Supported Nano Sized Zeolite Catalyst for Alkylation Reactions

Abstract

A catalyst containing nanosize zeolite particles supported on a support material for alkylation reactions, such as the alkylation of benzene to form ethylbenzene, and processes using such a catalyst is disclosed.

1 - 26 . (canceled) 
     
     
         27 . A method for making a catalyst via incipient wetness impregnation comprising:
 dispersing nanosize zeolite particles in a diluent to form a solution;   adding a support material to the solution; and   mixing the solution containing the nanosize zeolite particles and the support material until dry, wherein the nanosize zeolite particles form conglomerations bound inside pores of the support material.   
     
     
         28 . The method of  claim 27 , wherein the dispersing comprises sonication. 
     
     
         29 . The method of  claim 27 , wherein the diluent is methanol or toluene. 
     
     
         30 . The method of  claim 27 , wherein the catalyst comprises less than 15 weight percent sodium based on a total weight of the catalyst. 
     
     
         31 . The method of  claim 27 , wherein the catalyst comprises less than 25 weight percent aluminum based on a total weight of the catalyst. 
     
     
         32 . The method of  claim 27 , wherein the catalyst comprises less than 30 weight percent silicon based on a total weight of the catalyst. 
     
     
         33 . The method of  claim 27 , wherein the catalyst comprises at least 5 weight percent alumina based on a total weight of the catalyst. 
     
     
         34 . The method of  claim 27 , wherein the support material is selected from the group consisting of silica, silicon carbide, alumina, aluminosilica, titania, zirconia and combinations thereof. 
     
     
         35 . The method of  claim 27 , wherein the nanosize zeolite particles are formed from a zeolite selected from the group consisting of FAU, BEA, MFI, MTW, FAU, MWW, and combinations thereof. 
     
     
         36 . The method of  claim 27 , wherein the nanosize zeolite particles have a particle size of less than 1000 nm. 
     
     
         37 . The method of  claim 27 , wherein the nanosize zeolite particles have a Si/Al ratio of 1.0 to 300. 
     
     
         38 . The method of  claim 27 , wherein the catalyst comprises form 1 to 99 weight percent of the nanosize zeolite particles. 
     
     
         39 . The method of  claim 27 , wherein the catalyst comprises from 5 to 20 weight percent of the support material.