Alloyed zeolite catalyst component, method for making and catalytic application thereof

1. A method of preparing a solid catalyst component, comprising:

(a) dissolving a noble metal precursor and a transition metal precursor, respectively into water to form solutions, and mixing the obtained solutions with each other to obtain a metal salt solution, wherein the noble metal precursor comprises one or more salts comprising a noble metal selected from the group consisting of silver, gold, rhodium, iridium, and combinations thereof;

(b) mixing a modified zeolite with a solvent to obtain a zeolite slurry, wherein the zeolite is selected from the group consisting of chabazite, erionite, faujasite, ferrierite, mordenite, offretite, TEA-mordenite, zeolite A, zeolite beta, zeolite boron beta, zeolite L, zeolite X, zeolite Y, zeolite ZK-5, Breck-6, HZSM-5, ITQ-1, ITQ-21, MCM-22, MCM-36, MCM-39, MCM-41, MCM-48, PSH-3, SUZ-4, EU-1, SAPO-5, SAPO-11, SAPO-34, (S)AIPO-31, SSZ-23, SSZ-32, TUD-1, VPI-5, ZSM-4, ZSM-5, ZSM-8, ZSM-11, ZSM-12, ZSM-20, ZSM-21, ZSM-22, ZSM-23, ZSM-34, ZSM-35, ZSM-38, ZSM-48, ZSM-50, ZSM-57, and combinations thereof, and wherein the modified zeolite is modified with a modifier selected from the group consisting of (a) phosphorous, (b) phosphorous and boron, (c) an additive selected from the group consisting of gallium, zinc, zirconium, niobium, tantalum, and combinations thereof, and (d) combinations thereof;

(c) contacting the metal salt solution with the zeolite slurry to form a mixture;

(d) adjusting a pH of the mixture to obtain a product;

(e) heating the product to form catalyst particles;

(f) isolating and washing the catalyst particles; and

(g) heat-treating the catalyst particles obtained from the step (f) to form the solid catalyst component.

2. The method of claim 1 , wherein the step of contacting the metal salt solution with the zeolite slurry of step (c) includes wet impregnation, incipient wetness impregnation, ion exchange, framework substitution, physical vapor deposition, chemical vapor deposition, atomic layer deposition, physical bending, and combinations thereof.

3. The method of claim 1 , wherein the transition metal precursor comprises one or more salts comprising a transition metal selected from the group consisting of titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, molybdenum, tungsten, and combinations thereof.

4. The method of claim 1 , wherein the solvent in step (b) is an organic solvent containing at least one hydroxy functional group.

5. The method of claim 1 , wherein the modified zeolite is further modified with at least one additive selected from the group consisting of gallium, zinc, zirconium, niobium, tantalum, and combinations thereof.

6. The method of claim 1 , wherein the pH of the product in step (d) is adjusted to a range of from about 11 to about 13.

7. The method of claim 1 , wherein the pH of the product in step (d) is adjusted using a pH adjuster selected from the group consisting of NaOH, NH 4 OH, KOH, Ca(OH) 2 , and combinations thereof.

8. The method of claim 1 , wherein heating the product in step (e) comprises: (i) raising the temperature of the product to about 50 to 80° C. over about 20 to 40 minutes; and (ii) maintaining the temperature at about 50 to 80° C. for about 1 to 5 hours.

9. A method of preparing a solid catalyst component, comprising:

(a) dissolving a noble metal precursor in water to form a noble metal solution, wherein the noble metal precursor comprises one or more salts comprising a noble metal selected from the group consisting of silver, gold, rhodium, iridium, and combinations thereof;

(b) mixing a modified zeolite with a solvent to obtain a zeolite slurry, wherein the zeolite is selected from the group consisting of chabazite, erionite, faujasite, ferrierite, mordenite, offretite, TEA-mordenite, zeolite A, zeolite beta, zeolite boron beta, zeolite L, zeolite X, zeolite Y, zeolite ZK-5, Breck-6, HZSM-5, ITQ-1, ITQ-21, MCM-22, MCM-36, MCM-39, MCM-41, MCM-48, PSH-3, SUZ-4, EU-1, SAPO-5, SAPO-11, SAPO-34, (S)AIPO-31, SSZ-23, SSZ-32, TUD-1, VPI-5, ZSM-4, ZSM-5, ZSM-8, ZSM-11, ZSM-12, ZSM-20, ZSM-21, ZSM-22, ZSM-23, ZSM-34, ZSM-35, ZSM-38, ZSM-48, ZSM-50, ZSM-57, and combinations thereof, and wherein the modified zeolite is modified with a modifier selected from the group consisting of (a) phosphorous, (b) phosphorous and boron, (c) an additive selected from the group consisting of gallium, zinc, zirconium, niobium, tantalum, and combinations thereof, and (d) combinations thereof;

