Catalysis over activated high silica zeolites

Claim 2

A process for converting feedstock aromatic compounds selected from the group consisting of benzene, monocyclic alkyl-substituted benzene of from 7 to 10 carbon atoms and mixtures thereof, alkyl being methyl, ethyl or a combination thereof, to conversion product aromatic compounds which differ from feedstock aromatic compounds, which comprises contacting said feedstock at conversion conditions with a catalyst composition comprising a crystalline zeolite having an initial silica:alumina mole ratio of at least about 100:1 prepared by a method which comprises calcining the zeolite at a temperature of from about 200° C. to about 600° C. for a period of time ranging from about 1 minute to about 48 hours, contacting said calcined zeolite with from about 0.1 to about 1 gram of solid aluminum fluoride per gram of zeolite at a temperature of from about 0° C. to about 650° C., and converting said aluminum fluoride contacted zeolite to hydrogen form.

Claim 3

The process of claim 1 wherein said zeolite has an initial silica:alumina mole ratio greater than about 500:1.

Claim 4

The process of claim 1 wherein said conversion of said aluminum fluoride contacted zeolite to the hydrogen form comprises contact of said zeolite with a hydrogen ion precursor solution followed by calcination.

Claim 5

The process of claim 3 wherein said hydrogen ion precursor solution is an ammonium salt solution.

Claim 6

The process of claim 1 wherein said zeolite has the structure of ZSM-5, ZSM-11, ZSM-5/ZSM-11 intermediate, ZSM-12, ZSM-23, ZSM-35, ZSM-38 or ZSM-48.

Claim 7

The process of claim 5 wherein said zeolite has the structure of ZSM-5 or ZSM-11.

Claim 8

The process of claim 4 wherein said ammonium salt solution is ammonium nitrate.

Claim 9

The process of claim 1 which comprises an additional step of hydrolyzing said zeolite subsequent to said aluminum fluoride contacting step.

Claim 10

The process of claim 6 which comprises an additional step of hydrolyzing said zeolite subsequent to said aluminum fluoride contacting step.

Claim 11

The process of claim 3 which comprises an additional step of steaming said zeolite subsequent to said contact with hydrogen ion precursor solution and prior to said calcination.

Claim 12

The process of claim 1 wherein said aluminum fluoride is provided as a precipitate in solution with said zeolite from the reaction of an aluminum salt and a source of fluoride ions.

Claim 13

The process of claim 1 wherein said catalyst composition is in the form of an extrudate.

Claim 14

The process of claim 1 wherein said conversion conditions include a temperature of from about 200° C. to about 760° C., a pressure of from about atmospheric to about 200 atmospheres, a weight hourly space velocity of from about 0.08 hr -1 to about 2000 hr -1 and a hydrogen/feedstock hydrocarbon compound mole ratio of from 0 to about 100.

Claim 15

A process for converting feedstock aromatic compounds selected from the group consisting of benzene, monocyclic alkyl-substituted benzene of from 7 to 10 carbon atoms and mixtures thereof, alkyl being methyl, ethyl or a combination thereof, to conversion product aromatic compounds which differ from feedstock aromatic compounds which comprises contacting said feedstock at conversion conditions with a catalyst composition comprising a crystalline zeolite having an initial silica:alumina mole ratio of at least about 100:1 and the structure of zeolite ZSM-5 prepared by a method which comprises calcining the zeolite at a temperature of from about 200° C. to about 600° C. for a period of time ranging from about 1 minute to about 48 hours, contacting said calcined zeolite with from about 0.1 to about 1 gram of solid aluminum fluoride per gram of zeolite at a temperature of from about 0° C. to about 650° C., and converting said aluminum fluoride contacted zeolite to hydrogen form.

