Hydrocarbon conversion process employing catalysts containing a molybdenum-exchanged crystalline aluminosilicate zeolite

Claim 2

In a process for dealkylating hydrocarbons, the improvement comprising contacting a hydrocarbon feedstock containing a component selected from the group consisting of toluene and alkylated naphthenes under dealkylating conditions with a catalyst comprising a molybdenum-containing zeolite prepared by calcining a crystalline aluminosilicate having at least some of its ion exchange capacity satisfied with cations containing molybdenum.

Claim 3

In a process for dealkylating hydrocarbons selected from the group consisting of toluene and alkylated naphthenes, the improvement comprising contacting said hydrocarbons under dealkylating conditions with a catalyst comprising a crystalline aluminosilicate zeolite prepared by the method comprising: (1) contacting a crystalline aluminosilicate zeolite having an ordered structure with an aqueous solution containing a precursor of MoO 2 +2 cations, said solution having sufficient of an organic base added thereto to maintain the pH of the solution below 7.0 but higher than that which would substantially affect the crystal structure of the zeolite, said contacting being under conditions sufficient to replace at least some of the cations in the zeolite with molybdenum-containing cations and increase the molybdenum-containing cation content of the zeolite, and (2) subsequently calcining the zeolite containing the molybdenum-containing cations in an oxygen-containing oxidizing atmosphere.

Claim 4

In a process for dealkylating hydrocarbons selected from the group consisting of toluene and alkylated naphthenes, the improvement comprising contacting said hydrocarbons under dealkylating conditions with a catalyst comprising a crystalline aluminosilicate zeolite prepared by the method comprising: (1) contacting a crystalline aluminosilicate zeolite having an ordered structure with an aqueous solution containing a precursor of MoO 2 +2 cations, said solution having sufficient of an organic base added thereto to maintain the pH of the solution below 7.0 but higher than that which would substantially affect the crystal structure of the zeolite, said contacting being under conditions sufficient to replace at least some of the cations in the zeolite with molybdenum-containing cations and increase the molybdenum-containing cation content of the zeolite, and (2) subsequently calcining the zeolite containing the molybdenum-containing cations in an oxygen-containing oxidizing atmosphere.

Claim 5

A process as defined in claim 2 wherein said zeolite contacted in step (1) is selected from the group consisting of Zeolite Y, Zeolite L, Zeolite ZSM-4, Zeolite ZSM-5, Zeolite T, Zeolite Omega, erionite, and faujasite.

Claim 6

A process as defined in claim 2 or 3 wherein said zeolite in step (1) initially contains only metal cations as essentially the only exchangeable cations therein.

Claim 7

A hydrocarbon conversion process for upgrading hydrocarbons comprising contacting a hydrocarbon feedstock at an elevated temperature with a hydrocarbon conversion catalyst comprising a zeolite selected from the group consisting of calcined or sulfided crystalline aluminosilicate zeolites containing molybdenum-containing cations exchanged thereinto, said contacting being under conditions promoting the conversion of an acid catalyzed hydrocarbon conversion reaction.

Claim 8

A hydrocarbon conversion process for upgrading hydrocarbons comprising contacting a hydrocarbon feedstock at an elevated temperature with a hydrocarbon conversion catalyst comprising a zeolite selected from the group consisting of calcined or sulfided crystalline aluminosilicate zeolites containing molybdenum-containing cations exchanged thereinto, said contacting being under conditions promoting the conversion of an acid catalyzed hydrocarbon conversion reaction.

Claim 9

A process as defined in claim 5 wherein said catalyst is further characterized by a Group VIII metal component deposited on the surfaces of said zeolite.

Claim 10

A process as defined in claim 5 wherein said catalyst is further characterized by one or more metal components deposited on the surfaces of said zeolite, said metal components being selected from the group consisting of uranium and Group VIII and Group VIB metals, the sulfides thereof, and the oxides thereof.

Claim 11

A hydrocarbon conversion process for upgrading hydrocarbons comprising contacting a hydrocarbon feedstock at an elevated temperature with a hydrocarbon conversion catalyst in sulfided or calcined form, said catalyst containing a zeolite into which molybdenum-containing cations were introduced by ion exchange and said contacting being under conditions promoting the conversion of an acid catalyzed hydrocarbon conversion reaction.

Claim 12

A hydrocarbon conversion process for upgrading hydrocarbons comprising contacting a hydrocarbon feedstock at an elevated temperature with a hydrocarbon conversion catalyst in sulfided or calcined form, said catalyst containing a zeolite into which molybdenum-containing cations were introduced by ion exchange and said contacting being under conditions promoting the conversion of an acid catalyzed hydrocarbon conversion reaction.

Claim 13

A process as defined in claim 8 wherein said catalyst further comprises a refractory oxide in intimate admixture with said zeolite.

Claim 14

A process as defined in claim 9 wherein said catalyst further comprises one or more hydrogenation components deposited on said intimate admixture, said hydrogenation components being selected from the group consisting of uranium and the Group VIII and Group VIB metals, their oxides, and their sulfides.

