Hydroalkylation using a rhenium, nickel, rare earth zeolite

Claim 2

A process for producing monocyclic alkylaromatic hydrocarbons and alkyl-substituted monocyclic alkylaromatic hydrocarbons which comprises contacting a reaction mixture comprising a monocyclic aromatic hydrocarbon or an alkyl-substituted monocyclic aromatic hydrocarbon and hydrogen under hydroalkylation conditions with a catalyst consisting essentially of at least one rhenium compound supported on a calcined, acidic, nickel and rare earth-treated crystalline zeolite selected from the group consisting of type L, type X and type Y zeolites.

Claim 3

A process according to claim 1 wherein the rhenium content of the catalyst is within the range of about 0.01 to about 1 percent by weight of said catalyst.

Claim 4

A process according to claim 1 wherein the rhenium content of the catalyst is within the range of about 0.05 to about 0.25 percent by weight of said catalyst.

Claim 5

A process according to claim 1 wherein the crystalline zeolite is selected from the group consisting of zeolites having a pore diameter within the range of about 7 to about 12 angstroms; wherein the rare earth metal compounds and the nickel compounds are selected from the group consisting of nitrates, bromides, acetates, chlorides, iodides, sulfates and mixtures of any two or more thereof; wherein the rare earth metal is selected from the group consisting of cerium, lanthanum, praseodymium, neodymium, samarium, europium, gadolinium, terbium, dysprosium, holmium, erbium, thulium, ytterbium, lutetium and mixtures of any two or more thereof, and wherein the rhenium compound is selected from the group consisting of perrhenic acid -- HReO 4 , ammonium perrhenate -- NH 4 ReO 4 , potassium hexachlororhenate -- K 2 ReCl 6 , potassium perrhenate -- KReO 4 , rhenium carbonyl -- Re 2 (CO) 10 , rhenium heptoxide -- Re 2 O 7 , rhenium pentachloride -- ReCl 5 , rhenium trichloride -- ReCl 3 , rhenium trioxide -- ReO 3 , sodium perrhenate -- NaReO 4 and mixtures of any two or more thereof.

Claim 6

A process according to claim 1 wherein the crystalline zeolite is the alkali metal form with the alkali metal content of the calcined, acidic, nickel and rare earth metal-treated crystalline zeolite being within the range of about 0.01 to about 2 percent by weight of said zeolite; wherein the rare earth metal content of the calcined acidic, nickel and rare earth metal-treated crystalline zeolite is within the range of about 2 to about 25 percent by weight of said zeolite; and wherein the nickel content of the calcined, acidic, nickel and rare earth metal-treated crystalline zeolite is within the range of about 0.01 to about 15 percent by weight of said zeolite.

Claim 7

A process according to claim 1 wherein the crystalline zeolite is the alkali metal form with the alkali metal content of the calcined, acidic, nickel and rare earth metal-treated crystalline zeolite being within the range of about 0.05 to about 1 percent by weight of said zeolite; wherein the rare earth content of the calcined, acidic, rare earth metal-treated crystalline zeolite is within the range of about 5 to about 20 percent by weight of said zeolite; and wherein the nickel content of the calcined, acidic, nickel and rare earth metal-treated crystalline zeolite is within the range of about 1 to about 8 percent by weight of said zeolite.

Claim 8

A process according to claim 1 wherein the catalyst is treated with hydrogen prior to being contacted with the aromatic hydrocarbon.

Claim 9

A process according to claim 1 wherein the aromatic hydrocarbon is benzene which is contacted with said catalyst at a liquid hourly space velocity within the range of about 1 to about 100, a hydrogen pressure within the range of about 690 to about 13,800 kilopascals, a hydrogen feed rate within the range of about 0.1 to about 10 mols per hour of hydrogen per mole of aromatic hydrocarbon per hour, and a temperature within the range of about 100° to about 250° C.

Claim 10

A process according to claim 1 wherein the aromatic hydrocarbon is benzene which is contacted with said catalyst at a liquid hourly space velocity within the range of about 5 to about 25, a hydrogen pressure within the range of about 1,380 to about 6,900 kilopascals, a hydrogen feed rate within the range of about 0.2 to about 1 mole of hydrogen per mole of aromatic hydrocarbon per hour, and a temperature within the range of about 140° to about 200° C.

Claim 11

A process according to claim 1 wherein the crystalline zeolite is selected from the group consisting of Type X, Type L and Type Y zeolites; and the rhenium compound is rhenium trichloride, the nickel compound is nickel chloride hexahydrate and the rare earth metal compound is a mixture of the chlorides of at least one of lanthanum, cerium, praseodymium, neodymium, samarium and gadolinium.