is the mole fraction of E and varies from 0 to about 1.0, y' is the
mole ratio of Si to (Al+E) and is greater than about 9 and z'' is
the mole ratio of O to (Al+E) and has a value determined by the
equation: z''=(aN+3+4y')/2 wherein the zeolite is characterized in
that it has the x-ray diffraction pattern having at least the
d-spacings and intensities set forth in Table B: TABLE-US-00009
TABLE B 2-Theta d( ) I/Io % 7.71 11.47 m-s 8.84 10.00 m-s 9.24 9.56
m 11.76 7.52 vw-w 12.46 7.10 m 14.38 6.15 vw 14.64 6.05 w 15.26
5.80 w 15.52 5.70 w-m 16.58 5.34 w 17.72 5.00 w-m 18.64 4.76 w
22.56 3.94 w-m 23.06 3.85 vs 23.40 3.80 s 24.12 3.69 m 25.06 3.55 m
26.16 3.40 vw-w 26.74 3.33 w-m 28.82 3.10 w-m 30.12 2.96 w 35.86
2.50 vw-w 45.32 2.00 w 46.05 1.97 vw-w 46.92 1.93 vw-w
4. (canceled)
5. The process of claim 1 wherein the at least one enhancement
treatment step comprises at least one treatment to incorporate
silica.
6. The process of claim 1 wherein the catalyst is steamed after the
at least one enhancement treatment step.
7. The process of claim 1 wherein the molar ratio of benzene to
xylene is in the range of about 1.00 to about 1.08 and wherein the
molar ratio of para-xylene to xylene is in the range of about 0.80
to about 0.95.
8. The process of claim 1 wherein a selectivity to xylenes is
greater than 52% when the molar ratio of para-xylene to xylene is
in the range of about 0.80 to about 0.90.
9. The process of claim 1 wherein a selectivity to light ends is
less than about 3.5% when the molar ratio of para-xylene to xylene
is in the range of about 0.80 to about 0.90.
10. The process of claim 1 wherein the disproportionation
conditions include one or more of: a temperature in a range of
about 200.degree. C. to about 600.degree. C.; a pressure in a range
of about 1.4 to about 4.5 MPa(g); a weight hourly space velocity in
a range of about 0.1 to about 10 hr.sup.-1; or a hydrogen to
hydrocarbon ratio in a range of about 0.25:1 to about 10:1.
11. The process of claim 1 wherein ring loss is less than about
1.5%.
12. A toluene disproportionation process comprising contacting a
feed comprising toluene with a catalyst comprising a microporous
crystalline zeolite at disproportionation conditions to produce an
effluent stream comprising para-xylene and benzene, wherein a molar
ratio of benzene to xylene in the effluent stream is in a range of
about 1.00 to about 1.20, wherein a molar ratio of para-xylene to
xylene in the effluent stream is in a range of about 0.60 to about
1.0, the zeolite having a three-dimensional framework of at least
AlO.sub.2 and SiO.sub.2 tetrahedral units and an empirical
composition in hydrogen form expressed by an empirical formula of
M1.sub.a.sup.N+Al.sub.(1-x)E.sub.xSi.sub.y'O.sub.z'' and where M1
is at least one exchangeable cation selected from the group
consisting of alkali, alkaline earth metals, rare earth metals,
zinc, ammonium ion, hydrogen ion and combinations thereof, "a" is
the mole ratio of M1 to (Al+E) and varies from about 0.05 to about
50, "N" is the weighted average valence of M1 and has a value of
about +1 to about +3, E is an element selected from the group
consisting of gallium, iron, boron, and combinations thereof, "x"
is the mole fraction of E and varies from 0 to about 1.0, y' is the
mole ratio of Si to (Al+E) and is greater than about 9, and z'' is
the mole ratio of O to (Al+E) and has a value determined by the
equation: z''=(aN+3+4y')/2 wherein the zeolite is characterized in
that it has the x-ray diffraction pattern having at least the
d-spacings and intensities set forth in Table B: TABLE-US-00010
TABLE B 2-Theta d( ) I/Io % 7.71 11.47 m-s 8.84 10.00 m-s 9.24 9.56
m 11.76 7.52 vw-w 12.46 7.10 m 14.38 6.15 vw 14.64 6.05 w 15.26
5.80 w 15.52 5.70 w-m 16.58 5.34 w 17.72 5.00 w-m 18.64 4.76 w
22.56 3.94 w-m 23.06 3.85 vs 23.40 3.80 s 24.12 3.69 m 25.06 3.55 m
26.16 3.40 vw-w 26.74 3.33 w-m 28.82 3.10 w-m 30.12 2.96 w 35.86
2.50 vw-w 45.32 2.00 w 46.05 1.97 vw-w 46.92 1.93 vw-w
and wherein the catalyst has been enhanced with at least one
enhancement treatment step selected from treatment for deposition
of carbon, treatment for deposition of silica, or both.
13. The process of claim 12 wherein conversion of toluene is about
20% to about 40%.
14. (canceled)
15. The process of claim 14 wherein the catalyst is steamed after
the at least one enhancement treatment step.
16. The process of claim 12 wherein the molar ratio of benzene to
xylene is in the range of about 1.00 to about 1.08 and wherein the
molar ratio of para-xylene to xylene is in the range of about 0.80
to about 0.95.
17. The process of claim 12 wherein a selectivity to xylenes is
greater than 52% when the molar ratio of para-xylene to xylene is
in the range of about 0.80 to about 0.90.
18. The process of claim 12 wherein a selectivity to light ends is
less than about 3.5% when the molar ratio of para-xylene to xylene
is in the range of about 0.80 to about 0.9.
19. The process of claim 12 wherein the disproportionation
conditions include one or more of: a temperature in a range of
about 200.degree. C. to about 600.degree. C.; a pressure in a range
of about 1.4 to about 4.5 MPa(g); a weight hourly space velocity in
a range of about 0.1 to about 10 hr-1; or a hydrogen to hydrocarbon
ratio in a range of about 0.25 to about 10.
20. A toluene disproportionation process comprising contacting a
feed comprising toluene with a catalyst comprising a microporous
crystalline zeolite at disproportionation conditions to produce an
effluent stream comprising para-xylene and benzene, wherein PXX is
a molar ratio of para-xylene to xylene in the effluent stream,
wherein BX is a molar ratio of benzene to xylene in the effluent
stream, and wherein PXX is in a range of about 0.60 to about 1.0,
BX is in a range of about 1.00 to about 0.375*PXX+0.825, the
zeolite having a three-dimensional framework of at least AlO.sub.2
and SiO.sub.2 tetrahedral units and an empirical composition in
hydrogen form expressed by an empirical formula of
M1.sub.a.sup.N+Al.sub.(1-x)E.sub.xSi.sub.y'O.sub.z'' and where M1
is at least one exchangeable cation selected from the group
consisting of alkali, alkaline earth metals, rare earth metals,
zinc, ammonium ion, hydrogen ion and combinations thereof, "a" is
the mole ratio of M1 to (Al+E) and varies from about 0.05 to about
50, "N" is the weighted average valence of M1 and has a value of
about +1 to about +3, E is an element selected from the group
consisting of gallium, iron, boron, and combinations thereof, "x"
is the mole fraction of E and varies from 0 to about 1.0, y' is the
mole ratio of Si to (Al+E) and is greater than about 9, and z'' is
the mole ratio of O to (Al+E) and has a value determined by the
equation: z''=(aN+3+4y')/2 wherein the zeolite is characterized in
that it has the x-ray diffraction pattern having at least the
d-spacings and intensities set forth in Table B: TABLE-US-00011
TABLE B 2-Theta d( ) I/Io % 7.71 11.47 m-s 8.84 10.00 m-s 9.24 9.56
m 11.76 7.52 vw-w 12.46 7.10 m 14.38 6.15 vw 14.64 6.05 w 15.26
5.80 w 15.52 5.70 w-m 16.58 5.34 w 17.72 5.00 w-m 18.64 4.76 w
22.56 3.94 w-m 23.06 3.85 vs 23.40 3.80 s 24.12 3.69 m 25.06 3.55 m
26.16 3.40 vw-w 26.74 3.33 w-m 28.82 3.10 w-m 30.12 2.96 w 35.86
2.50 vw-w 45.32 2.00 w 46.05 1.97 vw-w 46.92 1.93 vw-w
and wherein the catalyst has been enhanced with at least one
enhancement treatment step selected from treatment for deposition
of carbon, treatment for deposition of silica, or both.
Description
BACKGROUND
[0001] Zeolites are crystalline aluminosilicate compositions which
are microporous and which are formed from corner sharing AlO.sub.2
and SiO.sub.2 tetrahedra. Numerous zeolites, both naturally
occurring and synthetically prepared, are used in various
industrial processes. Synthetic zeolites are prepared via
hydrothermal synthesis employing suitable sources of Si, Al and
structure directing agents such as alkali metals, alkaline earth
metals, amines, or organoammonium cations. The structure directing
agents reside in the pores of the zeolite and are largely
responsible for the particular structure that is ultimately formed.
These species balance the framework charge associated with aluminum
and can also serve as space fillers. Zeolites are characterized by
having pore openings of uniform dimensions, having a significant
ion exchange capacity, and being capable of reversibly desorbing an
adsorbed phase which is dispersed throughout the internal voids of
the crystal without significantly displacing any atoms which make
up the permanent zeolite crystal structure. Zeolites can be used as
catalysts for hydrocarbon conversion reactions, which can take
place on outside surfaces as well as on internal surfaces within
the pore.
[0002] One particular zeolite, IM-5 was first disclosed by Benazzi,
et al. in 1996 (FR96/12873; WO98/17581) who describe the synthesis
of IM-5 from the flexible dicationic structure directing agent,
1,5-bis(N-methylpyrrolidinium)pentane dibromide or
1,6-bis(N-methylpyrrolidinium)hexane dibromide in the presence of
sodium. After the structure of IM-5 was solved by Baerlocher et al.
(Science, 2007, 315, 113-6), the International Zeolite Structure
Commission gave the code of IMF to this zeolite structure type, see
Atlas of Zeolite Framework Types which is maintained by the
International Zeolite Association Structure Commission at
http://www.iza-structure.org/databases/. The IMF structure type was
also found to contain three mutually orthogonal sets of channels in
which each channel is defined by a 10-membered ring of
tetrahedrally coordinated atoms. However, connectivity in the third
dimension is interrupted every 2.5 nm; therefore, diffusion is
somewhat limited. In addition, multiple different sizes of
10-membered ring channels exist in the structure.
