Bound phosphorus-modified zeolite catalyst, method of preparing and method of using thereof

Abstract

Disclosed is a bound phosphorus-modified zeolite catalyst. Zeolite is treated with a phosphorus compound to form the phosphorus-treated zeolite. Binder material is treated with a mineral acid prior to being bound with the phosphorus-modified zeolite. The binder material includes inorganic oxide materials, such as alumina, clay, aluminum phosphate and silica-alumina, in particular, a binder of alumina or clay or their combinations. The mineral acid includes hydrochloric acid, nitric acid, phosphoric acid or sulfuric acid. The phosphorus-treated zeolite is combined with the acid-treated inorganic oxide binder material to form a zeolite-binder mixture. Water is added to form an extrudable paste which maybe shaped and is heated to a temperature of about 400° C. or higher to form a bound phosphorus-modified zeolite catalyst. For aromatic alkylation, the bound phosphorus-modified zeolite catalyst is contacted with an aromatic alkylation feed of an aromatic compound and an alkylating agent under reaction conditions suitable for aromatic alkylation.

1 - 43 . (canceled) 
   
   
       44 . A method of preparing an alkyl aromatic product comprising:
 a) treating a zeolite containing 10-oxygen ring pores with a phosphorus compound to form a phosphorus-treated zeolite;   b) treating an inorganic oxide binder material with a mineral acid;   c) combining the phosphorus-treated zeolite with an inorganic oxide binder material to form a zeolite-binder mixture;   d) heating the zeolite-binder mixture at temperature of about 400° C. or higher to form a bound zeolite catalyst; and   e) contacting the bound zeolite catalyst with an aromatic alkylation feed of an aromatic compound and an alkylating agent under reaction conditions suitable for aromatic alkylation.   
   
   
       45 . The method of  claim 44  wherein the binder material includes at least one of alumina, clay, aluminum phosphate and silica-alumina. 
   
   
       46 . The method of  claim 44  wherein the binder material is an alumina-containing material. 
   
   
       47 . The method of  claim 44  wherein the binder material is present in an amount of from about 1% to about 99% by weight of the bound zeolite catalyst. 
   
   
       48 . The method of  claim 44  wherein the binder material contains from about 1% to 99% by weight alumina or clay or their combinations. 
   
   
       49 . The method of  claim 44  wherein the zeolite is a ZSM-5 zeolite. 
   
   
       50 . The method of  claim 44  wherein the phosphorus-treated zeolite is heated to a temperature of about 300° C. or higher. 
   
   
       51 . The method of  claim 44  wherein the zeolite-binder mixture is heated to a temperature of from 400° C. to about 700° C. 
   
   
       52 . The method of  claim 44  further comprising adding water to the zeolite-binder mixture and shaping the zeolite-binder mixture 
   
   
       53 . The method of  claim 44  wherein the aromatic compound is toluene. 
   
   
       54 . The method of  claim 44  wherein the aromatic compound is toluene and the alkylating agent is methanol. 
   
   
       55 . The method of  claim 44  further comprising steaming the bound zeolite at a temperature of 300° C. or less prior to contacting with the aromatic alkylation feed. 
   
   
       56 . The method of  claim 44  wherein the zeolite is treated with a phosphorus compound to form a phosphorus-treated zeolite having a phosphorus content of from 0.01 to about 0.15 gram of phosphorus per gram of zeolite. 
   
   
       57 . The method of  claim 56  wherein the zeolite is a ZSM-5 zeolite. 
   
   
       58 . The method of  claim 57  wherein the binder material includes at least one of alumina, clay, aluminum phosphate and silica-alumina. 
   
   
       59 . The method of  claim 57  wherein the binder material is an alumina-containing material. 
   
   
       60 . The method of  claim 57  wherein the binder material is present in an amount of from about 1% to about 99% by weight of the bound ZSM-5 zeolite catalyst. 
   
   
       61 . The method of  claim 57  wherein the binder material contains from about 1% to 99% by weight alumina. 
   
   
       62 . The method of  claim 57  wherein the phosphorus-treated ZSM-5 zeolite is heated to a temperature of about 300° C. or higher. 
   
   
       63 . The method of  claim 56  wherein the zeolite-binder mixture is heated to a temperature of from 400° C. to about 700° C. 
   
   
       64 . The method of  claim 54  further comprising steaming the bound ZSM-5 zeolite at a temperature of 300° C. or less prior to contacting with the feed of toluene. 
   
   
       65 . The method of  claim 44  wherein the mineral acid is hydrochloric acid, nitric acid, phosphoric acid or sulfuric acid 
   
   
       66 . The method of  claim 65  wherein the mineral acid is nitric acid.