Particles Including Zeolite Catalysts And Their Use In Oligomerization Processes

Abstract

Embodiments of an invention disclosed herein relate to particles made from zeolite catalysts and their use in oligomerization processes. In particular, shaped particles (for example, spheroid particles) are made from compositions including the contact product of at least one zeolite catalyst and at least one binder.

1 . A particle for the oligomerization of olefins and made from a composition comprising the contact product of:
 (1) at least one zeolite catalyst; and   (2) at least one binder;   
       wherein the particle is a spheroid particle and has an average particle size of from 0.1 mm to 5.0 mm. 
     
     
         2 . The spheroid particle of  claim 1 , wherein the spheroid particle is shaped not utilizing a sprayed-dried process. 
     
     
         3 . The spheroid particle of  claim 1 , wherein the at least one zeolite catalyst is selected from one or more family members belonging to a TON structure, MFI structure, MFS structure, MWW structure, and mixtures thereof. 
     
     
         4 . The spheroid particle of  claim 1 , wherein the at least one zeolite catalyst is selected from at least one of ZSM-5, ZSM-22, ZSM-57, MCM-22, MCM-48, and mixtures thereof. 
     
     
         5 . The spheroid particle of  claim 1 , wherein the spheroid particle has an average particle size of from 0.1 mm to 4.0 mm. 
     
     
         6 . The spheroid particle of  claim 1 , wherein the spheroid particle has an average particle size of from 0.3 mm to 3.0 mm. 
     
     
         7 . The spheroid particle of  claim 1 , wherein the spheroid particle has an average particle size of from 0.5 mm to 1.5 mm. 
     
     
         8 . The spheroid particle of  claim 1 , wherein the at least one binder is selected from at least one of alumina, silica, an aluminosilicate, clay, and mixtures thereof. 
     
     
         9 . The spheroid particle of  claim 1 , wherein the at least one binder is aluminum oxide (Al 2 O 3 ). 
     
     
         10 . The spheroid particle of  claim 1 , wherein the composition comprises from 25 to 99 wt % of the at least one zeolite catalyst based upon the total weight of the composition. 
     
     
         11 . The spheroid particle of  claim 1 , the composition comprises from 45 to 80 wt % of the at least one zeolite catalyst based upon the total weight of the composition. 
     
     
         12 . The spheroid particle of  claim 1 , wherein the composition comprises from 50 to 75 wt % of the at least one zeolite catalyst based upon the total weight of the composition. 
     
     
         13 . A process for producing the spheroid particle of  claim 1 , the process comprising producing the spheroid particle by the spherical granulation of the composition by a vibrational dropping process. 
     
     
         14 . A process for producing the spheroid particle of  claim 1 , the process comprising producing the spheroid particle by a spheronization process. 
     
     
         15 . A process for the oligomerization of olefins, the process comprising:
 contacting at least one spheroid particle in accordance with  claim 1 , under oligomerization conditions with a feedstock comprising at least one C 3 -C 15  olefin or a mixture thereof to form at least one oligomer product.   
     
     
         16 . The process of  claim 15 , wherein the feedstock comprises at least one C 3 -C 6  olefin, preferably, at least one C 3 -C 5  olefin, or a mixture thereof. 
     
     
         17 . The process of  claim 15 , wherein the mixture comprises one or more of a C 3 -C 6  alkane, an isomeric equivalent of the olefin, or a mixture thereof. 
     
     
         18 . The process of  claim 15 , wherein the process comprises a catalyst life of 10% or greater as compared to an extrudate of the same chemical composition in the shape of a ( 1/16th inch (1.5875 mm) quadrulobe or 1/20th inch (1.2700 mm) quadrulobe); at oligomerization temperatures of from 180° C. to 320° C.; at an olefin constant per pass conversion rate of from 60 to 99 wt % based upon the total weight of olefins; and at a space velocity of from 1 to 20 h −1 . 
     
     
         19 . The process of  claim 15 , wherein the process comprises a catalyst life of 30% or greater as compared to an extrudate of the same chemical composition in the shape of a ( 1/16th inch (1.5875 mm) quadrulobe or 1/20th inch (1.2700 mm) quadrulobe); at oligomerization temperatures of from 180° C. to 320° C.; at an olefin constant per pass conversion rate of from 60 to 99 wt % based upon the total weight of olefins; and at a space velocity of from 1 to 20 h −1 . 
     
     
         20 . The process of  claim 15 , wherein the process comprises a catalyst life of 50% or greater as compared to an extrudate of the same chemical composition in the shape of a ( 1/16th inch (1.5875 mm) quadrulobe or 1/20th inch (1.2700 mm) quadrulobe); at oligomerization temperatures of from 180° C. to 320° C.; at an olefin constant per pass conversion rate of from 60 to 99 wt % based upon the total weight of olefins; and at a space velocity of from 1 to 20 h −1 . 
     
     
         21 . The process of  claim 15 , wherein the process comprises a catalyst life of 75% or greater as compared to an extrudate of the same chemical composition in the shape of a ( 1/16th inch (1.5875 mm) quadrulobe or 1/20th inch (1.2700 mm) quadrulobe); at oligomerization temperatures of from 180° C. to 320° C.; at an olefin constant per pass conversion rate of from 60 to 99 wt % based upon the total weight of olefins; and at a space velocity of from 1 to 20 h −1 . 
     
     
         22 . The process of  claim 15 , wherein the process comprises an olefin selectivity increase of 1 wt % or greater as compared to an extrudate of the same chemical composition in the shape of a ( 1/16th inch (1.5875 mm) quadrulobe or 1/20th inch (1.2700 mm) quadrulobe); at oligomerization temperatures of from 180° C. to 320° C.; at an olefin constant per pass conversion rate of from 60 to 99 wt % based upon the total weight of olefins; and at a space velocity of from 1 to 20 h −1 . 
     
     
         23 . The process of  claim 15 , wherein the process comprises an olefin selectivity increase of 2 wt % or greater as compared to an extrudate of the same chemical composition in the shape of a ( 1/16th inch (1.5875 mm) quadrulobe or 1/20th inch (1.2700 mm) quadrulobe); at oligomerization temperatures of from 180° C. to 320° C.; at an olefin constant per pass conversion rate of from 60 to 99 wt % based upon the total weight of olefins; and at a space velocity of from 1 to 20 h −1 . 
     
     
         24 . The process of  claim 15 , wherein the process comprises an olefin selectivity increase of 3 wt % or greater as compared to an extrudate of the same chemical composition in the shape of a ( 1/16th inch (1.5875 mm) quadrulobe or 1/20th inch (1.2700 mm) quadrulobe); at oligomerization temperatures of from 180° C. to 320° C.; at an olefin constant per pass conversion rate of from 60 to 99 wt % based upon the total weight of olefins; and at a space velocity of from 1 to 20 h −1 . 
     
     
         25 . A composition comprising the spheroid particle of  claim 1  and a feedstock comprising one or more olefins.