[0003] Applicants have successfully prepared a new family of
materials designated UZM-44. The topology of the materials is
similar to that observed for IM-5. The materials are prepared via
the use of a mixture of simple commercially available structure
directing agents, such as 1,5-dibromopentane and
1-methylpyrrolidine and have been described in U.S. Pat. Nos.
8,609,920, and 8,623,321. UZM-44 has been utilized as a catalyst in
several reactions, including methane conversion (U.S. Pat. No.
8,921,634), dehydrocyclodimerization (U.S. Pat. No. 8,889,939),
catalytic pyrolysis (U.S. Pat. Nos. 8,609,911 and 8,710,285),
transalkylation (U.S. Pat. Nos. 8,609,921 and 8,704,026), and
transformation of aromatics (U.S. Pat. Nos. 8,609,919, 8,748,685,
and 8,716,540). UZM-44 may be used as a catalyst in toluene
disproportionation reactions.
[0004] The xylene isomers are produced in large volumes from
petroleum as feedstocks for a variety of important industrial
chemicals. The most important of the xylene isomers is para-xylene,
the principal feedstock for polyester which continues to enjoy a
high growth rate from large base demand Ortho-xylene is used to
produce phthalic anhydride, which has high-volume, but mature
markets. Meta-xylene is used in lesser but growing volumes for such
products as plasticizers, azo dyes, and wood preservers.
[0005] Among the aromatic hydrocarbons, the overall importance of
the xylenes rivals that of benzene as a feedstock for industrial
chemicals. Neither the xylenes nor benzene are produced from
petroleum by the reforming of naphtha in sufficient volume to meet
demand. Therefore, conversion of other hydrocarbons is necessary to
increase production of xylenes and benzene. Often toluene is
selectively disproportionated to yield benzene and C.sub.8
aromatics from which the individual xylene isomers are
recovered.
[0006] Para-selective toluene disproportionation is a process that
was commercialized in the 1980's with the aim of converting toluene
to benzene and xylenes with high para-xylene to total xylenes molar
ratio (pX/X molar ratio) of typically greater than 0.85. This
technology is particularly desired when there is a demand for
polyesters and other chemicals derived from para-xylene, but
limited demand for other xylenes. High pX/X was initially achieved
by "selectivation" of the catalyst with carbon and/or coke to
narrow the MFI pore size and to cover acid sites on the exterior
surface of the MFI crystals. Later, it was learned that depositing
silica on the catalyst achieved similar results.
[0007] U.S. Pat. No. 4,016,219 B1 (Kaeding) discloses a process for
toluene disproportionation using a catalyst comprising a zeolite
which has been modified by the addition of phosphorus in an amount
of at least 0.5 mass-%. The crystals of the zeolite are contacted
with a phosphorus compound to effect reaction of the zeolite and
phosphorus compound. The modified zeolite then may be incorporated
into indicated matrix materials.
[0008] U.S. Pat. No. 4,097,543 B1 (Haag et al.) teaches toluene
disproportionation for the selective production of para-xylene
using a zeolite which has undergone controlled pre-coking. The
zeolite may be ion-exchanged with a variety of elements from Group
IB to VIII, and composited with a variety of clays and other porous
matrix materials.
[0009] U.S. Pat. No. 6,114,592 B1 (Gajda et al.), teaches an
improved process combination for the selective disproportionation
of toluene. The combination comprises selective hydrogenation of a
toluene feedstock followed by contacting with a zeolitic catalyst
which has been oil-dropped in an aluminum phosphate binder to
achieve a high yield of para-xylene.
[0010] U.S. Pat. No. 6,429,347 B1 (Boldingh) teaches toluene
disproportionation for the selective production of para-xylene
using a catalyst comprising MFI zeolite bound with alumina
phosphate after selectively pre-coking the catalyst by contacting
the catalyst with a coke-forming feed at pre-coking conditions.
[0011] In these processes, the zeolite of choice was ZSM-5 which
has an MFI framework. Using these catalysts, the molar ratio of
para-xylene to xylene (pX/X) can be increased from the equilibrium
level of about 0.24 to 0.90 or more by deposition of sufficient
amounts of coke or silica. Although this increases the pX/X molar
ratio, it is always accompanied by an increase in the molar ratio
of benzene to xylene (Bz/X) to significantly greater than the
theoretical value of 1. The higher the pX/X molar ratio, the higher
the Bz/X molar ratio.
[0012] Although not wishing to be bound by theory, it appears the
increase in the Bz/X molar ratio is caused by a loss in total
xylene yield. In general, as the para-xylene yield is increased
beyond a certain level, the total xylene yield typically decreases.
This is considered inevitable, and much research has been aimed at
optimizing the use of coke or silica to minimize Bz/X molar ratio.
Using the best silica deposition technology to increase pX/X molar
ratio to 0.90 or more, it is quite common to see Bz/X molar ratio
values up to 1.4 at disproportionation conditions of 30% toluene
conversion, H.sub.2/HC=2, WHSV=4, at a pressure of 400 psig.
[0013] Therefore, there is a need for an improved toluene
disproportionation process in which the pX/X molar ratio is high
(e.g., 0.70 or more) and the Bz/X molar ratio is less than 1.2.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is an illustration of one embodiment of a toluene
disproportionation process.
[0015] FIG. 2 is a graph showing the Bz/X molar ratio as a function
of the pX/X molar ratio for various catalysts at 30%
conversion.
[0016] FIG. 3 is a graph showing the selectivity to xylene as a
function of pX/X molar ratio for various catalysts at 30%
conversion.
[0017] FIG. 4 is a graph showing the selectivity to light ends
(C1-C6) as a function of pX/X molar ratio for various catalysts at
30% conversion.
[0018] FIG. 5 is a graph showing the temperature required to
achieve 30% conversion for various catalysts plotted against pX/X
molar ratio achieved.
DETAILED DESCRIPTION
[0019] One aspect of the invention is a toluene disproportionation
process. In one embodiment, the process comprises contacting a feed
comprising toluene with a microporous crystalline zeolite at
disproportionation conditions to produce an effluent stream
comprising para-xylene and benzene, wherein a molar ratio of
benzene to xylene (Bz/X) in the effluent stream is in a range of
about 1.00 to about 1.14, wherein a molar ratio of para-xylene to
xylene (pX/X) in the effluent stream is in a range of about 0.80 to
about 1.0, and wherein a conversion of toluene is about 20% to
about 40%.
[0020] The present invention relates to a catalytic use of an
aluminosilicate zeolite designated UZM-44. UZM-44 is a material
having a three-dimensional framework of at least AlO.sub.2 and
SiO.sub.2 tetrahedral units and an empirical composition in the
as-synthesized and anhydrous basis expressed by an empirical
formula of:
Na.sub.nM.sub.m.sup.k+T.sub.tAl.sub.1-xE.sub.xSi.sub.yO.sub.z
[0021] where "n" is the mole ratio of Na to (Al+E) and has a value
from approximately 0.05 to 0.5, M represents at least one metal
selected from the group consisting of zinc, Group 1 (IUPAC 1),
Group 2 (IUPAC 2), Group 3 (IUPAC 3), and the lanthanide series of
the periodic table, and any combination thereof, "m" is the mole
ratio of M to (Al+E) and has a value from 0 to 0.5, "k" is the
average charge of the metal or metals M, T is the organic structure
directing agent or agents derived from reactants R and Q where R is
an A,.OMEGA.-dihalogen substituted alkane having 5 carbon atoms and
Q is at least one neutral monoamine having 6 or fewer carbon atoms,
"t" is the mole ratio of N from the organic structure directing
agent or agents to (Al+E) and has a value of from about 0.5 to
about 1.5, E is an element selected from the group consisting of
gallium, iron, boron and combinations thereof, "x" is the mole
fraction of E and has a value from 0 to about 1.0, "y" is the mole
ratio of Si to (Al+E) and varies from greater than 9 to about 25
and "z" is the mole ratio of O to (Al+E) and has a value determined
by the equation:
z=(n+km+3+4y)/2.
[0022] The as-synthesized UZM-44 is characterized by the x-ray
diffraction pattern, having at least the d-spacings and relative
intensities set forth in Table A below. Diffraction patterns herein
were obtained using a typical laboratory powder diffractometer,
with a high-intensity x-ray tube operated at 45 kV and 35 ma
utilizing the K.sub..alpha. line of copper; Cu K alpha. Flat
compressed powder samples were continuously scanned at 2.degree. to
56.degree. (2.theta.). From the position of the diffraction peaks
represented by the angle 2 theta (2.theta.), the characteristic
interplanar distances d.sub.hkl of the sample can be calculated
using the Bragg equation. As will be understood by those skilled in
the art, the determination of the parameter 2.theta. is subject to
both human and mechanical error, which in combination can impose an
uncertainty of about .+-.0.4.degree. on each reported value of
2.theta.. This uncertainty is, of course, also manifested in the
reported values of the d-spacings, which are calculated from the
2.theta. values. This imprecision is general throughout the art and
is not sufficient to preclude the differentiation of the present
crystalline materials from each other and from the compositions of
the prior art.
[0023] The intensity is calculated on the basis of a relative
intensity scale attributing a value of 100 to the line representing
the strongest peak on the X-ray diffraction pattern, and then: very
weak (vw) means less than 5; weak (w) means less than 15; medium
(m) means in the range 15 to 50; strong (s) means in the range 50
to 80; very strong (vs) means more than 80. Intensities may also be
shown as inclusive ranges of the above. The X-ray diffraction
patterns from which the data (d spacing and intensity) are obtained
are characterized by a large number of reflections, some of which
are broad peaks or peaks which form shoulders on peaks of higher
intensity. Some or all of the shoulders may not be resolved. This
may be the case for samples of low crystallinity, of particular
coherently grown composite structures, or for samples with crystals
which are small enough to cause significant broadening of the
X-rays. This can also be the case when the equipment or operating
conditions used to produce the diffraction pattern differ
significantly from those used in the present case.
[0024] The zeolite may be further characterized by the x-ray
diffraction pattern having at least the d-spacings and intensities
set forth in Table A.
TABLE-US-00001 TABLE A 2-Theta d( ) I/Io % 7.72 11.45 m 8.88 9.95 m
9.33 9.47 m 12.47 7.09 w-m 12.85 6.88 vw 14.62 6.05 vw-w 15.27 5.80
w 15.57 5.68 w 16.60 5.34 w 17.70 5.01 vw-w 18.71 4.74 w-m 19.30
4.59 w 22.55 3.94 m 23.03 3.86 vs 23.39 3.80 s 24.17 3.68 m 25.01
3.56 m 26.19 3.40 vw-w 26.68 3.34 w-m 28.76 3.10 w-m 30.07 2.97 w
35.72 2.51 vw-w 45.08 2.01 w 45.83 1.98 vw-w 46.77 1.94 vw-w
[0025] As has been shown, the zeolite is thermally stable up to a
temperature of greater than 600.degree. C. in one embodiment and at
least 800.degree. C. in another embodiment.
