Phosphorous promotion of zeolite-containing catalysts
View Patent ↗Disclosed are methods of making, and processes of using phosphorous-promoted zeolite-containing catalysts in the conversion of hydrocarbonaceous materials such as hydrocarbons and biomass. Such disclosed methods of making include: spray drying of the catalyst precursor slurry followed by phosphorous promotion of the resulting spray dried material.
1. A method of making a phosphorous-promoted catalyst comprising:
a) preparing an aqueous slurry comprising a zeolite and a binder precursor selected from the group consisting of an alumina precursor, aluminum phosphate, and combinations thereof;
b) spray drying said aqueous slurry thereby gelling said binder precursor and forming particles from said aqueous slurry; and
c) promoting said particles with phosphorous forming said phosphorous-promoted catalyst.
2. The method of claim 1 wherein said promoting of said particles with phosphorous in step c) comprises:
i) contacting said particles with an aqueous solution comprising a phosphorous compound thereby forming phosphorous-impregnated particles;
ii) separating said phosphorous-impregnated particles from said aqueous solution; and
iii) drying said phosphorous-impregnated particles thereby forming said phosphorous-promoted catalyst.
3. The method of claim 2 wherein said phosphorous compound is selected from the group consisting of phosphoric acid, monoammonium phosphate, diammonium phosphate, triammonium phosphate, tetrasodium pyrophosphate, and combinations thereof.
4. The method of claim 2 wherein said drying of said phosphorous-impregnated particles in step iii) is at a temperature in the range of from about 40° C. to about 150° C., and for a time period in the range of from about 0.05 hours to about 24 hours.
5. The method of claim 1 wherein said aqueous slurry further comprises a matrix material.
6. The method of claim 5 wherein said matrix material comprises clay.
7. The method of claim 6 wherein said clay comprises kaolin, and said catalyst is free of or substantially free of amorphous alumina.
8. The method of claim 1 wherein said zeolite used in preparing said aqueous slurry in step a) comprises ZSM-5.
9. The method of claim 1 wherein said zeolite used in preparing said aqueous slurry in step a) is substantially phosphorous free.
10. The method of claim 1 wherein said phosphorous-promoted catalyst is calcined to form a calcined catalyst.
11. A phosphorous-promoted catalyst prepared by the method of claim 1 .
12. A process for the conversion of particulate biomass comprising contacting said particulate biomass with the phosphorous-promoted catalyst of claim 1 at temperatures ranging from about 200° C. to about 1000° C., and in the substantial absence of oxygen.