Nitrogen Containing Catalyst for Coupling Reactions

Abstract

A process for making styrene including providing a C 1 source to a reactor containing a catalyst and reacting toluene with the C 1 source in the presence of the catalyst to form a product stream comprising ethylbenzene and styrene. The C 1 source can be selected from the group of methanol, formaldehyde, formalin, trioxane, methylformcel, paraformaldehyde, methylal, dimethyl ether, and combinations thereof, and wherein the catalyst contains a nitrogen-substituted zeolite.

1 . A method of preparing a catalyst, comprising:
 providing a substrate;   providing a first solution comprising a nitrogen containing material;   contacting the substrate with the first solution; and   obtaining a catalyst comprising nitrogen.   
     
     
         2 . The method of  claim 1 , wherein the contacting of the substrate with the nitrogen containing material subjects the substrate to the substitution of oxygen with nitrogen. 
     
     
         3 . The method of  claim 1 , wherein the substrate is a zeolite. 
     
     
         4 . The method of  claim 1 , wherein the substrate is a zeolite selected from the group consisting of faujasites. 
     
     
         5 . The method of  claim 1 , wherein the nitrogen containing material is selected from the group consisting of ammonia, an alkyl amine, and any combinations thereof. 
     
     
         6 . The method of  claim 1 , wherein the nitrogen containing material is selected from the group consisting of ammonia, methyl amine, ethyl amine, and any combinations thereof. 
     
     
         7 . The method of  claim 1 , further comprising contacting the catalyst comprising nitrogen with a second solution comprising a promoter to obtain a promoted catalyst comprising nitrogen. 
     
     
         8 . The method of  claim 7 , wherein the promoter is selected from the group consisting of Co, Mn, Ti, Zr, V, Nb, K, Cs, Ga, B, P, Rb, Ag, Na, Cu, Mg, Fe, Mo, Ce, and any combinations thereof. 
     
     
         9 . The method of  claim 7 , wherein the catalyst comprises one or more of the promoters in an amount ranging from 0.1 wt % to 5 wt % based on the total weight of the catalyst. 
     
     
         10 . The method of  claim 1 , wherein the catalyst is capable of effecting a reaction of at least a portion of a C 1  source with toluene to form a product stream comprising one or more of styrene or ethylbenzene. 
     
     
         11 . The method of  claim 10 , wherein a promoter source is combined with the C 1  source prior to contact with the catalyst. 
     
     
         12 . The method of  claim 1 , wherein a promoter source is combined with the substrate prior to contacting the substrate with the first solution. 
     
     
         13 . The method of  claim 1 , wherein a promoter source is combined with a substrate material that is subsequently combined with the catalyst comprising nitrogen to form a supported catalyst comprising promoter and nitrogen. 
     
     
         14 . A catalyst comprising:
 a nitrogen-substituted zeolite support; and   a promoter;   wherein the promoter is supported onto the zeolite support by ion exchange.   
     
     
         15 . The catalyst of  claim 14 , wherein the zeolite support is selected from the group consisting of faujasites. 
     
     
         16 . The catalyst of  claim 14 , wherein the promoter is selected from the group consisting of Co, Mn, Ti, Zr, V, Nb, K, Cs, Ga, B, P, Rb, Ag, Na, Cu, Mg, Fe, Mo, Ce, and any combinations thereof. 
     
     
         17 . The catalyst of  claim 14 , wherein the catalyst comprises the promoter in an amount ranging from 0.1 wt % to 5 wt % based on the total weight of the catalyst. 
     
     
         18 . The catalyst of  claim 14 , wherein the ion exchange is performed in an aqueous medium utilizing water soluble promoter precursors. 
     
     
         19 . The catalyst of  claim 14 , wherein a nitrogen source is combined with a substrate material that is subsequently combined with the nitrogen-substituted zeolite support comprising at least one promoter to form a supported catalyst comprising nitrogen and at least one promoter. 
     
     
         20 . The catalyst of  claim 14 , wherein the catalyst is capable of effecting a reaction of at least a portion of a C 1  source with toluene to form a product stream comprising one or more of styrene or ethylbenzene, wherein the catalyst is capable of effecting selectivity to styrene of greater than 30 mol %. 
     
     
         21 . (canceled)