[0026] As synthesized, the UZM-44 material will contain some
exchangeable or charge balancing cations in its pores. These
exchangeable cations can be exchanged for other cations, or in the
case of organic cations, they can be removed by heating under
controlled conditions. It is also possible to remove some organic
cations from the UZM-44 zeolite directly by ion exchange. The
UZM-44 zeolite may be modified in many ways to tailor it for use in
a particular application. Modifications include calcination,
ion-exchange, steaming, various acid extractions, ammonium
hexafluorosilicate treatment, or any combination thereof, as
outlined for the case of UZM-4M in U.S. Pat. No. 6,776,975 B1 which
is incorporated by reference in its entirety. Conditions may be
more severe than shown in U.S. Pat. No. 6,776,975. Properties that
are modified include porosity, adsorption, Si/Al ratio, acidity,
thermal stability, and the like.
[0027] After calcination, ion-exchange and calcination and on an
anhydrous basis, the modified microporous crystalline zeolite
UZM-44 has a three-dimensional framework of at least AlO.sub.2 and
SiO.sub.2 tetrahedral units and an empirical composition in the
hydrogen form expressed by an empirical formula of
M1.sub.a.sup.N+Al.sub.(1-x)E.sub.xSi.sub.y'O.sub.z''
where M1 is at least one exchangeable cation selected from the
group consisting of alkali, alkaline earth metals, rare earth
metals, ammonium ion, hydrogen ion and combinations thereof, "a" is
the mole ratio of M1 to (Al+E) and varies from about 0.05 to about
50, "N" is the weighted average valence of M1 and has a value of
about +1 to about +3, E is an element selected from the group
consisting of gallium, iron, boron, and combinations thereof, x is
the mole fraction of E and varies from 0 to 1.0, y' is the mole
ratio of Si to (Al+E) and varies from greater than about 9 to
virtually pure silica and z'' is the mole ratio of O to (Al+E) and
has a value determined by the equation:
z''=(aN+3+4y')/2
[0028] In the hydrogen form, after calcination, ion-exchange and
calcination to remove NH.sub.3, modified UZM-44 (UZM-44M) displays
the x-ray diffraction pattern having at least the d-spacings and
intensities set forth in Table B. Those peaks characteristic of
UZM-44 are shown in Tables B. Additional peaks, particularly those
of very weak intensity, may also be present. All peaks of medium or
higher intensity present in UZM-44 are indicated in Table B.
TABLE-US-00002 TABLE B 2-Theta d( ) I/Io % 7.71 11.47 m-s 8.84
10.00 m-s 9.24 9.56 m 11.76 7.52 vw-w 12.46 7.10 m 14.38 6.15 vw
14.64 6.05 w 15.26 5.80 w 15.52 5.70 w-m 16.58 5.34 w 17.72 5.00
w-m 18.64 4.76 w 22.56 3.94 w-m 23.06 3.85 vs 23.40 3.80 s 24.12
3.69 m 25.06 3.55 m 26.16 3.40 vw-w 26.74 3.33 w-m 28.82 3.10 w-m
30.12 2.96 w 35.86 2.50 vw-w 45.32 2.00 w 46.05 1.97 vw-w 46.92
1.93 vw-w
[0029] Surface area, micropore volume, and total pore volume may be
determined, for example, by N.sub.2 adsorption using the
conventional BET method of analysis (J. Am. Chem. Soc., 1938, 60,
309-16) coupled with t-plot analysis of the adsorption isotherm as
implemented in Micromeritics ASAP 2010 software. The t-plot is a
mathematical representation of multi-layer adsorption and allows
determination of the amount of N.sub.2 adsorbed in the micropores
of the zeolitic material under analysis. In particular, for the
materials described herein, points at 0.45, 0.50, 0.55, 0.60, and
0.65 P/P.sub.0 are used to determine the slope of the t-plot line,
the intercept of which is the micropore volume. Total pore volume
is determined at 0.98 P/P.sub.0. The UZM-44 utilized in the instant
invention has a micropore volume of less than 0.155 mL/g, typically
less than 0.150 mL/g, and often less than 0.145 mL/g. Additionally,
by looking at the dV/d log D versus pore diameter plot (the
differential volume of nitrogen adsorbed as a function of pore
diameter), the UZM-44 utilized in the instant invention contains no
feature at around 200-300 .ANG.. UZM-44 has an adsorption feature
occurring at greater than 450 .ANG.. In an embodiment, greater than
0.1 mL N.sub.2/g.ANG. is differentially adsorbed at a pore diameter
of 475 .ANG.. Preferably, greater than 0.1 mL N.sub.2/g.ANG. is
differentially adsorbed at pore diameters greater than 475 .ANG.
where differentially adsorbed indicates the differential volume of
nitrogen adsorbed at a particular pore diameter.
[0030] In specifying the proportions of the zeolite starting
material or adsorption properties of the zeolite product and the
like herein, the "anhydrous state" of the zeolite will be intended
unless otherwise stated. The term "anhydrous state" is employed
herein to refer to a zeolite substantially devoid of both
physically adsorbed and chemically adsorbed water.
[0031] UZM-44 or UZM-44M may be enhanced in order to increase the
pX/X ratio achieved during toluene disproportionation Enhancement
is meant to indicate a step that increases the pX/X molar ratio
significantly above the equilibrium value of 0.24 during toluene
disproportionation. Three known examples are deposition of carbon,
treatment with silica, and steaming following deposition of carbon
and/or silica.
[0032] It has been surprisingly found that a catalyst comprising
UZM-44 which has undergone an enhancement step until the pX/X molar
ratio achieved during disproportionation conditions is greater than
0.6 had a unique combination of high pX/X molar ratio and high
total xylene selectivity without production of excess benzene.
[0033] The catalyst may further comprise a refractory binder or
matrix for the purpose of facilitating fabrication of the
disproportionation catalyst, providing strength, reducing
fabrication costs, or combinations thereof. The binder may be
uniform in composition and relatively refractory to the conditions
used in the process. Suitable binders may include inorganic oxides
such as one or more of alumina, magnesia, zirconia, chromia,
titania, boria, thoria, zinc oxide and silica. Alumina and/or
silica are preferred binders. The amount of zeolite present in the
bound catalyst can vary considerably but usually is present in an
amount from about 30 to 90 mass percent and preferably from about
50 to 80 mass percent of the catalyst.
[0034] An exemplary enhancement step to deposit silica comprises
exposing the zeolite to a silicon reagent, such as
tetraethylorthosilicate (TEOS), followed by a calcination step. The
exemplary enhancement by silica treatment incorporates silica onto
the zeolite. The enhancement by deposition of silica may be
effected by treatment of the zeolite, may be carried out on the
zeolite prior to binding with a refractory oxide, or may be carried
out on the bound catalyst.
[0035] In an aspect, UZM-44 may be extruded with a metal oxide
binder prior to enhancement. Ion-exchanged zeolite powder may be
extruded as cylinders or trilobes with refractory metal oxides
comprising SiO.sub.2, TiO.sub.2, ZrO.sub.2, Al.sub.2O.sub.3, or
mixtures thereof. In an aspect, the refractory metal oxide may be
SiO.sub.2. Relative loadings of zeolite and refractory metal oxide
may vary. Zeolite content in the catalyst extrudate may be greater
than 50 wt %, or greater than 55 wt %, or greater than 60 wt %, or
greater than 65 wt %, or less than 95 wt %, or less than 90 wt %,
or less than 80 wt %. Extrudate size and shape may vary within
known technical bounds, with cylinders and trilobes of
approximately 1.6 mm preferred. Extrudate width may be from 0.75 mm
to about 4 mm, or from about 1.0 mm to about 3 mm.
[0036] Dried extrudate may be calcined in air for from about 5
minutes to about 6 hours at temperatures in the range of about
350.degree. C. to about 600.degree. C. Times of about 15 minutes to
about 4 hours, or about 30 minutes to about 3 hours may be
acceptable. Temperatures of from about 400.degree. C. to about
550.degree. C., or from about 450.degree. C. to about 550.degree.
C. may be acceptable. Optionally, extrudates may be ion-exchanged
at 75.degree. C. for 1 hour using a 10:1:1 weight ratio of
water:ammonium nitrate:extrudate. If ion-exchanged, the extrudate
would be rinsed multiple times with deionized H.sub.2O. If
utilized, ion-exchange may be repeated if necessary. The final
dried extrudate may then be calcined as described above.
[0037] Enhancement treatment by silica may proceed by placing the
sample in a container, and adding an organic solvent. In an aspect,
the amount of organic solvent to be added may be determined from
Table 1. The container may be heated for 1 hour at reflux
temperature of the organic solvent, during which time water may be
removed from the system. The silicon reagent may then be added to
the container. In an aspect, the silicon reagent includes, but is
not limited to, a silicon alkoxide. Suitable silicon alkoxides
include, but are not limited to, tetramethyl orthosilicate (TMOS),
tetraethyl orthosilicate (TEOS), tetrapropyl orthosilicate (TPOS),
tetraisopropyl orthosilicate (TiPOS), tetrabutyl orthosilicate
(TBOS). The silicon reagent may be partially hydrolyzed alkoxides
or siloxanes of silicon. A suitable source may be one of the
Dynaslan.RTM. Silbond.RTM. family of products available from
Evonik. The silicon reagent may be a chlorosilane. Concentration of
the silicon reagent used may be in the range of 5 to 25 wt % on a
basis of the sample weight.
[0038] Once the silicon reagent has been added, the contents of the
container may be reacted at reflux from about 5 minutes to about 8
hours, or from about 30 minutes to about 4 hours. After reflux,
solvent may be removed from the sample. Suitable solvent removal
methods may involve decanting, distillation, or reduced pressure
distillation. The sample may then be exposed to a heat treatment
step of at least about 175.degree. C. up to about 600.degree. C. to
form the enhanced catalyst. The enhancement treatment may be
repeated as many times as needed to achieve the desired pX/X
selectivity.
[0039] The enhancement by deposition of carbon may be effected at
conditions relative to the subsequent disproportionation step
comprising one or more of a higher temperature, lower pressure,
higher space velocity, or higher hydrogen to hydrocarbon ratio.
