US4595670A — Zeolite catalyst

Claim 1

Independent Claim 88 words

A catalyst comprising a type L zeolite containing at least one Group VIII noble metal from the Periodic Table of Elements, characterized in that the particles of the noble metal are well dispersed over the surface of the catalyst, and at least about 90% of the noble metal, prior to reduction and after calcination thereof, is dispersed in the form of particles having a diameter of less than about 7 Å as measured by bright field imaging on a scanning transmission electron microscope with 4 Å point-to-point resolution.

Claim 2

Dependent Claim 88 words

A catalyst comprising a type L zeolite containing at least one Group VIII noble metal from the Periodic Table of Elements, characterized in that the particles of the noble metal are well dispersed over the surface of the catalyst, and at least about 90% of the noble metal, prior to reduction and after calcination thereof, is dispersed in the form of particles having a diameter of less than about 7 Å as measured by bright field imaging on a scanning transmission electron microscope with 4 Å point-to-point resolution.

Claim 3

Dependent Claim 70 words

The catalyst of claim 1 wherein at least 90% of the at least one noble metal is inside the channels of the catalyst and at least 90% of the at least one noble metal inside the channels is dispersed in the form of particles having a diameter of less than about 7 Å as measured by bright field imaging on scanning transmission electron microscope with a 4 Å point-to-point resolution.

Claim 4

Dependent Claim 54 words

The catalyst of claim 1 wherein more than about 98% of the at least one noble metal, before or after reduction thereof, is dispersed in the form of particles having a diameter less than about 7 Å as measured by bright field imaging on a scanning transmission electron microscope with 4 Å point-to-point resolution.

Claim 5

Dependent Claim 70 words

The catalyst of claim 1 wherein greater than 90% of the at least one noble metal is inside the channels of the catalyst and at least 98% of the at lease one noble metal inside the channels is dispersed in the form of particles having a diameter of less than about 7 Å as measured by bright field imaging on a scanning transmission electron microscope with 4 Å point-to-point resolution.

Claim 6

Dependent Claim 33 words

The catalyst of claim 1 wherein the zeolite contains exchangeable cations of which at least 75 percent are selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, calcium, and barium cations.

Claim 7

Dependent Claim 39 words

The catalyst of claim 5 having a catalyst activity maintenance which provides a benzene yield greater than 7 weight percent after 24 hours using a feed of 20% by volume methylcyclopentane and 80% by volume n-hexane under ECAT conditions.

Claim 8

Dependent Claim 11 words

The catalyst of claim 5 wherein the exchangeable cation is potassium.

Claim 9

Dependent Claim 11 words

The catalyst of claim 7 wherein the noble metal is platinum.

Claim 10

Dependent Claim 45 words

The catalyst of claim 6 wherein the average size of the crystals of the zeolite is no greater than about 0.2 micron and the at least one noble metal is present in an amount of from about 1.0 to 6% by weight of the catalyst.

Claim 11

Dependent Claim 44 words

The catalyst of claim 6 wherein the average size of the crystals of the zeolite is greater than about 0.2 microns and the at least one noble metal is present in an amount of from about 0.1 to 2.0% by weight of the catalyst.

Claim 12

Dependent Claim 24 words

The catalyst of claim 5 wherein the pH of the zeolite when measured in water before noble metal loading is between 9 and 11.5.

Claim 13

Dependent Claim 123 words

A catalyst comprising a type-L zeolite containing exchangeable cations of which at least 75 percent are selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, calcium, and barium cations and containing at least one Group VIII noble metal from the Periodic Table of Elements, characterized in that at least about 90% of the at least one noble metal is inside the channels of the zeolite and at least about 90% of the at least one noble metal inside the channels, prior to reduction and after calcination of the catalyst is dispersed in the form of particles having a diameter of less than 7 Å as measured by bright field imaging on a scanning transmission electron microscope with 4 Å point-to-point resolution.

Claim 14

Dependent Claim 123 words

A catalyst comprising a type-L zeolite containing exchangeable cations of which at least 75 percent are selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, calcium, and barium cations and containing at least one Group VIII noble metal from the Periodic Table of Elements, characterized in that at least about 90% of the at least one noble metal is inside the channels of the zeolite and at least about 90% of the at least one noble metal inside the channels, prior to reduction and after calcination of the catalyst is dispersed in the form of particles having a diameter of less than 7 Å as measured by bright field imaging on a scanning transmission electron microscope with 4 Å point-to-point resolution.

Claim 15

Dependent Claim 15 words

The catalyst of claim 12 which exhibits a terminal cracking index of greater than 1.5.

Claim 16

Dependent Claim 41 words

The catalyst of claim 12 which exhibits a catalyst activity maintenance under ECAT conditions, to provide a benzene yield greater than 7 wt. % after 24 hours using a feed comprising 20% by volume methyl cyclopentantane and 80% by volume n-hexane.

