Catalyst with an Ion-Modified Binder

Abstract

A solid catalyst, such as a molecular sieve catalyst or solid acid catalyst, is supported by a binder, such as amorphous silica or alumina, wherein the binder is charged with metal ions to form an ion-modified binder. The ion-modified binder is capable of attachment to polar contaminants and inhibit their contact with the catalyst. The catalyst can be a zeolite and can be the catalyst for an alkylation reaction, such as the alkylation of benzene with ethylene.

1 - 22 . (canceled) 
     
     
         23 . A binder for providing mechanical support for a molecular sieve catalyst comprising:
 an ion-modified binder having at least one active metal species;   wherein the ion-modified binder is adapted to attach to polar contaminants and thereby inhibit the contact of polar contaminants with the catalyst component;   wherein metal ions make up 0.1% to 50% by weight of the ion-modified binder; and   wherein the metal ions are chosen from the group consisting of Cu, Zn, Sn, Pb, Bi, Ba, Mn, and combinations thereof.   
     
     
         24 . The binder according to  claim 23 , wherein the binder is composed primarily of amorphous silica or alumina. 
     
     
         25 . The binder according to  claim 23 , wherein the metal ions make up 0.1% to 20% by weight of the ion-modified binder. 
     
     
         26 . The binder according to  claim 23 , wherein the binder comprises silica, alumina, titania, zirconia, zinc oxide, magnesia, boria, silica-alumina, silica-magnesia, chromia-alumina, alumina-boria, silica-zirconia, silica gel, clays, or combinations thereof. 
     
     
         27 . The binder according to  claim 26 , wherein the binder is amorphous silica or alumina. 
     
     
         28 . The binder according to  claim 27 , wherein the binder is gamma-, eta-, or theta-alumina. 
     
     
         29 . A method for forming an ion-modified binder comprising:
 providing a binder;   adding a metal ion precursor to an aqueous solution to form a metal ion solution;   pouring the metal ion solution over the binder;   drying the binder;   calcining the binder.   
     
     
         30 . The method according to  claim 29 , wherein the binder is composed primarily of amorphous silica or alumina. 
     
     
         31 . The binder according to  claim 29 , wherein the metal ions make up 0.1% to 20% by weight of the ion-modified binder. 
     
     
         32 . The binder according to  claim 29 , wherein the binder comprises silica, alumina, titania, zirconia, zinc oxide, magnesia, boria, silica-alumina, silica-magnesia, chromia-alumina, alumina-boria, silica-zirconia, silica gel, clays, or combinations thereof. 
     
     
         33 . The binder according to  claim 32 , wherein the binder is amorphous silica or alumina. 
     
     
         34 . The binder according to  claim 33 , wherein the binder is gamma-, eta-, or theta-alumina.