Such carbon deposition conditions may comprise a pressure of from
about 100 kPa to 4 MPa absolute, and a liquid hourly space velocity
of from about 0.2 to 10 hr.sup.-1. The conditions may comprise one
or more of an inlet temperature at least about 50.degree. C. higher
than the reaction temperature; a pressure at least about 100 kPa
lower than the reaction pressure, or preferably no more than about
half of the pressure utilized in the subsequent disproportionation
step. Preferably, the molar ratio of free hydrogen to feedstock
coke-forming hydrocarbons is no more than about half of that
utilized in the subsequent disproportionation step. Lower pressure
and/or a lower hydrogen/hydrocarbon ratio will lower the proportion
of exothermic aromatic-saturation reactions, and thus restrict the
temperature rise; the result should be a relatively flatter
temperature profile. Thus, a typical temperature range would be
from about 300.degree. C. to about 700.degree. C., and a typical
hydrogen to coke-forming feed range would be about 0.01 to about 5.
Enhancement by deposition of carbon may result in a catalyst carbon
content of between about 5 and 40 mass-% carbon, and preferably
between about 10 and 30 mass-% carbon. A coke-forming feed for
deposition of carbon may comprise the feedstock to the
disproportionation step as described below. In an aspect, toluene,
or other specific hydrocarbons or mixtures known in the art
preferably comprising aromatics may be used as the coke forming
feed.
[0040] The UZM-44 may be enhanced one or more times with carbon
and/or silica. The enhancement may incorporate carbon or silica
into the catalyst comprising zeolite. Into means into or onto the
surface of and is meant to indicate that the carbon or silica
enhancement may deposit material onto the external surfaces of
zeolite crystals, and/or on the exterior surfaces and/or within the
pore structure of any refractory oxide present. Without wishing to
be bound by theory, into does not describe depositing of material
within the micropores of the zeolite. In an embodiment, enhancement
may be carried out on the zeolite, may be carried out on the
zeolite prior to binding with said refractory oxide, or may be
carried out on the bound catalyst, comprising UZM-44 or UZM-44M.
Individual enhancement steps may be repeated until a desired
selectivity is achieved at disproportionation conditions. In an
aspect, enhancement steps may be carried out until pX/X is greater
than 0.6, or greater than 0.7, or greater than 0.8, or greater than
0.85, or greater than 0.9.
[0041] Following enhancement by deposition of carbon or deposition
of silica, the enhanced UZM-44 may optionally undergo a steaming
treatment. Steaming after enhancement may increase the pX/X
achieved during disproportionation. However, steaming may also
reduce the activity of the zeolite or catalyst. In an aspect, the
steaming treatment conditions may utilize a temperature of from
100.degree. C. to 750.degree. C., or from about 200.degree. C. to
about 700.degree. C., or from about 450.degree. C. to about
650.degree. C.; a partial pressure of water of about 0.1 to about
0.5, or about 0.15 to about 0.35; for a time of from about 10
minutes to about 26 hours, or from about 30 minutes to about 6
hours. In an aspect, high pX/X ratios during disproportionation may
be achieved by enhancement step or steps, or by a combination of
enhancement step or steps and steaming step or steps. Steaming and
enhancement steps may be carried out in any order found to achieve
high pX/X.
[0042] The enhanced UZM-44 zeolite of this invention may be
utilized as a catalyst or catalyst support in the toluene
disproportionation process.
[0043] The toluene disproportionation process comprises contacting
a feed stream comprising toluene with a catalyst comprising a
zeolite at disproportionation conditions to yield an effluent
stream comprising benzene and xylenes. In a selective
disproportionation process such as that of the instant invention,
the catalyst may have been enhanced by one or more treatment steps
in order to increase the molar ratio of para-xylene to xylene
(pX/X) from the equilibrium level of about 0.24 to 0.60 or more by
deposition of sufficient amounts of coke or silica. Although this
enhancement increases the pX/X molar ratio, it has previously been
accompanied by an increase in the molar ratio of benzene to xylene
(Bz/X) to significantly greater than the theoretical value of 1.
Using the best silica deposition technology to increase pX/X molar
ratio to 0.90 or more, it has been common to see Bz/X molar ratio
values up to 1.4 at disproportionation conditions which may
comprise 30% toluene conversion, H.sub.2/HC=2, WHSV=4 hr.sup.-1, at
a pressure of 2.8 MPa(g).
[0044] Ideally, the toluene disproportionation process operates at
the highest toluene conversion possible while maximizing the xylene
yield from the reaction. In an aspect, the toluene conversion may
be greater than about 20 wt %, or greater than about 25 wt % or
greater than about 28 wt % or greater than about 30 wt % or greater
than 32 wt % or greater than about 35 wt % or less than about 50 wt
%, or less than about 40 wt %, or less than about 35 wt %.
[0045] The feed for the disproportionation reaction may comprise
toluene, optionally in combination with C.sub.9 aromatics, and
suitably is derived from one or a variety of sources. The feedstock
may be produced synthetically, for example, from naphtha by
catalytic reforming, or by pyrolysis followed by hydrotreating to
yield an aromatics-rich product. The feedstock may be derived from
such product with suitable purity by extraction of aromatic
hydrocarbons from a mixture of aromatic and nonaromatic
hydrocarbons and fractionation of the extract. For instance,
aromatics may be recovered from a reformate. The feed may comprise
at least about 80% toluene by mass, or greater than about 85%
toluene, or greater than about 90% toluene, or greater than about
95% toluene, or even greater than about 98.5% toluene. The feed may
comprise greater than about 90% aromatic compounds by mass, or
greater than about 95% aromatic compounds, or greater than about
98% aromatic compounds, or greater than about 99% aromatic
compounds, or even greater than about 99.5% aromatic compounds. In
an aspect, the feedstock may contain no more than about 10%
non-aromatic compounds by mass. In an aspect, the feed may contain
no more than about 10% benzene by mass. In an aspect, the feed may
contain no more than about 10% xylenes by mass. In an aspect, the
feed may contain no more than 10% A9 aromatic compounds by mass.
Desirably, non-aromatic compounds, benzene, xylenes, and A9
aromatic compounds are close to 0% by mass. In an aspect, all or
mixtures of any of the conditions listed in this paragraph may
apply to the characterization of the feed.
[0046] The disproportionation reaction conditions may include a
temperature in the range of from about 200.degree. C. to about
600.degree. C., or from about 300.degree. C. to about 450.degree.
C., or from 350.degree. C. to about 425.degree. C. The pressure may
be in the range from about 1.0 MPa to about 7.0 MPa, or about 1.4
MPa(g) to about 4.5 MPa(g), or about 2.0 MPa(g) to about 3.5
MPa(g). The disproportionation reaction can be effected over a wide
range of space velocities, with higher space velocities effecting a
higher ratio of para-xylene at the expense of conversion. The
weight hourly space velocity (WHSV) may be in the range of about
0.5 to about 10 hr.sup.-1, or about 1.0 to about 7 hr.sup.-1, or
about 1.0 to about 5 hr.sup.-1. The ratio of hydrogen to
hydrocarbon is calculated based on the molar ratio of free hydrogen
compared against the feedstock hydrocarbon. Periodic increases in
hydrogen to hydrocarbon above about 0.5, and preferably in the
range of about 1 to about 5 may permit catalyst rejuvenation by
hydrogenation of soft coke. The hydrogen to hydrocarbon ratio may
be in the range of about 0.25 to about 10, or about 0.5 to about
5.
[0047] The molar ratio of para-xylene to xylene (pX/X) in the
effluent is an important factor in the selective toluene
disproportionation process. The equilibrium pX/X is about 0.24 at
toluene disproportionation conditions, so a para-selective toluene
disproportionation process produces an effluent comprising a pX/X
of greater than about 0.25, or greater than about 0.30. The
effluent from the toluene disproportionation process may have a
pX/X molar ratio of greater than about 0.60, or greater than about
0.70, or greater than about 0.75, or greater than about 0.80, or
greater than about 0.85, or greater than about 0.90, and may be
less than about 0.98, or less than about 0.96, or less than about
0.94.
[0048] Ideally, the toluene disproportionation process operates at
a benzene to xylene molar ratio (Bz/X) in the effluent of 1.00. A
Bz/X of 1.00 indicates that for every mole of benzene produced, a
mole of xylene is produced. Bz/X ratios closer to 1.00 are
preferred, and in an aspect, the Bz/X molar ratio may be less than
about 1.20, or less than about 1.16, or less than about 1.12, or
less than about 1.08, or less than about 1.06, or less than about
1.05, or less than about 1.04, or less than about 1.03, or less
than about 1.02, or less than about 1.01, and greater than about
1.00, or greater than about 0.99, or greater than about 0.98. For
example, in some embodiments, the Bz/X molar ratio is in the range
of about 0.98 to about 1.20 over a pX/X molar ratio in the range of
about 0.25 to about 0.95. In some embodiments, the Bz/X molar ratio
is in the range of about 0.98 to about 1.16 over a pX/X molar ratio
in the range of about 0.25 to about 0.95. In some embodiments, the
Bz/X molar ratio is in the range of about 0.98 to about 1.12 over a
pX/X molar ratio in the range of about 0.25 to about 0.95. In some
embodiments, the Bz/X molar ratio is in the range of about 0.98 to
about 1.08 over a pX/X molar ratio in the range of about 0.25 to
about 0.95. In some embodiments, the Bz/X molar ratio is in the
range of about 0.98 to about 1.06 over a pX/X molar ratio in the
range of about 0.25 to about 0.90. In some embodiments, the Bz/X
molar ratio is about 0.98 to about 1.05 over a pX/X molar ratio in
the range of about 0.25 to about 0.85. In some embodiments, the
Bz/X molar ratio is in the range of about 0.98 to about 1.02 over
the range of a pX/X molar ratio in the range of about 0.25 to about
0.85. In some embodiments, the Bz/X molar ratio is in the range of
about 0.98 to about 1.01 over a pX/X molar ratio in the range of
about 0.25 to about 0.80. In some embodiments, the Bz/X ratio is in
the range of about 1.00 to about 1.20 over a pX/X molar ratio in
the range of about 0.80 to about 0.95. In some embodiments, the
Bz/X ratio is in the range of about 1.00 to about 1.16 over a pX/X
molar ratio in the range of about 0.80 to about 0.95. In some
embodiments, the Bz/X molar ratio is in the range of about 1.00 to
about 1.12 over a pX/X molar ratio in the range of about 0.80 to
about 0.95. In some embodiments, the Bz/X ratio is in the range
about 1.00 to about 1.08 over a pX/X molar ratio in the range of
about 0.80 to about 0.95. In some embodiments, the Bz/X ratio is in
the range of about 1.00 to about 1.06 over a pX/X molar ratio in
the range of about 0.80 to about 0.90.