Claim 17

Dependent Claim 11 words

The catalyst of claim 12 wherein the exchangeable cation is potassium.

Claim 18

Dependent Claim 11 words

The catalyst of claim 15 wherein the noble metal is platinum.

Claim 19

Dependent Claim 123 words

A reforming catalyst comprising zeolite L and containing at least one Group VIII noble metal selected from the group consisting of platinum, rhodium and iridium, at least one exchangeable cation of which at least 75 percent are selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, calcium, and barium and at least about 90% of the at least one noble metal is inside the channels of the zeolite and at least about 90% of the at least one noble metal inside the channels, prior to reduction and after calcination, is dispersed in the form of particles having a diameter of less than 7 Å as measured by bright field imaging on a scanning transmission electron microscope with 4 Å point-to-point resolution.

Claim 20

Dependent Claim 123 words

A reforming catalyst comprising zeolite L and containing at least one Group VIII noble metal selected from the group consisting of platinum, rhodium and iridium, at least one exchangeable cation of which at least 75 percent are selected from the group consisting of lithium, sodium, potassium, rubidium, cesium, calcium, and barium and at least about 90% of the at least one noble metal is inside the channels of the zeolite and at least about 90% of the at least one noble metal inside the channels, prior to reduction and after calcination, is dispersed in the form of particles having a diameter of less than 7 Å as measured by bright field imaging on a scanning transmission electron microscope with 4 Å point-to-point resolution.

Claim 21

Dependent Claim 15 words

The catalyst of claim 17 which exhibits a terminal cracking index of greater than 1.5.

Claim 22

Dependent Claim 40 words

The catalyst of claim 17 which exhibits a catalyst activity maintenance, under ECAT conditions, to provide a benzene yield greater than 7 wt. % after 24 hours using a feed comprising 20% by volume methycyclopentane and 80% by volumne n-hexane.

Claim 23

Dependent Claim 11 words

The catalyst of claim 17 wherein the noble metal is platinum.

Claim 24

Dependent Claim 49 words

The catalyst of claim 20 wherein at least about 98% of the at least one noble metal is dispersed in the form of particles having a diameter of less than 7 Å as measured by bright field imaging on a scanning transmission electron microscope with 4 Å point-to-point resolution.

Claim 25

Dependent Claim 46 words

The catalyst of claim 20 wherein the average size of the crystals of the zeolite is no greater than about 0.2 microns and the at least one noble metal is present in an amount of from about 1.0 to about 6% by weight of the catalyst.

Claim 26

Dependent Claim 45 words

The catalyst of claim 20 wherein the average size of the crystals of the zeolite is greater than about 0.2 microns and the at least one noble metal is present in an amount of from about 0.1 to about 2.0% by weight of the catalyst.

Claim 27

Dependent Claim 136 words

A process for preparing a catalyst in which at least one Group VIII noble metal is highly dispersed over the surface of a type L zeolite and the catalyst is characterized in that at least 90% of the at least one noble metal is dispersed in the form of particles having a diameter of less than about 7 Å as measured by bright field imaging on a scanning transmission electron miscroscope with 4 Å point-to-point resolution, and further in which at least about 75% of the exchangeable cation sites in the zeolite are occupied by at least one selected from the group consisting of lithium, sodium, potassium, cesium, calcium and barium, which comprises adjusting the pH of the type-L zeolite to about 9 to 11.5 and loading the at least one noble metal onto the zeolite.

Claim 28

Dependent Claim 136 words

A process for preparing a catalyst in which at least one Group VIII noble metal is highly dispersed over the surface of a type L zeolite and the catalyst is characterized in that at least 90% of the at least one noble metal is dispersed in the form of particles having a diameter of less than about 7 Å as measured by bright field imaging on a scanning transmission electron miscroscope with 4 Å point-to-point resolution, and further in which at least about 75% of the exchangeable cation sites in the zeolite are occupied by at least one selected from the group consisting of lithium, sodium, potassium, cesium, calcium and barium, which comprises adjusting the pH of the type-L zeolite to about 9 to 11.5 and loading the at least one noble metal onto the zeolite.

Claim 29

Dependent Claim 23 words

The process of claim 24 wherein the at least one noble metal is selected from the group consisting of platinum, iridium and rhodium.

Claim 30

Dependent Claim 18 words

The process of claim 24 wherein the at least one noble metal loading is effected by ion exchange.

Claim 31

Dependent Claim 17 words

The process of claim 24 wherein the pH of the zeolite is from about 10 to 11.

Claim 32

Dependent Claim 11 words

The process of claim 24 wherein the noble metal is platinum.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1989-06-16	1989-12-16	1990-06-17	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1993-06-16	1993-12-16	1994-06-17	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1997-06-16	1997-12-16	1998-06-17	$7700.00	Window Closed / Lapsed

Zeolite catalyst

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