Abstract: This invention is for a catalyst for conversion of hydrocarbons. The catalyst contains a zeolite having germanium and at least one selected from the group consisting of tin and boron incorporated into the zeolite framework and at least one metal selected from Group 10 deposited on the zeolite. The catalyst is prepared by synthesizing a zeolite having germanium and at least one selected from the group consisting of tin and boron incorporated into the zeolite framework; depositing the metal; and calcining after preparation of the zeolite and before or after depositing the metal. The catalyst may be used in a process for the conversion of hydrocarbons, such as propane to aromatics, by contacting the catalyst with alkanes having 2 to 12 carbon atoms per molecule and recovering the product.

Abstract: This invention is for a catalyst for conversion of hydrocarbons. The catalyst contains a zeolite with one element from Group 13, Group 14, or the first series transition metals and, optionally, germanium and/or aluminum in the zeolite framework. At least one Group 10 metal, such as platinum, is deposited on the zeolite. Examples of the elements in the framework are tin, boron, iron or titanium. The catalyst is prepared by synthesizing a zeolite with one element from Group 13, Group 14, or the first series transition metals and, optionally, germanium and/or aluminum in the zeolite framework; depositing the metal; and calcining after preparation of the zeolite and before or after depositing the metal. The catalyst may be used in a process for the conversion of hydrocarbons, such as propane to aromatics, by contacting the catalyst with alkanes having 2 to 12 carbon atoms per molecule and recovering the product.

Abstract: A method for forming a catalyst can comprise: heating a Ge-ZSM-5 zeolite powder at a temperature of 400 to 600° C.; ion-exchanging the heat-treated zeolite powder with an alkali metal and impregnating the heat-treated zeolite powder with noble metal; heating the ion-exchanged, impregnated zeolite powder to a temperature of 250 to 350° C.; mixing the second heat-treated zeolite powder with a solid silica binder and a colloidal silica binder to form a mixture, wherein if the solid silica has a purity of less than or equal to 66 wt % of silica oxide based on the total weight of the solid silica, then the mixture is free of an extrusion aide and the colloidal silica has a particle size of less than 20 nm as measured along a major axis; forming the mixture into a shaped body; and heating the shaped body to 100 to 350° C. to result in the catalyst.

Abstract: This invention is for a catalyst for conversion of hydrocarbons. The catalyst is a medium pore germanium zeolite, a germanium aluminophosphate (AlPO) or a germanium silicoaluminophosphate (SAPO). At least one metal selected from Group 10 is deposited on the medium pore zeolite and, optionally on the germanium aluminophosphate (AlPO) or a germanium silicoaluminophosphate (SAPO). The catalyst is prepared by synthesizing a medium pore zeolite, an aluminophosphate (AlPO) or a silicoaluminophosphate (SAPO) with germanium incorporated into the framework and calcining the medium pore germanium zeolite, germanium aluminophosphate (AlPO) or germanium silicoaluminophosphate (SAPO). At least one metal may be deposited on the germanium zeolite, germanium aluminophosphate (AlPO) or a germanium silicoaluminophosphate (SAPO).

Abstract: This invention is for a catalyst for conversion of hydrocarbons. The catalyst contains a zeolite with one element from Group 13, Group 14, or the first series transition metals and, optionally, germanium and/or aluminum in the zeolite framework. At least one Group 10 metal, such as platinum, is deposited on the zeolite. Examples of the elements in the framework are tin, boron, iron or titanium. The catalyst is prepared by synthesizing a zeolite with one element from Group 13, Group 14, or the first series transition metals and, optionally, germanium and/or aluminum in the zeolite framework; depositing the metal; and calcining after preparation of the zeolite and before or after depositing the metal. The catalyst may be used in a process for the conversion of hydrocarbons, such as propane to aromatics, by contacting the catalyst with alkanes having 2 to 12 carbon atoms per molecule and recovering the product.

Abstract: In an embodiment a catalyst comprises a medium or large pore zeolite having germanium incorporated into the zeolite framework. The zeolite can have a pore structure that is one dimensional, two dimensional or three dimensional. A metal selected from Group 10 can be deposited on the zeolite. In an embodiment, a process for synthesizing the zeolite comprises preparing a medium pore zeolite containing germanium in the framework of the zeolite and calcining the zeolite. In an embodiment, the catalyst can be used in a process for the conversion of hydrocarbons comprising contacting a hydrocarbon stream containing alkanes, olefins, or mixtures thereof having 2 to 12 carbon atoms per molecule with the catalyst and recovering the product.