[0049] When the feed contains benzene or xylenes, the amount of
benzene or xylenes or para-xylene in the feed is subtracted from
the amount in the product in order to determine the Bz/X ratio and
pX/X ratio. In other words:
Bz/X molar
ratio=(Bz.sub.product-Bz.sub.Feed)/(X.sub.Product-X.sub.Feed).
[0050] Additionally, the para-xylene to total xylene molar ratio
may be determined by pX/X molar
ratio=(pX.sub.product-pX.sub.Feed)/(X.sub.Product-X.sub.Feed)=PXX.
[0051] A relationship exists between the benzene to xylene molar
ratio Bz/X and the para-xylene to xylene molar ratio pX/X, with
increasing Bz/X as pX/X increases. Surprisingly, catalysts
comprising UZM-44 suffer significantly less than previously known
catalysts from this problem. Hence, when pX/X is in a range of
about 0.60 to about 1.0, Bz/X may be in a range of about 1.00 to
about 0.375*PXX+0.825, where PXX is the para-xylene to xylene molar
ratio. Without being bound by theory, this equation allows one
skilled in the art to calculate that at a pX/X of 0.60, the Bz/X
may be in the range of about 1.00 to about 1.05. At a pX/X of 0.80,
the Bz/X may be in the range of about 1.00 to about 1.13. At a pX/X
of 0.90, the Bz/X may be in the range of about 1.00 to about
1.16.
[0052] Very high selectivity to xylenes at all pX/X molar ratios
may be achieved utilizing enhanced catalysts made using UZM-44,
even at pX/X molar ratios greater than about 0.8. The selectivity
to xylene may be greater than 52% at a pX/X molar ratio in the
range of about 0.3 to about 0.9 or more, or greater than 53% at a
pX/X molar ratio in the range of about 0.3 to about 0.85 or more,
or greater than 54% at a pX/X molar ratio of about 0.3 to about
0.85 or more, or greater than 55% at a pX/X molar ratio of about
0.3 to about 0.8 or more. In an aspect, all or mixtures of any of
the conditions listed in this paragraph may apply at a pX/X molar
ratio in the range of about 0.6 to about 0.95 or at a pX/X molar
ratio in the range of about 0.8 to about 0.95.
[0053] Very low selectivity to light ends (e.g., C.sub.1-C.sub.6
hydrocarbons) may be achieved utilizing enhanced catalysts made
using UZM-44 at all pX/X molar ratios, even at pX/X molar ratios
greater than about 0.8. The selectivity to light ends may be less
than about 3.5 wt % at a pX/X molar ratio in the range of about 0.3
to about 0.9 or more, or less than about 3 wt % at a pX/X molar
ratio in the range of about 0.3 to about 0.9 or more, or less than
about 2 wt % at a pX/X molar ratio in the range of about 0.3 to
about 0.85 or more, or less than about 1.5 wt % at a pX/X molar
ratio in the range of about 0.3 to about 0.8 or more, or even less
than about 1 wt % at a pX/X molar ratio in the range of about 0.3
to about 0.8 or more. In an aspect, all or mixtures of any of the
conditions listed in this paragraph may apply at a pX/X molar ratio
in the range of about 0.6 to about 0.95 or at a pX/X molar ratio in
the range of about 0.8 to about 0.95.
[0054] Enhanced catalysts of the instant invention may possess low
ring loss. Ring loss may be calculated by subtracting the moles of
single-ring aromatic compounds in the product from the number of
moles of single-ring aromatics in the feed divided by the number of
moles of single-ring aromatics in the feed multiplied by 100.
Hence, ring loss=(Ar.sub.product-Ar.sub.Feed)/(Ar.sub.Feed)*100.
Single-ring aromatics may comprise benzene, toluene, xylenes, 9
carbon aromatic molecules, 10 carbon aromatic molecules, etc.
Single-ring aromatics do not comprise naphthalene. Without being
bound by theory, selectivity to light ends and ring loss may be
proportional due to cracking. That is, catalysts with high
selectivity to light ends may also have high ring loss. Light ends
indicate non-aromatic hydrocarbons possessing 1 to 6 carbon atoms.
In an aspect, methane, ethane, propane, butanes, pentanes, hexanes,
and cyclohexane may comprise light ends. In an aspect, the ring
loss may be less than about 1.5%, or less than about 1.4%, or less
than about 1.3%, or less than about 1.2%, or less than about 1.1%,
or less than about 1.0%, or less than about 0.8%, or less than
about 0.65%, or less than about 0.5%.
[0055] In an aspect, the industry desires retention of methyl
groups during disproportionation. Benzene has zero moles of methyl
groups per mole of benzene, toluene 1 mole methyl groups per mole
toluene, xylenes 2, etc. Methyl to phenyl ratio in a stream may be
calculated by dividing the number of moles of methyl groups in the
stream by the number of moles of single-ring aromatics in the
stream. In an aspect, the methyl to phenyl ratio of the product may
be similar to the methyl to phenyl ratio of the feed. MPP is
calculated by dividing the methyl to phenyl ratio of the product
stream by that of the feedstream. MPP may be greater than about
0.96, or 0.97, or 0.98, or 0.99, and less than 1.0.
[0056] The enhanced UZM-44 zeolite can be used in a toluene
disproportion process, such as the one illustrated in FIG. 1. The
toluene disproportionation process may comprise multiple modules.
In an aspect, a feed stream 100 comprising toluene is combined with
second stream 304 to form a combined feed stream 102 which is
passed to a reaction zone 200. Within the disproportionation
process, the feed stream or combined feed stream may be first
heated by indirect heat exchange against the effluent of the
reaction zone and then further heated in a fired heater. The
resulting vaporous stream may then be passed through a reaction
zone which may comprise one or more individual reactors. The feed
desirably contains less than 10% benzene by mass, less than 10%
xylenes by mass, less than 10% A9 aromatic compounds by mass, and
less than 10% non-aromatic compounds by mass. Benzene, xylenes, A9
aromatic compounds, and non-aromatic compounds may be less than 5%
by mass in combined feed stream 102. Desirably, all of these are
close to 0% by mass.
[0057] The reaction zone 200 may comprise one or more reactors. The
one or more reactors may be fixed bed reactors, wherein a fixed bed
or beds of catalyst comprising UZM-44 are located. The use of a
single reaction vessel having a fixed cylindrical bed of catalyst
is preferred, but other reaction configurations utilizing moving
beds of catalyst or radial-flow reactors may be employed if
desired. Reaction conditions in the reaction zone 200 may comprise
disproportionation reaction conditions as described previously.
[0058] Passage of the combined feed stream 102 through the reaction
zone effects the production of a vaporous effluent 204 comprising
hydrogen, product hydrocarbons, and unconverted feed hydrocarbons.
An effluent 204 from the reaction zone 200 is generated in which
the effluent 204 has a higher concentration of pX than that present
in combined stream 102. In an aspect, the PXX may be higher than
0.6 or higher than 0.7, or higher than 0.8, or higher than 0.85, or
higher than 0.9 Effluent 204 may be passed into a separation zone
300 to separate unreacted toluene from products benzene and
xylenes. This effluent may be normally cooled by indirect heat
exchange against the stream entering the reaction zone and then
further cooled through the use of air or cooling water. The
temperature of the effluent stream may be lowered by heat exchange
sufficiently to effect the condensation of substantially all of the
feed and product hydrocarbons having six or more carbon atoms per
molecule. The resultant mixed-phase stream may be passed into a
vapor-liquid separator wherein the two phases are separated and
from which the hydrogen-rich vapor is recycled in a first recycle
stream to the reaction zone.
[0059] The separation zone 300 may comprise one or more
distillation columns. The condensate from the separator may be
passed into a stripping column in which substantially all C.sub.5
and lighter hydrocarbons present in the effluent are concentrated
into an overhead stream and removed from the process. An
aromatics-rich stream which is referred to as the
disproportionation effluent stream may be recovered as net stripper
bottoms. In an aspect, a benzene column and a toluene column may be
present. The disproportionation effluent stream may be fed to the
benzene column and the toluene column in the separation zone. A
first stream 302 comprising benzene may be separated and utilized
for other reaction operations in an aromatic complex, or may be
routed to a tank for sale. In an aspect, first stream 302 may be an
overhead stream from a benzene column. A second stream 304
comprising toluene may be separated. In an aspect, all or part of
the second stream 304 may be recycled to the reaction zone as part
of the combined feed stream 102. In an aspect, second stream 304
comprises less than 10% benzene by mass, or less than 5% benzene by
mass, or less than 3% benzene by mass, or less than 1% benzene by
mass. In an aspect, second stream 304 is essentially free of
benzene. By "essentially free" we mean less than 0.1 mass %. In an
aspect, second stream 304 comprises less than 10% xylene by mass,
or less than 5% xylene by mass, or less than 3% xylene by mass, or
less than 1% xylene by mass. In an aspect, second stream 304 is
essentially free of xylene. In an aspect, second stream 304 may be
an overhead stream of the toluene column. In an aspect, a bottom
stream from the benzene column may feed the toluene column. A third
stream 306 comprising xylene may be separated.
[0060] Third stream 306 may be utilized as is, depending on the
para-xylene purity desired, or it may be passed to a pX
purification section 400. In an aspect, the separation zone, or pX
purification section, may also comprise a catalytic alkyl-aromatic
zone for ethylbenzene conversion and dealkylation. The purification
section 400 may comprise one or more pX purification devices. Many
pX purification devices are known, and these include, but are not
limited to, crystallization processes and adsorptive separation
processes like the Parex.TM. process available from UOP. In each
case, a purified pX stream 404 comprising up to 100% pX may be
formed. The purification section 400 may also produce a reject
stream 402 comprising meta-xylene (mX) and ortho-xylene (oX).
Reject stream 402 may also comprise ethylbenzene (EB). The reject
stream may be purged from the process. Exemplary uses of the reject
stream may be as a feed to a xylene isomerization process such as
the Isomar.TM. process available from UOP. The xylene isomerization
product may be recycled back to purification section 400.
[0061] By the term "about," we mean within 10% of the value, or
within 5%, or within 1%.