Claim 15

A process as defined in claim 8 wherein said catalyst comprises about 2 to 25 weight percent of the zeolite and about 75 to 98 weight percent of a refractory oxide in intimate admixture.

Claim 16

A process as defined in claim 9 or 10 wherein said zeolite is a zeolite Y.

Claim 17

A process as defined in claim 10 wherein said zeolite is a selected from the group consisting of Zeolite L, Zeolite ZSM-4, Zeolite ZSM-5, Zeolite T, Zeolite Omega, erionite, and faujasite.

Claim 18

A process as defined in claim 12 wherein, after said ion exchange, at least 10% of the ion exchange sites of the zeolite were occupied with said molybdenum-containing cations.

Claim 19

A process as defined in claim 10 wherein, after said ion exchange, said zeolite had at least 0.10 equivalent of molybdenum-containing cations per gram atom of aluminum in the electronegative crystal framework of said zeolite.

Claim 20

A process as defined in claim 10 wherein said ion exchange of said zeolite was accomplished with a liquid aqueous solution containing a dissolved molybdenum component containing molybdenyl cation.

Claim 21

A process as defined in claim 8 or 10 wherein said ion exchange was accomplished by contacting a crystalline aluminosilicate zeolite having an ordered crystalline structure with an aqueous solution containing a precursor of MoO 2 +2 ions, said solution having sufficient of an organic base added thereto to maintain the pH of the solution during said contacting below 7.0 but higher than that which would substantially affect the crystalline structure of the zeolite, said contacting being under conditions sufficient to replace at least some of the cations in the zeolite with molybdenum-containing cations and increase the molybdenum-containing cation content of the zeolite.

Claim 22

A process as defined in claim 17 wherein, after said ion exchange, at least 10% of the ion exchange sites were occupied with molybdenum-containing cations.

Claim 23

A process as defined in claim 17 wherein said zeolite is Zeolite Y.

Claim 24

A process as defined in claim 19 wherein, after said ion exchange, at least 10% of the ion exchange capacity is filled with molybdenum-containing cations.

Claim 25

A process as defined in claim 9 wherein said ion exchange was accomplished by contacting a crystalline aluminosilicate zeolite having an ordered crystalline structure with an aqueous solution containing a precursor of MoO 2 +2 ions, said solution having sufficient of an organic base added thereto to maintain the pH of the solution during said contacting below 7.0 but higher than that which would substantially affect the crystalline structure of the zeolite, said contacting being under conditions sufficient to replace at least some of the cations in the zeolite with molybdenum-containing cations and increase the molybdenum-containing cation content of the zeolite.

Claim 26

A process as defined in claim 21 wherein said upgrading involves dealkylation with a calcined catalyst.

Claim 27

A process as defined in claim 22 wherein the hydrocarbon being dealkylated includes a component selected from the group consisting of toluene and alkylated naphthenes.

Claim 28

A process as defined in claim 21 wherein, after said ion exchange, said zeolite had at least 0.10 equivalent of molybdenum-containing cations per gram atom of aluminum in the electronegative crystal framework of said zeolite.

Claim 29

A process as defined in claim 21 wherein said zeolite is Zeolite Y.

Claim 30

A process as defined in claim 3, 10, 21, 23, or 25 wherein sufficient molybdenum-containing cations have been exchanged into said zeolite such that said zeolite has a yellow-green color.

Claim 31

A process as defined in claim 7, 10, 21, or 25 wherein sufficient molybdenum-containing cations have been exchanged into said zeolite such that said zeolite contains at least 5 percent by weight molybdenum, calculated as Mo.

Claim 32

A process as defined in claim 8, 10, 21, or 25 wherein sufficient molybdenum-containing cations have been exchanged into said zeolite such that said zeolite contains about 5 percent by weight molybdenum, calculated as Mo.

Claim 33

A process as defined in claim 5, 7, 8, 9, 10, 11, 21, 23, or 25 wherein, after said ion exchange, at least 10 percent of the ion exchange sites are occupied with molybdenum-containing cations.

Claim 34

A process as defined in claim 1 wherein at least 10 percent of said ion exchange capacity is occupied with cations containing molybdenum.

Claim 35

A process as defined in claim 30 wherein said zeolite is zeolite Y.

Claim 36

A process as defined in claim 2 or 3 wherein in step (1) the conditions are such that at least 10 percent of the cations in the zeolite are replaced with molybdenum-containing cations.

Claim 37

A process as defined in claim 27 wherein said molybdenum-containing cations comprise molybdenyl cations.

Claim 38

A process as defined in claim 29 wherein said molybdenum-containing cations comprise molybdenyl cations.

Claim 39

A process as defined in claim 30 or 31 wherein said cations containing molybdenum comprise molybdenyl cations.

Claim 40

A process as defined in claim 32 wherein at least some of the cations in the zeolite are replaced with molybdenyl cations.