Abstract: An integrated facility is disclosed for simultaneous production of butanal and methacrylic acid products where the facility utilizes a mixed methacrolein and isobutanal stream to make methacrylic acid. The facility is also designed to utilize downstream n-butanal products such as n-butanol and/or 2-ethyl-hexanol to make butyl-methacrylates and 2-ethyl-hexyl-methacrylate. A method is also disclosed which integrates the production of butanal derived products and methacrylic acid derived products.

Abstract: In one embodiment, a formed catalyst can comprise: a Ge-ZSM-5 zeolite; a binder comprising silica with 1 to less than 5 wt % non-silica oxides; less than or equal to 0.1 wt % residual carbon; 0.4 to 1.5 wt % platinum; and 4.0 to 4.8 wt % Cs; wherein the weight percentages are based upon a total weight of the catalyst. In one embodiment, a method of making a formed catalyst can comprise: mixing an uncalcined Ge-ZSM-5 zeolite and a binder to form a mixture; forming the mixture into a formed zeolite; calcining the formed zeolite to result in the formed zeolite having less than or equal to 0.1 wt % of residual carbon; ion-exchanging the formed zeolite with cesium; depositing platinum on the formed zeolite; and heating the formed zeolite to result in a final catalyst; wherein the final catalyst comprises 4.0 to 4.8 wt % cesium and 0.4 to 1.5 wt % platinum.

Abstract: A catalyst and its preparation and use are disclosed. The catalyst is a silicalite having germanium (Ge) included within the framework of the silicalite prepared in a particular manner. The catalyst may be used in a method of converting hydrocarbons wherein a hydrocarbon feed is contacted with the catalyst. The catalyst may be formed by preparing an aqueous reaction mixture of a silica-containing silicalite precursor material and a germanium source. The reactants of the reaction mixture are allowed to react. The reacted reaction mixture is heated under conditions to form crystals of a silicalite having germanium included within the framework of the silicalite. The crystals are then calcined to form the catalyst. In certain embodiments, a noble metal may be deposited upon the germanium-containing silicalite.

Abstract: The disclosure is for a process for producing propylene and hexene (along with ethylene, pentenes, product butenes, heptenes and octenes) by metathesis from butenes (iso-, 1- and cis and trans 2-) and pentenes and then aromatizing the hexenes (along with higher olefins, such as heptenes and octenes) to benzene (along with toluene, xylenes, ethylbenzene and styrene). Since the desired products of the metathesis reaction are propylene and hexene, the feed to the metathesis reaction has a molar ratio for 1-butene:2-butene which favors production of propylene and 3-hexene with the concentration of hexenes and higher olefins in the metathesis product being up to 30 mole %. An isomerization reactor may be used to obtain the desired molar ratio of 1-butene:2-butene for the feed composition into the metathesis reactor. After the metathesis reaction, of hexene and higher olefins are separated for aromatization to benzene and other aromatics.

Abstract: The invention is for a process for producing propylene and hexene (along with ethylene, pentenes, product butenes, heptenes and octenes) by metathesis from butenes (iso-, 1- and cis and trans 2-) and pentenes and then aromatizing the hexenes (along with higher olefins, such as heptenes and octenes) to benzene (along with toluene, xylenes, ethylbenzene and styrene). Since the desired products of the metathesis reaction are propylene and hexene, the feed to the metathesis reaction has a molar ratio for 1-butene:2-butene which favors production of propylene and 3-hexene with the concentration of hexenes and higher olefins in the metathesis product being up to 30 mole %. An isomerization reactor may be used to obtain the desired molar ratio of 1-butene:2-butene for the feed composition into the metathesis reactor. After the metathesis reaction, of hexene and higher olefins are separated for aromatization to benzene and other aromatics.

Abstract: A catalyst and its preparation and use are disclosed. The catalyst is a silicalite having germanium (Ge) included within the framework of the silicalite prepared in a particular manner. The catalyst may be used in a method of converting hydrocarbons wherein a hydrocarbon feed is contacted with the catalyst. The catalyst may be formed by preparing an aqueous reaction mixture of a silica-containing silicalite precursor material and a germanium source. The reactants of the reaction mixture are allowed to react. The reacted reaction mixture is heated under conditions to form crystals of a silicalite having germanium included within the framework of the silicalite. The crystals are then calcined to form the catalyst. In certain embodiments, a noble metal may be deposited upon the germanium-containing silicalite.

