Use of a co-feed in the coupling of toluene with a carbon source

Abstract

A process for making styrene is disclosed that includes providing toluene, a co-feed, and a C 1 source to a reactor containing a catalyst, reacting toluene with the C 1 source in the presence of the catalyst and the co-feed to form a product stream containing ethylbenzene and styrene. The co-feed can be selected from the group of water, carbon monoxide, hydrogen, and combinations thereof.

1 . A process for making styrene comprising:
 providing toluene, a co-feed, and a C 1  source to a reactor comprising a catalyst; and   reacting toluene with the C 1  source in the presence of the catalyst and the co-feed to form a product stream comprising ethylbenzene and styrene;   wherein the co-feed includes water.   
     
     
         2 . The process of  claim 1 , wherein the C 1  source is selected from the group consisting of methanol, formaldehyde, formalin, trioxane, methylformcel, paraformaldehyde, methylal, dimethyl ether, and combinations thereof. 
     
     
         3 . The process of  claim 1 , wherein the catalyst comprises at least one promoter on a support material. 
     
     
         4 . The process of  claim 3 , wherein the at least one 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 combinations thereof. 
     
     
         5 . The process of  claim 3 , wherein the at least one promoter is selected from the group consisting of Ce, Cu, P, Cs, B, Co, Ga, and combinations thereof. 
     
     
         6 . The process of  claim 3 , wherein the support material comprises a zeolite. 
     
     
         7 . The process of  claim 1 , wherein the catalyst comprises B and Cs supported on a zeolite. 
     
     
         8 . The process of  claim 1 , wherein the co-feed is simultaneously fed to the reactor with the toluene and the C 1  source. 
     
     
         9 . The process of  claim 1 , wherein the co-feed is present in amounts of 0.0001 to 15 wt % of the combined feed of the toluene, co-feed and C 1  source. 
     
     
         10 . The process of  claim 1 , resulting in a toluene conversion from 2 to 50%. 
     
     
         11 . The process of  claim 1 , having a selectivity to styrene from 15 to 80%. 
     
     
         12 . The process of  claim 1 , having a selectivity to ethylbenzene from 15 to 80%. 
     
     
         13 . A method of making styrene, comprising:
 providing a reactor comprising a catalyst;   providing a reactant feed stream comprising toluene and a C 1  source;   providing a co-feed including water; and   reacting the toluene with the C 1  source in the presence of the co-feed and the catalyst to form a product stream comprising ethylbenzene and styrene.   
     
     
         14 . The method of  claim 13 , wherein the co-feed further includes carbon monoxide, hydrogen, or a combination thereof. 
     
     
         15 . The method of  claim 13 , wherein the catalyst comprises at least one promoter supported on a zeolite, wherein the at least one 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 combinations thereof. 
     
     
         16 . The method of  claim 13 , resulting in a toluene conversion of from 2 to 50%. 
     
     
         17 . The method of  claim 13 , having a selectivity to styrene from 15 to 80%. 
     
     
         18 . The method of  claim 13 , having a selectivity to ethylbenzene from 15 to 80%. 
     
     
         19 . A method of producing styrene comprising:
 providing toluene, a co-feed, and a C 1  source to a reactor comprising a catalyst; and   reacting toluene with the C 1  source in the presence of the catalyst and the co-feed to form a product stream comprising ethylbenzene and styrene;   wherein the C 1  source is selected from the group consisting of methanol, formaldehyde, formalin, trioxane, methylformcel, paraformaldehyde, methylal, dimethyl ether, and combinations thereof;   wherein the catalyst comprises boron and cesium supported on an X-type zeolite;   wherein the co-feed includes water;   wherein the reaction gives a toluene conversion of from 2 to 50%, a selectivity to styrene from 15 to 80%, and a selectivity to ethylbenzene from 15 to 80%.   
     
     
         20 . The method of  claim 19 , wherein the catalyst further comprises at least one promoter 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 combinations thereof. 
     
     
         21 . The process of  claim 1 , wherein the co-feed only includes water. 
     
     
         22 . The process of  claim 1 , wherein the co-feed further includes carbon monoxide, hydrogen, or a combination thereof.