Claim 16

A process for converting feedstock aromatic compounds selected from the group consisting of benzene, monocyclic alkyl-substituted benzene of from 7 to 10 carbon atoms and mixtures thereof, alkyl being methyl, ethyl or a combination thereof, to conversion product aromatic compounds which differ from feedstock aromatic compounds which comprises contacting said feedstock at conversion conditions with a catalyst composition comprising a crystalline zeolite having an initial silica:alumina mole ratio of at least about 100:1 and the structure of zeolite ZSM-5 prepared by a method which comprises calcining the zeolite at a temperature of from about 200° C. to about 600° C. for a period of time ranging from about 1 minute to about 48 hours, contacting said calcined zeolite with from about 0.1 to about 1 gram of solid aluminum fluoride per gram of zeolite at a temperature of from about 0° C. to about 650° C., and converting said aluminum fluoride contacted zeolite to hydrogen form.

Claim 17

The process of claim 14 wherein said zeolite has an initial silica:alumina mole ratio greater than about 500:1.

Claim 18

The process of claim 14 wherein said catalyst composition comprises said zeolite and alumina.

Claim 19

The process of claim 14 wherein said conversion conditions include a temperature of from about 200° C. to about 760° C., a pressure of from about atmospheric to about 200 atmospheres, a weight hourly space velocity of from about 0.08 hr -1 to about 2000 hr -1 and a hydrogen/feedstock hydrocarbon compound mole ratio of from 0 to about 100.

Claim 20

A process for converting feedstock aromatic compounds selected from the group consisting of benzene, monocyclic alkyl-substituted benzene of from 7 to 10 carbon atoms and mixtures thereof, alkyl being methyl, ethyl or a combination thereof, to conversion product aromatic compounds which differ from feedstock aromatic compounds which comprises contacting said feedstock at conversion conditions with a catalyst composition comprising a crystalline zeolite having an initial silica:alumina mole ratio of at least about 100:1 and the structure of zeolite ZSM-11 prepared by a method which comprises calcining the zeolite at a temperature of from about 200° C. to about 600° C. for a period of time ranging from about 1 minute to about 48 hours, contacting said calcined zeolite with from about 0.1 to about 1 gram of solid aluminum fluoride per gram of zeolite at a temperature of from about 0° C. to about 650° C., and converting said aluminum fluoride contacted zeolite to hydrogen form.

Claim 21

A process for converting feedstock aromatic compounds selected from the group consisting of benzene, monocyclic alkyl-substituted benzene of from 7 to 10 carbon atoms and mixtures thereof, alkyl being methyl, ethyl or a combination thereof, to conversion product aromatic compounds which differ from feedstock aromatic compounds which comprises contacting said feedstock at conversion conditions with a catalyst composition comprising a crystalline zeolite having an initial silica:alumina mole ratio of at least about 100:1 and the structure of zeolite ZSM-11 prepared by a method which comprises calcining the zeolite at a temperature of from about 200° C. to about 600° C. for a period of time ranging from about 1 minute to about 48 hours, contacting said calcined zeolite with from about 0.1 to about 1 gram of solid aluminum fluoride per gram of zeolite at a temperature of from about 0° C. to about 650° C., and converting said aluminum fluoride contacted zeolite to hydrogen form.

Claim 22

The process of claim 18 wherein said zeolite has an initial silica:alumina mole ratio greater than about 500:1.

Claim 23

The process of claim 18 wherein said catalyst composition comprises said zeolite and alumina.

Claim 24

The process of claim 18 wherein said conversion conditions include a temperature of from about 200° C. to about 760° C., a pressure of from about atmospheric to about 200 atmospheres, a weight hourly space velocity of from about 0.08 hr -1 to about 2000 hr -1 and a hydrogen/feedstock hydrocarbon compound mole ratio of from 0 to about 100.

Claim 25

The process of claim 1 wherein said feedstock aromatic compounds comprise benzene and said conversion comprises alkylation of said benzene.

Claim 26

The process of claim 1 wherein said feedstock aromatic compounds comprise toluene and said conversion comprises disproportionation of said toluene.

Claim 27

The process of claim 1 wherein said feedstock aromatic compounds comprise xylene isomers and said conversion comprises isomerization of said xylene isomers.

Claim 28

The process of claim 1 wherein said feedstock aromatic compounds comprise alkyl-substituted benzene compounds of from 7 to 10 carbon atoms wherein alkyl is methyl, ethyl or a combination thereof and said conversion comprises transalkylation of said alkyl-substituted benzene compounds.