Abstract: This invention is for a catalyst for conversion of hydrocarbons. The catalyst contains a zeolite with one element from Group 13, Group 14, or the first series transition metals and, optionally, germanium and/or aluminum in the zeolite framework. At least one Group 10 metal, such as platinum, is deposited on the zeolite. Examples of the elements in the framework are tin, boron, iron or titanium. The catalyst is prepared by synthesizing a zeolite with one element from Group 13, Group 14, or the first series transition metals and, optionally, germanium and/or aluminum in the zeolite framework; depositing the metal; and calcining after preparation of the zeolite and before or after depositing the metal. The catalyst may be used in a process for the conversion of hydrocarbons, such as propane to aromatics, by contacting the catalyst with alkanes having 2 to 12 carbon atoms per molecule and recovering the product.

Abstract: Methods for preparing bound non-acidic germanium zeolite catalysts arc disclosed, where the preparation is reproducible and scalable and where the catalysts have similar or the same activity and selectivities of a standard naphtha aromatization catalyst and methods for aromatizing naphtha.

Abstract: Methods for olefin metathesis including contacting a olefin feed stream with a metathesis catalyst at a temperature and at a pressure sufficient to maintain the reactor olefin compositions in a mixed-phase condition including components in the liquid phase and components in the vapor phase, where the mixed-phase reaction conditions shift the equilibrium to desired product olefins.

Abstract: The present invention is for a catalyst, a process for making the catalyst and a process for using the catalyst in aromatization of alkanes having three to five carbon atoms per molecule, such as propane, to aromatics, such as benzene, toluene and xylene. The catalyst is an aluminum-silicon zeolite having a silicon to aluminum atomic ratio (Si:Al) greater than 15:1, such as MFI or ZSM-5, on which germanium, aluminum and a noble metal, such as platinum, have been deposited. The catalyst may be bound with magnesia, alumina, titania, zirconia, thoria, silica, boria or mixtures thereof. The aluminum and germanium may be deposited simultaneously on the zeolite.

Abstract: Methods for preparing catalysts for oxidation of unsaturated and/or saturated aldehydes to unsaturated acids is disclosed where the catalyst includes at least molybdenum (Mo), phosphorus (P), vanadium (V), bismuth (Bi), where the bismuth component was dissolved in an organic acid solution prior to adding the bismuth containing solution to a solution of the other components.

Abstract: This invention is for a catalyst for conversion of hydrocarbons. The catalyst is a non-acidic germanium zeolite, such as Ge-ZSM-5, on which at least two metals, platinum and at least one other metal selected from Group 7, Group 8, Group 9, Group 10 and tin, are deposited on the germanium zeolite. Examples of the other metal are iridium, rhenium, palladium, ruthenium, rhodium, iron, cobalt and tin. The catalyst is prepared by synthesizing a germanium zeolite; depositing platinum and at least one other metal on the germanium zeolite; and calcining after preparation of the zeolite, before depositing the metals or after depositing the metals. The catalyst may be used in a process for the conversion of hydrocarbons, such as propane to aromatics, by contacting the catalyst with a hydrocarbon stream containing alkanes, olefins and mixtures thereof having 2 to 12 carbon atoms per molecule and recovering the product.

Abstract: The present invention is for a catalyst, a process for making the catalyst and a process for using the catalyst in aromatization of alkanes having three to five carbon atoms per molecule, such as propane, to aromatics, such as benzene, toluene and xylene. The catalyst is an aluminum-silicon zeolite having a silicon to aluminum atomic ratio (Si:Al) greater than 15:1, such as MFI or ZSM-5, on which germanium, aluminum and a noble metal, such as platinum, have been deposited. The catalyst may be bound with magnesia, alumina, titania, zirconia, thoria, silica, boria or mixtures thereof. The aluminum and germanium may be deposited simultaneously on the zeolite.

Abstract: This invention is for a catalyst for conversion of alkanes having two to six carbon atoms per molecule to aromatics. The catalyst is a MFI zeolite with a crystallite size of less than 15 microns with, in addition to silicon and aluminum, germanium as a framework element. Platinum is deposited on the zeolite. The zeolite may contain other optional tetravalent and trivalent elements in the zeolite framework. The catalyst is synthesized by preparing a zeolite containing aluminum, silicon, germanium and, optionally, other elements in the framework, calcining the zeolite and depositing platinum on the zeolite. The catalyst may be used for aromatization of alkanes, such as propane, to aromatics, such as benzene, toluene and xylenes.