[0062] One aspect of the invention is a toluene disproportionation
process. In one embodiment, the process comprises contacting a feed
comprising toluene with a catalyst comprising a microporous
crystalline zeolite at disproportionation conditions to produce an
effluent stream comprising para-xylene and benzene, wherein a molar
ratio of benzene to xylene in the effluent stream is in a range of
about 1.00 to about 1.14, wherein a molar ratio of para-xylene to
xylene in the effluent stream is in a range of about 0.80 to about
1.0, and wherein a conversion of toluene is about 20% to about
40%.
[0063] In some embodiments, the molar ratio of benzene to xylene is
in the range of about 1.00 to about 1.08.
[0064] In some embodiments, the microporous crystalline zeolite
comprises a three-dimensional framework of at least AlO.sub.2 and
SiO.sub.2 tetrahedral units and an empirical composition in
hydrogen form expressed by an empirical formula of:
M1.sub.a.sup.N+Al.sub.(1-x)E.sub.xSi.sub.y'O.sub.z''
and where M1 is at least one exchangeable cation selected from the
group consisting of alkali, alkaline earth metals, rare earth
metals, zinc, ammonium ion, hydrogen ion and combinations thereof,
"a" is the mole ratio of M1 to (Al+E) and varies from about 0.05 to
about 50, "N" is the weighted average valence of M1 and has a value
of about +1 to about +3, E is an element selected from the group
consisting of gallium, iron, boron, and combinations thereof, "x"
is the mole fraction of E and varies from 0 to about 1.0, y' is the
mole ratio of Si to (Al+E) and varies from greater than about 9 to
virtually pure silica and z'' is the mole ratio of O to (Al+E) and
has a value determined by the equation:
z''=(aN+3+4y')/2
wherein the zeolite is characterized in that it has the x-ray
diffraction pattern having at least the d-spacings and intensities
set forth in Table B:
TABLE-US-00003 TABLE B 2-Theta d( ) /Io % 7.71 11.47 m-s 8.84 10.00
m-s 9.24 9.56 m 11.76 7.52 w-w 12.46 7.10 m 14.38 6.15 vw 14.64
6.05 w 15.26 5.80 w 15.52 5.70 w-m 16.58 5.34 w 17.72 5.00 w-m
18.64 4.76 w 22.56 3.94 w-m 23.06 3.85 vs 23.40 3.80 s 24.12 3.69 m
25.06 3.55 m 26.16 3.40 w-w 26.74 3.33 w-m 28.82 3.10 w-m 30.12
2.96 w 35.86 2.50 w-w 45.32 2.00 w 46.05 1.97 w-w 46.92 1.93 w-w
indicates data missing or illegible when filed
[0065] In some embodiments, the catalyst has been enhanced with at
least one enhancement treatment step.
[0066] In some embodiments, the at least one enhancement treatment
step comprises at least one treatment to incorporate silica.
[0067] In some embodiments, the catalyst is steamed after the at
least one enhancement treatment step.
[0068] In some embodiments, the molar ratio of benzene to xylene is
in the range of about 1.00 to about 1.08 over the molar ratio of
para-xylene to xylene in the range of about 0.80 to about 0.95.
[0069] In some embodiments, the selectivity to xylenes is greater
than 52% when the molar ratio of para-xylene to xylene is in the
range of about 0.80 to about 0.9.
[0070] In some embodiments, the selectivity to light ends is less
than about 3.5% when the molar ratio of para-xylene to xylene is in
the range of about 0.80 to about 0.9. In some embodiments, the
disproportionation conditions include one or more of: a temperature
in a range of about 200.degree. C. to about 600.degree. C.; a
pressure in a range of about 1.4 to about 4.5 MPa(g); a weight
hourly space velocity in a range of about 0.1 to about 10
hr.sup.-1; or a hydrogen to hydrocarbon ratio in a range of about
0.25:1 to about 10:1.
[0071] In some embodiments, ring loss is less than about 1.5%.
[0072] Another aspect of the invention is a toluene
disproportionation process. In one embodiment, the process
comprises contacting a feed comprising toluene with a catalyst
comprising a microporous crystalline zeolite at disproportionation
conditions to produce an effluent stream comprising para-xylene and
benzene, wherein a molar ratio of benzene to xylene in the effluent
stream is in a range of about 1.00 to about 1.20, wherein a molar
ratio of para-xylene to xylene in the effluent stream is in a range
of about 0.60 to about 1.0, the zeolite having a three-dimensional
framework of at least AlO.sub.2 and SiO.sub.2 tetrahedral units and
an empirical composition in hydrogen form expressed by an empirical
formula of
M1.sub.a.sup.N+Al.sub.(1-x)E.sub.xSi.sub.y'O.sub.z''
and where M1 is at least one exchangeable cation selected from the
group consisting of alkali, alkaline earth metals, rare earth
metals, zinc, ammonium ion, hydrogen ion and combinations thereof,
"a" is the mole ratio of M1 to (Al+E) and varies from about 0.05 to
about 50, "N" is the weighted average valence of M1 and has a value
of about +1 to about +3, E is an element selected from the group
consisting of gallium, iron, boron, and combinations thereof, "x"
is the mole fraction of E and varies from 0 to about 1.0, y' is the
mole ratio of Si to (Al+E) and varies from greater than about 9 to
virtually pure silica, and z'' is the mole ratio of O to (Al+E) and
has a value determined by the equation:
z''=(aN+3+4y')/2
wherein the zeolite is characterized in that it has the x-ray
diffraction pattern having at least the d-spacings and intensities
set forth in Table B:
TABLE-US-00004 TABLE B 2-Theta d( ) /Io % 7.71 11.47 m-s 8.84 10.00
m-s 9.24 9.56 m 11.76 7.52 w-w 12.46 7.10 m 14.38 6.15 vw 14.64
6.05 w 15.26 5.80 w 15.52 5.70 w-m 16.58 5.34 w 17.72 5.00 w-m
18.64 4.76 w 22.56 3.94 w-m 23.06 3.85 vs 23.40 3.80 s 24.12 3.69 m
25.06 3.55 m 26.16 3.40 w-w 26.74 3.33 w-m 28.82 3.10 w-m 30.12
2.96 w 35.86 2.50 w-w 45.32 2.00 w 46.05 1.97 w-w 46.92 1.93 w-w
indicates data missing or illegible when filed
[0073] In some embodiments, conversion of toluene is about 20% to
about 40%.
[0074] In some embodiments, the zeolite has been enhanced with at
least one enhancement selected from treatment for deposition of
carbon, treatment for deposition of silica, or both.
[0075] In some embodiments, the catalyst is steamed after the at
least one enhancement treatment step.
[0076] In some embodiments, the molar ratio of benzene to xylene is
in the range of about 1.00 to about 1.08 over the molar ratio of
para-xylene to xylene in the range of about 0.80 to about 0.95.
[0077] In some embodiments, a selectivity to xylenes is greater
than 52% when the molar ratio of para-xylene to xylene is in the
range of about 0.80 to about 0.9.
[0078] In some embodiments, a selectivity to light ends is less
than about 3.5% when the molar ratio of para-xylene to xylene is in
the range of about 0.80 to about 0.9.
[0079] In some embodiments, the disproportionation conditions
include one or more of: a temperature in a range of about
200.degree. C. to about 600.degree. C.; a pressure in a range of
about 1.4 to about 4.5 MPa(g); a weight hourly space velocity in a
range of about 0.1 to about 10 hr.sup.-1; or a hydrogen to
hydrocarbon ratio in a range of about 0.25 to about 10.
[0080] Another aspect of the invention is a toluene
disproportionation process. In one embodiment, the process
comprises contacting a feed comprising toluene with a catalyst
comprising a microporous crystalline zeolite at disproportionation
conditions to produce an effluent stream comprising para-xylene and
benzene, wherein PXX is a molar ratio of para-xylene to xylene in
the effluent stream, wherein BX is a molar ratio of benzene to
xylene in the effluent stream, and wherein when PXX is in a range
of about 0.60 to about 1.0, BX is in a range of about 1.00 to about
0.375*PXX+0.825.
[0081] In certain instances the purity of a synthesized product may
be assessed with reference to its x-ray powder diffraction pattern.
Thus, for example, if a sample is stated to be pure, it is intended
only that the x-ray pattern of the sample is free of lines
attributable to crystalline impurities, not that there are no
amorphous materials present.
[0082] In order to more fully illustrate the invention, the
following examples are set forth. It is to be understood that the
examples are only by way of illustration and are not intended as an
undue limitation on the broad scope of the invention as set forth
in the appended claims.
Examples
[0083] UZM-44 zeolite materials were prepared at approximately 28
SiO.sub.2/Al.sub.2O.sub.3 ratio according to the procedures
described in U.S. Pat. Nos. 8,609,920 and 8,623,321. MFI #1 is a
MFI zeolite of approximately 38 SiO.sub.2/Al.sub.2O.sub.3 ratio
available from UOP. MFI #2 is a MFI zeolite of approximately 23
SiO.sub.2/Al.sub.2O.sub.3 ratio available from Zeolyst.
Standard Catalyst Extrusion
[0084] Zeolites were typically extruded prior to enhancement.
Ion-exchanged zeolite powder was extruded as 1/16'' cylinders or
trilobes with 35 wt % SiO.sub.2, unless otherwise stated, and dried
overnight. The dried extrudate was calcined in air for 2-4 hours at
550.degree. C. In some cases, the extrudate was ion-exchanged at
75.degree. C. for 1 hour using a 10:1:1 weight ratio of water
ammonium nitrate:extrudate. If ion-exchanged, the sample was rinsed
multiple times with deionized H.sub.2O. Ion-exchange was repeated 3
times, and the final dried extrudate was calcined for 4 hours in
air at 450-500.degree. C.
General Enhancement Procedure:
[0085] The sample to be enhanced was placed in a glass round-bottom
flask, and the appropriate amount of organic solvent from Table 1
was added. A Dean-Stark trap and condenser were attached to the
round-bottom flask, filled with additional solvent, and insulated
with tinfoil. The flask was heated with a heating mantle for 1 hour
of reflux, after which the Dean-Stark trap was drained and removed
from the flask. The tetraethylorthosilicate or other silicon
reagent was added to the flask at 14 wt % on a basis of the sample
weight unless otherwise specified. The condenser was reattached,
and the contents of the flask were reacted at reflux for 2 hours.
Solvent was then removed from the sample via decanting,
distillation, or reduced pressure distillation. The sample then
went through a heat treatment step of at least 175.degree. C. to
form the enhanced catalyst. The enhancement treatment was repeated
as many times as needed to achieve the desired pX/X
selectivity.
