Catalyst Composition

Abstract

The present invention provides an improved catalyst and a method for its manufacture. The catalyst comprises an acidic, porous crystalline material and has a Proton Density Index of greater than about 1.0, for example from greater than 1.0 to about 2.0, e.g. from about 1.01 to about 1.85. This catalyst may be used to effect conversion in chemical reactions, and is particularly useful in a process for selectively producing a monoalkylated aromatic compound comprising the step of contacting an alkylatable aromatic compound with an alkylating agent under at least partial liquid phase conditions. The acidic, porous crystalline material of the catalyst may comprise an acidic, crystalline molecular sieve having the structure of zeolite Beta, an MWW structure type material, e.g. MCM-22, MCM-36, MCM-49 MCM-56, or a mixture thereof.

1 . A method for producing a catalyst composition, said method comprising the steps of:
 (a) providing a first catalyst comprising an acidic, porous crystalline material, said first catalyst having a first proton density;   (b) contacting said first catalyst of step (a) with water in liquid or gaseous form at a contact temperature up to about 500° C., to add protons and generate a second catalyst having a second proton density, wherein the value of said second proton density is greater than said value of said first proton density when said values are measured under the same conditions; and   (c) drying said second catalyst of step (b) at a drying temperature of up to about 550° C., to remove at least a portion of said protons from said second catalyst and generate said catalyst composition having a third proton density, wherein the value of said third proton density is between said value of said first proton density and said value of said second proton density when said values are measured under the same conditions.   
     
     
         2 . The method of  claim 1 , wherein the catalytic activity of said third catalyst is greater than the catalytic activity of said second catalyst. 
     
     
         3 . The method of  claim 1 , wherein the acidic, porous crystalline material is selected from the group consisting of MWW structure type material, zeolite Beta and mixtures thereof. 
     
     
         4 . The method of  claim 3 , wherein said MWW structure type material is selected from the group consisting of MCM-22, PSH-3, SSZ-25, ERB-1, ITQ-1, ITQ-2, ITQ-30, MCM-36, MCM-49, MCM-56 and mixtures thereof. 
     
     
         5 . The method of  claim 1 , wherein the first catalyst further comprises a binder, said binder comprises an inorganic material selected from the group consisting of clay, silica, alumina, metal oxide and mixtures thereof. 
     
     
         6 . The method of  claim 1 , wherein step (b) is conducted at a contact temperature of from about 1° C. to about 99° C. for from about 1 minute to about 60 minutes 
     
     
         7 . The method of  claim 1 , wherein step (c) is conducted at a drying temperature of from about 100° C. to about 200° C. for from about 0.01 to about 24 hours. 
     
     
         8 . The method of  claim 1 , wherein said catalyst composition resulting from step (c) has a Proton Density Index of from greater than 1.0 to less than 2.0. 
     
     
         9 . The method of  claim 8 , wherein said catalyst composition resulting from step (c) has a Proton Density Index of from about 1.01 to about 1.85. 
     
     
         10 . The method of  claim 1 , wherein said third proton density is greater than 2.24 mmol protons per gram. 
     
     
         11 . The method of  claim 1 , wherein said acidic, porous crystalline material has an average particle size of from about 0.05 to about 200 microns. 
     
     
         12 . A catalyst composition comprising an acidic, porous crystalline material having a structure selected from the group consisting of MCM-22, MCM-36 and MCM-56, wherein said acidic, porous crystalline material having a proton density of greater than 2.24 mmol protons per gram. 
     
     
         13 . The catalyst composition of  claim 12  having a Proton Density Index of from greater than 1.0 to about 2.0. 
     
     
         14 . A catalyst composition comprising an acidic, porous crystalline material having the structure of MCM-49, said acidic, porous crystalline material having a proton density of greater than 2.14 mmol protons per gram. 
     
     
         15 . The catalyst composition of  claim 14  having a Proton Density Index of from greater than 1.0 to about 2.0. 
     
     
         16 . A catalyst composition comprising an acidic, porous crystalline material having the structure of zeolite Beta, said acidic, porous crystalline material having a proton density of greater than 3.10 mmol protons per gram. 
     
     
         17 . The catalyst composition of  claim 16  having a Proton Density Index of from greater than 1.0 to about 2.0.