Hydrocarbon Conversion Process Using Improved MCM-56 Manufacture

摘要

The present invention provides a process for converting a feedstock comprising hydrocarbon compounds using a catalyst made by an improved method for manufacturing high quality porous crystalline MCM-56 material. One such conversion process involves production of monoalkylated aromatic compounds, particularly ethylbenzene and cumene, by the liquid or partial liquid phase alkylation of alkylatable aromatic compound, particularly benzene.

主权项

1. A process for converting feedstock comprising hydrocarbon compounds to conversion product which comprises contacting said feedstock at hydrocarbon compound conversion conditions with a catalyst composition comprising a synthetic porous crystalline MCM-56 material made by the method comprising the steps of:
a) preparing a first reaction mixture containing sources of alkali or alkaline earth metal (M) cation, an oxide of a trivalent element X, an oxide of a tetravalent element Y, zeolite seed crystals, and water, said first reaction mixture having a composition in terms of mole ratios of oxides within the following ranges:
YO2/X2O3=5 to 35;H2O/YO2=10 to 70;OH—/YO2=0.05 to 0.20;M/YO2=0.05 to 3.0;said first reaction mixture further comprising zeolite seed crystals in an amount from greater than or equal to 0.05 wt. % to less than or equal to 5 wt. %, based on the weight of said first reaction mixture;
b) adding directing agent R to the reaction mixture of step a) to form a second reaction mixture, having said directing agent R in terms of a mole ratio within the following range: R/YO2=0.08 to 0.3; and c) crystallizing said second reaction mixture of step b) under conditions of temperature of from about 90° C. to about 175° C. and a time for less than 90 hours to form a resulting mixture comprising crystals of said MCM-56 material and less than 10 wt. % non-MCM-56 impurity crystals based on the total weight of said MCM-56 crystals in said second reaction mixture, as identified by X-ray diffraction,wherein said crystals of said MCM-56 material have an X-ray diffraction pattern as shown in Table 1:TABLE 1Interplanar d-SpacingRelative (Angstroms)Intensity12.4 ± 0.2 vs9.9 ± 0.3m6.9 ± 0.1w6.4 ± 0.3w6.2 ± 0.1w3.57 ± 0.07m-s3.44 ± 0.07vs