TABLE-US-00005 TABLE 1 Weight ratio of solvent to base extrudate
for various solvents Solvent Solvent to Base Wt. Ratio Hexane 1.76
Toluene 1.65 Mesitylene (1,3,5 -Trimethylbenzene) 2.45 n-octane
2.53 n-decane 2.91 Cyclohexane 1.76
[0086] Example 1. UZM-44 was used in a standard preparation with 3
treatment cycles using rotary evaporation as the solvent removal
method.
[0087] Example 2. UZM-44 was used in a standard preparation with 6
treatment cycles using rotary evaporation as the solvent removal
method.
[0088] Example 3. UZM-44 was used in a standard preparation with 5
treatment cycles using rotary evaporation as the solvent removal
method.
[0089] Example 4. UZM-44 was used in a standard preparation with 6
treatment cycles at 14% TEOS concentration and a 7.sup.th treatment
cycle at 6% TEOS concentration using rotary evaporation as the
solvent removal method.
[0090] Comparative Examples 5-31. Examples 5-24 are made with MFI
#1. Examples 25-31 are made with MFI #2.
[0091] Comparative Example 5. MFI #1 was used in a preparation with
3 treatment cycles using hexane as the solvent.
[0092] Comparative Example 6. MFI #1 was used in a standard
preparation with 3 treatment cycles.
[0093] Comparative Example 7. MFI #1 was used in a standard
preparation with 3 treatment cycles.
[0094] Comparative Example 8. MFI #1 was used in a standard
preparation with 4 treatment cycles.
[0095] Comparative Example 9. MFI #1 was used in a standard
preparation with 3 treatment cycles.
[0096] Comparative Example 10. MFI #1 was used in a standard
preparation with 4 treatment cycles.
[0097] Comparative Example 11. MFI #1 was used in a standard
preparation with 3 treatment cycles.
[0098] Comparative Example 12. MFI #1 was used in a standard
preparation with 4 treatment cycles.
[0099] Comparative Example 13. MFI #1 was used in a standard
preparation with 3 treatment cycles where the solvent was removed
by distillation.
[0100] Comparative Example 14. MFI #1 was extruded with TiO.sub.2
at 70% zeolite content and treated with 4 standard treatment
cycles.
[0101] Comparative Example 15. MFI #1 was used in a standard
preparation with 3 treatment cycles.
[0102] Comparative Example 16. MFI #1 was used in a standard
preparation with 2 treatment cycles.
[0103] Comparative Example 17. MFI #1 was used in a standard
preparation prior to 3 treatment cycles using 20% TEOS in
hexane.
[0104] Comparative Example 18. MFI #1 was used in a standard
preparation with 3 treatment cycles using hexane as the solvent
followed by a 190.degree. C. heat step.
[0105] Comparative Example 19. MFI #1 was used in a standard
preparation with 3 treatment cycles using hexane as solvent and
distillation as solvent removal method.
[0106] Comparative Example 20. MFI #1 was used in a standard
preparation with 2 treatment cycles using n-octane as solvent and
decanting as solvent removal method.
[0107] Comparative Example 21. MFI #1 was used in a standard
preparation with 3 treatment cycles using n-decane as solvent and
decanting as solvent removal method.
[0108] Comparative Example 22. MFI #1 was used in a standard
preparation with 3 treatment cycles using 10.2% TMOS in
cyclohexane.
[0109] Comparative Example 23. MFI #1 was used in a standard
preparation with 2 treatment cycles using 14% TBOS in toluene using
rotary evaporation as the solvent removal method.
[0110] Comparative Example 24. MFI #1 was used in a standard
preparation with 4 treatment cycles of Dynaslan Silbond, a TEOS
derived product available from Evonik.
[0111] Comparative Example 25. MFI #2 was used in a standard
preparation with 3 treatment cycles.
[0112] Comparative Example 26. MFI #2 was used in a standard
preparation with 3 treatment cycles.
[0113] Comparative Example 27. MFI #2 was made into a spherical
form at 70% zeolite content with ZrO.sub.2 using the methods
described in U.S. Pat. No. 4,629,717. The 70/30 MFI/ZrO.sub.2
spheres were then enhanced with 3 treatment cycles.
[0114] Comparative Example 28. MFI #2 was used in a standard
preparation with 1 treatment cycle using rotary evaporation as the
solvent removal method.
[0115] Comparative Example 29. MFI #2 was used in a standard
preparation with 2 treatment cycles using rotary evaporation as the
solvent removal method.
[0116] Comparative Example 30. MFI #2 was used in a standard
preparation with 3 treatment cycles using rotary evaporation as the
solvent removal method.
[0117] Comparative Example 31. MFI #2 was used in a standard
preparation where 1 cycle of 14% TEOS in mesitylene
(1,3,5-trimethylbenzene) was used as solvent and decanting as
solvent removal method.
Catalyst Testing Procedure:
[0118] The catalysts were tested in a disproportionation reaction
using a feed of nominally 100 wt % toluene. The disproportionation
reaction conditions were a WHSV of 4 hr.sup.-1, a molar ratio of
hydrogen to feed of 2, a pressure of 2.8 MPa(g) (400 psig), and
temperatures from 350.degree. C. to 460.degree. C. The results
achieved are shown in Table 2 and were compared at a target overall
toluene conversion of 30 wt %.
[0119] FIG. 2 shows the results of Table 2 plotted as the benzene
to xylene molar ratio in the product (Bz/X) versus the para-xylene
molar ratio (pX/X) achieved. Catalysts made using MFI #1 are shown
in black circles with dark black trendline, those made using MFI #2
in open circles with a gray trendline, and catalysts of the instant
invention made with UZM-44 in open squares with a dashed trendline.
At all pX/X ratios, enhanced catalysts made using UZM-44 show very
low Bz/X ratios, even at pX/X greater than 0.8. Catalysts made
using MFI zeolite have Bz/X ratios of greater than 1.17 at pX/X
greater than 0.85.
[0120] FIG. 3 shows the results of Table 2 plotted as the xylene
selectivity in the product versus the para-xylene molar ratio
(pX/X) achieved. Catalysts made using MFI #1 are shown in black
circles with dark black trendline, those made using MFI #2 in open
circles with a gray trendline, and catalysts of the instant
invention made with UZM-44 in open squares with a dashed trendline.
At all pX/X ratios, enhanced catalysts made using UZM-44 show very
high selectivity to xylenes, even at pX/X greater than 0.8
Catalysts made using UZM-44 may have selectivity to xylene greater
than 52%, or greater than 53%, or greater than 54% at pX/X greater
than 0.8, or greater than 0.85, or greater than 0.9.
[0121] FIG. 4 shows the results of Table 2 plotted as the
selectivity to light ends (C1-C6 non-aromatic hydrocarbons) in the
product versus the para-xylene molar ratio (pX/X) achieved.
Catalysts made using MFI #1 are shown in black circles with dark
black trendline, those made using MFI #2 in open circles with a
gray trendline, and catalysts of the instant invention made with
UZM-44 in open squares with a dashed trendline. At all pX/X ratios,
enhanced catalysts made using UZM-44 show very low selectivity to
light ends, even at pX/X greater than about 0.8. Catalysts made
using UZM-44 may have selectivity to light ends less than about 3.5
wt %, or less than about 3 wt %, or less than about 2 wt %, or less
than about 1.5 wt %, or even less than about 1 wt % at pX/X of
greater than about 0.8, or greater than about 0.85, or greater than
about 0.9.
[0122] FIG. 5 shows the results of Table 2 plotted as the
temperature required to reach 30% conversion of toluene versus the
para-xylene molar ratio (pX/X) achieved. Catalysts made using MFI
#1 are shown in black circles with dark black trendline, those made
using MFI #2 in open circles with a gray trendline, and catalysts
of the instant invention made with UZM-44 in open squares with a
dashed trendline.
[0123] The enhanced UZM-44 catalyst is completely unique. In
addition to its surprisingly low Bz/X molar ratio, it shows higher
total xylene yield, lower ring loss, lower light ends (e.g.,
C.sub.1-C.sub.6 hydrocarbons), and better methyl/phenyl retention
than any of the other catalysts with similar pX/X molar ratio.
TABLE-US-00006 TABLE 2 Temperature Xylene C1-C6 pX/X at Bz/X at to
reach Selectivity Selectivity Solvent 30% 30% 30% at 30% at 30% Si
# Removal Example Conversion Conversion conversion conversion
Conversion solvent source [Si] Cycles Method 1 0.32 0.98 348 56.3
0.7 toluene TEOS 14 3 rotovap 2 0.82 1.02 384 55.1 1.3 toluene TEOS
14 6 rotovap 3 0.66 0.99 366 56.4 0.7 toluene TEOS 14 5 rotovap 4
0.91 1.08 400 52.2 3.3 toluene TEOS 14 6.5 rotovap 5 0.61 1.14 421
50.0 3.9 hexane TEOS 14 3 6 0.70 1.16 410 50.0 4.3 toluene TEOS 14
3 7 0.84 1.20 409 48.7 5.1 toluene TEOS 14 3 8 0.96 1.39 420 44.7
7.6 toluene TEOS 14 4 9 0.75 1.18 405 49.3 4.4 toluene TEOS 14 3 10
0.96 1.43 416 44.0 7.3 toluene TEOS 14 4 11 0.70 1.16 409 49.5 4.2
toluene TEOS 14 3 12 0.94 1.35 416 45.0 6.6 toluene TEOS 14 4 13
0.57 1.13 416 49.7 4.2 toluene TEOS 14 3 distill 14 0.44 1.04 414
51.7 3.9 toluene TEOS 14 4 distill 15 0.86 1.22 410 47.9 4.9
toluene TEOS 14 3 16 0.32 1.01 406 53.0 2.5 toluene TEOS 14 2 17
0.81 1.22 425 48.3 4.2 hexane TEOS 20 3 18 0.90 1.31 425 45.7 5.5
hexane TEOS 14 3 19 0.42 1.07 451 50.3 4.5 hexane TEOS 14 3 distill
20 0.27 1.04 415 51.5 3.0 n-octane TEOS 14 2 decant 21 0.39 1.09
403 51.0 2.6 n-decane TEOS 14 3 decant 22 0.86 1.32 413 46.0 5.7
cyclohexane TMOS 10 3 23 0.43 1.09 418 50.7 3.9 toluene TBOS 14 2
rotovap 24 0.82 1.34 427 Silbond 4 25 0.56 1.06 381 51.3 toluene
TEOS 14 3 26 0.90 1.20 391 48.1 5.3 toluene TEOS 14 3 27 0.35 1.05
408 52.8 2.2 toluene TEOS 14 3 28 0.25 1.04 375 51.7 2.2 toluene
TEOS 14 1 rotovap 29 0.41 1.04 379 52.4 3.0 toluene TEOS 14 2
rotovap 30 0.88 1.25 393 46.8 5.8 toluene TEOS 14 3 rotovap 31 0.46
1.08 374 51.3 2.8 mesitylene TEOS 14 1 decant
Specific Embodiments
[0124] While the following is described in conjunction with
specific embodiments, it will be understood that this description
is intended to illustrate and not limit the scope of the preceding
description and the appended claims.