(c) contacting the noble metal solution with the zeolite slurry to form a noble metal zeolite mixture;

(d) adjusting a pH of the noble metal zeolite mixture to obtain a noble metal zeolite product;

(e) heating the noble metal zeolite product to form a noble metal zeolite catalyst precursor;

(f) isolating and washing the noble metal zeolite catalyst precursor;

(g) heat-treating the noble metal zeolite catalyst precursor obtained from step (f) to dry the isolated noble metal zeolite catalyst precursor;

(h) dispersing the dried noble metal zeolite catalyst precursor of step (g) in a solvent to form a noble metal zeolite slurry;

(i) dissolving a transition metal precursor in water to form a transition metal solution;

(j) contacting the noble metal zeolite slurry with the transition metal solution to form a noble and transition metal zeolite mixture;

(k) adjusting a pH of the noble and transition metal zeolite mixture to obtain a noble and transition metal zeolite product;

(l) heating the noble and transition metal zeolite product to form noble and transition metal zeolite catalyst particles;

(m) isolating and washing the noble and transition metal zeolite catalyst particles; and

(n) heat-treating the catalyst particles obtained from step (m) to form the solid catalyst component.

10. The method of claim 9 , wherein the transition metal precursor comprises one or more salts comprising a transition metal selected from the group consisting of titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, molybdenum, tungsten, and combinations thereof.

11. The method of claim 9 , wherein the solvent in at least one of steps (b) and (h) is an organic solvent containing at least one hydroxy functional group.

12. The method of claim 9 , wherein the modified zeolite is further modified with at least one additive selected from the group consisting of gallium, zinc, zirconium, niobium, tantalum, and combinations thereof.

13. The method of claim 9 , wherein the pH of the product in at least one of steps (d) and (k) is adjusted to a range of from about 11 to about 13.

14. A method of preparing a solid catalyst component, comprising:

(a) dissolving a transition metal precursor in water to form a transition metal solution;

(b) mixing a modified zeolite with a solvent to obtain a zeolite slurry, wherein the zeolite is selected from the group consisting of chabazite, erionite, faujasite, ferrierite, mordenite, offretite, TEA-mordenite, zeolite A, zeolite beta, zeolite boron beta, zeolite L, zeolite X, zeolite Y, zeolite ZK-5, Breck-6, HZSM-5, ITQ-1, ITQ-21, MCM-22, MCM-36, MCM-39, MCM-41, MCM-48, PSH-3, SUZ-4, EU-1, SAPO-5, SAPO-11, SAPO-34, (S)AIPO-31, SSZ-23, SSZ-32, TUD-1, VPI-5, ZSM-4, ZSM-5, ZSM-8, ZSM-11, ZSM-12, ZSM-20, ZSM-21, ZSM-22, ZSM-23, ZSM-34, ZSM-35, ZSM-38, ZSM-48, ZSM-50, ZSM-57, and combinations thereof, and wherein the modified zeolite is modified with a modifier selected from the group consisting of (a) phosphorous, (b) phosphorous and boron, (c) an additive selected from the group consisting of gallium, zinc, zirconium, niobium, tantalum, and combinations thereof, and (d) combinations thereof;

(c) contacting the transition metal solution with the zeolite slurry to form a transition metal zeolite mixture;

(d) adjusting a pH of the transition metal zeolite mixture to obtain a transition metal zeolite product;

(e) heating the transition metal zeolite product to form a transition metal zeolite catalyst precursor;

(f) isolating and washing the transition metal zeolite catalyst precursor;

(g) heat-treating the transition metal zeolite catalyst precursor obtained from step (f) to dry the isolated transition metal zeolite catalyst precursor;

(h) dispersing the dried transition metal zeolite catalyst precursor of step (g) in a solvent to form a noble metal zeolite slurry;

(i) dissolving a noble metal precursor in water to form a noble metal solution, wherein the noble metal precursor comprises one or more salts comprising a noble metal selected from the group consisting of silver, gold, rhodium, iridium, and combinations thereof;

(j) contacting the transition metal zeolite slurry with the noble metal solution to form a transition and noble metal zeolite mixture;

(k) adjusting a pH of the transition and noble metal zeolite mixture to obtain a transition and noble metal zeolite product;

(l) heating the transition and noble metal zeolite product to form transition and noble metal zeolite catalyst particles;

(m) isolating and washing the transition and noble metal zeolite catalyst particles; and

(n) heat-treating the catalyst particles obtained from step (m) to form the solid catalyst component.

15. The method of claim 14 , wherein the transition metal precursor comprises one or more salts comprising a transition metal selected from the group consisting of titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, molybdenum, tungsten, and combinations thereof.