Supported nano sized zeolite catalyst for alkylation reactions

Abstract

A catalyst containing nanosize zeolite particles supported on a support material for alkylation reactions, such as the alkylation of benzene to form ethylbenzene, and processes using such a catalyst is disclosed.

What is claimed is: 
     
         1 . An alkylation catalyst comprising:
 nanosize zeolite particles; and   a support material.   
     
     
         2 . The alkylation catalyst of  claim 1 , wherein the nanosize zeolite particles have a particle size of less than about 1000 nm. 
     
     
         3 . The alkylation catalyst of  claim 1 , wherein the nanosize zeolite particles have a particle size of less than about 300 nm. 
     
     
         4 . The alkylation catalyst of  claim 1 , wherein the nanosize zeolite particles are formed from a zeolite selected from the group consisting of FAU type zeolite, BEA type zeolite, MFI type zeolite, MTW, FAU, MWW, and other 10 membered and 12 membered ring zeolites, and combinations thereof. 
     
     
         5 . The alkylation catalyst further comprising a promoter selected from the group consisting of Co, Mn, Ti, Zr, Nb, K, Cs, Ga, P, B, Rb, Ge, Cu, Mg, Ce, Li, Ag, and Na and combinations thereof. 
     
     
         6 . The alkylation catalyst of  claim 1 , wherein the support material is selected from the group consisting of silica, silicon carbide, alumina, aluminosilica, titania, and zirconia and combinations thereof. 
     
     
         7 . The alkylation catalyst of  claim 1 , wherein the support material comprises inert alumina that increases the catalyst strength, wherein the alumina is of one or more of alpha, beta, delta, or theta phase. 
     
     
         8 . The alkylation catalyst of  claim 1 , wherein the support material comprises high surface area silicon carbide or similar support material with high heat capacity and transfer properties is used, and wherein the heat from the exothermic alkylation reaction can be managed more effectively at the active sites of the catalyst 
     
     
         9 . The alkylation catalyst of  claim 1 , wherein the catalyst is produced by a method comprising:
 providing nanosize zeolite particles;   contacting the nanosize zeolite particles with a silane resulting in a modified nanosize zeolite;   grafting the modified nanosize zeolite onto a support; and   calcining the modified nanosize zeolite grafted onto the support, resulting in a catalyst comprising nanosize zeolite particles.   
     
     
         10 . The alkylation catalyst of  claim 1 , wherein the catalyst is produced by physically combining nanosize zeolite particles with a support to form extrudates. 
     
     
         11 . The alkylation catalyst of  claim 1 , wherein the catalyst is produced by simultaneously creating and supporting nanosize zeolite particles in situ with the support material. 
     
     
         12 . The alkylation catalyst of  claim 1 , wherein the catalyst further comprises silicon carbide. 
     
     
         13 . The alkylation catalyst of  claim 1 , wherein the catalyst further comprises alumina silicates. 
     
     
         14 . The alkylation catalyst of  claim 1 , wherein the nanosize zeolite particles are grown within the support material. 
     
     
         15 . The alkylation catalyst of  claim 1 , wherein at least a portion of the catalyst is hydrophilic. 
     
     
         16 . A process for making ethylbenzene comprising:
 providing a C 2  source to a reactor comprising a catalyst; and   reacting benzene with the C 2  source in the presence of the catalyst to form a product stream comprising ethylbenzene;   wherein the catalyst comprises nanosize zeolite particles.   
     
     
         17 . The process of  claim 16 , wherein the C 2  source is selected from the group consisting of ethanol, ethylene, and combinations thereof. 
     
     
         18 . The process of  claim 16 , wherein the nanosize zeolite particles have a particle size of less than about 1000 nm. 
     
     
         19 . The process of  claim 16 , wherein the nanosize zeolite particles have a particle size of less than about 300 nm. 
     
     
         20 . The process of  claim 16 , wherein the nanosize zeolite particles are formed from a zeolite selected from the group consisting of FAU type zeolite, BEA type zeolite, MFI type zeolite, MTW, FAU, MWW, and other 10 membered and 12 membered ring zeolites, and combinations thereof. 
     
     
         21 . The process of  claim 16 , wherein the alkylation catalyst further comprises a promoter selected from the group consisting of Co, Mn, Ti, Zr, Nb, K, Cs, Ga, P, B, Rb, Ge, Cu, Mg, Ce, Li, Ag, and Na and combinations thereof. 
     
     
         22 . The process of  claim 16 , wherein the support material is selected from the group consisting of silica, silicon carbide, alumina, aluminosilica, titania, and zirconia and combinations thereof. 
     
     
         23 . The process of  claim 16 , wherein the support material comprises inert alumina that increases the catalyst strength, wherein the alumina is of one or more of alpha, beta, delta, or theta phase. 
     
     
         24 . The process of  claim 16 , wherein the support material comprises high surface area silicon carbide or similar support material with high heat capacity and transfer properties is used, and wherein the heat from the exothermic alkylation reaction can be managed more effectively at the active sites of the catalyst. 
     
     
         25 . The process of  claim 16 , wherein the process achieves an overall benzene conversion of at least 0.01 mol. %, or from 0.1 mol. % to 80 mol. %, or from 10 mol. % to 60 mol. % or from 15 mol. % to 40 mol. %. 
     
     
         26 . The process of  claim 16 , wherein the process achieves a selectivity to ethylbenzene of at least 5 mol. %, or from 5 mol. % to 99.9 mol. %, or at least 50 mol. % or at least 75 mol. %, for example.