[0125] A first embodiment of the invention is a toluene
disproportionation process comprising contacting a feed comprising
toluene with a catalyst comprising a microporous crystalline
zeolite at disproportionation conditions to produce an effluent
stream comprising para-xylene and benzene, wherein a molar ratio of
benzene to xylene in the effluent stream is in a range of about
1.00 to about 1.14, wherein a molar ratio of para-xylene to xylene
in the effluent stream is in a range of about 0.80 to about 1.0,
and wherein a conversion of toluene is about 20% to about 40%. An
embodiment of the invention is one, any or all of prior embodiments
in this paragraph up through the first embodiment in this paragraph
wherein the molar ratio of benzene to xylene is in the range of
about 1.00 to about 1.08. An embodiment of the invention is one,
any or all of prior embodiments in this paragraph up through the
first embodiment in this paragraph wherein the microporous
crystalline zeolite comprises a three-dimensional framework of at
least AlO2 and SiO2 tetrahedral units and an empirical composition
in hydrogen form expressed by an empirical formula of
M1.sub.a.sup.N+Al.sub.(1-x)E.sub.xSi.sub.y'O.sub.z''
and where M1 is at least one exchangeable cation selected from the
group consisting of alkali, alkaline earth metals, rare earth
metals, zinc, ammonium ion, hydrogen ion and combinations thereof,
"a" is the mole ratio of M1 to (Al+E) and varies from about 0.05 to
about 50, "N" is the weighted average valence of M1 and has a value
of about +1 to about +3, E is an element selected from the group
consisting of gallium, iron, boron, and combinations thereof, "x"
is the mole fraction of E and varies from 0 to about 1.0, y' is the
mole ratio of Si to (Al+E) and varies from greater than about 9 to
virtually pure silica and z'' is the mole ratio of 0 to (Al+E) and
has a value determined by the equation
z''=(aN+3+4y')/2
wherein the zeolite is characterized in that it has the x-ray
diffraction pattern having at least the d-spacings and intensities
set forth in Table B:
TABLE-US-00007 TABLE B 2-Theta d( ) I/Io % 7.71 11.47 m-s 8.84
10.00 m-s 9.24 9.56 m 11.76 7.52 vw-w 12.46 7.10 m 14.38 6.15 vw
14.64 6.05 w 15.26 5.80 w 15.52 5.70 w-m 16.58 5.34 w 17.72 5.00
w-m 18.64 4.76 w 22.56 3.94 w-m 23.06 3.85 vs 23.40 3.80 s 24.12
3.69 m 25.06 3.55 m 26.16 3.40 vw-w 26.74 3.33 w-m 28.82 3.10 w-m
30.12 2.96 w 35.86 2.50 vw-w 45.32 2.00 w 46.05 1.97 vw-w 46.92
1.93 vw-w
An embodiment of the invention is one, any or all of prior
embodiments in this paragraph up through the first embodiment in
this paragraph wherein the catalyst has been enhanced with at least
one enhancement treatment step. An embodiment of the invention is
one, any or all of prior embodiments in this paragraph up through
the first embodiment in this paragraph wherein the at least one
enhancement treatment step comprises at least one treatment to
incorporate silica. An embodiment of the invention is one, any or
all of prior embodiments in this paragraph up through the first
embodiment in this paragraph wherein the catalyst is steamed after
the at least one enhancement treatment step. An embodiment of the
invention is one, any or all of prior embodiments in this paragraph
up through the first embodiment in this paragraph wherein the molar
ratio of benzene to xylene is in the range of about 1.00 to about
1.08 over the molar ratio of para-xylene to xylene in the range of
about 0.80 to about 0.95. An embodiment of the invention is one,
any or all of prior embodiments in this paragraph up through the
first embodiment in this paragraph wherein a selectivity to xylenes
is greater than 52% when the molar ratio of para-xylene to xylene
is in the range of about 0.80 to about 0.9. An embodiment of the
invention is one, any or all of prior embodiments in this paragraph
up through the first embodiment in this paragraph wherein a
selectivity to light ends is less than about 3.5% when the molar
ratio of para-xylene to xylene is in the range of about 0.80 to
about 0.9. An embodiment of the invention is one, any or all of
prior embodiments in this paragraph up through the first embodiment
in this paragraph wherein the disproportionation conditions include
one or more of a temperature in a range of about 200.degree. C. to
about 600.degree. C.; a pressure in a range of about 1.4 to about
4.5 MPa(g); a weight hourly space velocity in a range of about 0.1
to about 10 hr.sup.-1; or a hydrogen to hydrocarbon ratio in a
range of about 0.251 to about 101. An embodiment of the invention
is one, any or all of prior embodiments in this paragraph up
through the first embodiment in this paragraph wherein ring loss is
less than about 1.5%.
[0126] A second embodiment of the invention is a toluene
disproportionation process comprising contacting a feed comprising
toluene with a catalyst comprising a microporous crystalline
zeolite at disproportionation conditions to produce an effluent
stream comprising para-xylene and benzene, wherein a molar ratio of
benzene to xylene in the effluent stream is in a range of about
1.00 to about 1.20, wherein a molar ratio of para-xylene to xylene
in the effluent stream is in a range of about 0.60 to about 1.0,
the zeolite having a three-dimensional framework of at least AlO2
and SiO2 tetrahedral units and an empirical composition in hydrogen
form expressed by an empirical formula of
M1.sub.a.sup.N+Al.sub.(1-x)E.sub.xSi.sub.y'O.sub.z''
and where M1 is at least one exchangeable cation selected from the
group consisting of alkali, alkaline earth metals, rare earth
metals, zinc, ammonium ion, hydrogen ion and combinations thereof,
"a" is the mole ratio of M1 to (Al+E) and varies from about 0.05 to
about 50, "N" is the weighted average valence of M1 and has a value
of about +1 to about +3, E is an element selected from the group
consisting of gallium, iron, boron, and combinations thereof, "x"
is the mole fraction of E and varies from 0 to about 1.0, y' is the
mole ratio of Si to (Al+E) and varies from greater than about 9 to
virtually pure silica, and z'' is the mole ratio of 0 to (Al+E) and
has a value determined by the equation
z''=(aN+3+4y')/2
wherein the zeolite is characterized in that it has the x-ray
diffraction pattern having at least the d-spacings and intensities
set forth in Table B:
TABLE-US-00008 TABLE B 2-Theta d( ) I/Io % 7.71 11.47 m-s 8.84
10.00 m-s 9.24 9.56 m 11.76 7.52 vw-w 12.46 7.10 m 14.38 6.15 vw
14.64 6.05 w 15.26 5.80 w 15.52 5.70 w-m 16.58 5.34 w 17.72 5.00
w-m 18.64 4.76 w 22.56 3.94 w-m 23.06 3.85 vs 23.40 3.80 s 24.12
3.69 m 25.06 3.55 m 26.16 3.40 vw-w 26.74 3.33 w-m 28.82 3.10 w-m
30.12 2.96 w 35.86 2.50 vw-w 45.32 2.00 w 46.05 1.97 vw-w 46.92
1.93 vw-w
An embodiment of the invention is one, any or all of prior
embodiments in this paragraph up through the second embodiment in
this paragraph wherein conversion of toluene is about 20% to about
40%. An embodiment of the invention is one, any or all of prior
embodiments in this paragraph up through the second embodiment in
this paragraph wherein the zeolite has been enhanced with at least
one enhancement selected from treatment for deposition of carbon,
treatment for deposition of silica, or both. An embodiment of the
invention is one, any or all of prior embodiments in this paragraph
up through the second embodiment in this paragraph wherein the
catalyst is steamed after the at least one enhancement treatment
step. An embodiment of the invention is one, any or all of prior
embodiments in this paragraph up through the second embodiment in
this paragraph wherein the molar ratio of benzene to xylene is in
the range of about 1.00 to about 1.08 over the molar ratio of
para-xylene to xylene in the range of about 0.80 to about 0.95. An
embodiment of the invention is one, any or all of prior embodiments
in this paragraph up through the second embodiment in this
paragraph wherein a selectivity to xylenes is greater than 52% when
the molar ratio of para-xylene to xylene is in the range of about
0.80 to about 0.9. An embodiment of the invention is one, any or
all of prior embodiments in this paragraph up through the second
embodiment in this paragraph wherein a selectivity to light ends is
less than about 3.5% when the molar ratio of para-xylene to xylene
is in the range of about 0.80 to about 0.9. An embodiment of the
invention is one, any or all of prior embodiments in this paragraph
up through the second embodiment in this paragraph wherein the
disproportionation conditions include one or more of a temperature
in a range of about 200.degree. C. to about 600.degree. C.; a
pressure in a range of about 1.4 to about 4.5 MPa(g); a weight
hourly space velocity in a range of about 0.1 to about 10
hr.sup.-1; or a hydrogen to hydrocarbon ratio in a range of about
0.25 to about 10.
[0127] A third embodiment of the invention is a toluene
disproportionation process comprising contacting a feed comprising
toluene with a catalyst comprising a microporous crystalline
zeolite at disproportionation conditions to produce an effluent
stream comprising para-xylene and benzene, wherein PXX is a molar
ratio of para-xylene to xylene in the effluent stream, wherein BX
is a molar ratio of benzene to xylene in the effluent stream, and
wherein when PXX is in a range of about 0.60 to about 1.0, BX is in
a range of about 1.00 to about 0.375*PXX+0.825.
[0128] Without further elaboration, it is believed that using the
preceding description that one skilled in the art can utilize the
present invention to its fullest extent and easily ascertain the
essential characteristics of this invention, without departing from
the spirit and scope thereof, to make various changes and
modifications of the invention and to adapt it to various usages
and conditions. The preceding preferred specific embodiments are,
therefore, to be construed as merely illustrative, and not limiting
the remainder of the disclosure in any way whatsoever, and that it
is intended to cover various modifications and equivalent
arrangements included within the scope of the appended claims.
[0129] In the foregoing, all temperatures are set forth in degrees
Celsius and, all parts and percentages are by weight, unless
otherwise indicated.
* * * * *
References