Spray dried zeolite catalyst
An attrition-resistant catalyst is prepared contacting a spray dried zeolite with a modifying agent. The modifying agent is (i) a halogen-free compound hydrolyzable to an oxide selected from the group consisting of silica, alumina, titania, zirconia, niobia, and mixtures thereof; or (ii) a sol selected from the group consisting of silica, alumina, titania, zirconia, niobia, and mixtures thereof.
1 . A catalyst preparation method comprising contacting a spray dried zeolite with a modifying agent to form the catalyst, wherein the modifying agent is (i) a halogen-free compound hydrolyzable to an oxide selected from the group consisting of silica, alumina, titania, zirconia, niobia, and mixtures thereof; or (ii) a sol selected from the group consisting of silica, alumina, titania, zirconia, niobia, and mixtures thereof.
2 . The method of claim 1 wherein the catalyst is calcined at a temperature of 200 to 1000° C.
3 . The method of claim 1 wherein the spray dried zeolite comprises a binder.
4 . The method of claim 1 wherein the modifying agent is a halogen-free compound hydrolyzable to an oxide selected from the group consisting of silica, alumina, titania, zirconia, niobia, and mixtures thereof.
5 . The method of claim 1 wherein the zeolite is a transition metal zeolite.
6 . The method of claim 1 wherein the zeolite is a titanium zeolite.
7 . A catalyst prepared by contacting a spray dried zeolite with a modifying agent, wherein the modifying agent is (i) a halogen-free compound that may hydrolyzable to an oxide selected from the group consisting of silica, alumina, titania, zirconia, niobia, and mixtures thereof; or (ii) a sol selected from the group consisting of silica, alumina, titania, zirconia, niobia, and mixtures thereof.
8 . The catalyst of claim 7 calcined at a temperature from 200 to 1000° C.
9 . The catalyst of claim 7 wherein the spray dried zeolite comprises a binder.
10 . The catalyst of claim 7 wherein the modifying agent is a halogen-free compound hydrolyzable to an oxide selected from the group consisting of silica, alumina, titania, zirconia, niobia, and mixtures thereof.
11 . The catalyst of claim 7 wherein the zeolite is a transition metal zeolite.
12 . An epoxidation process comprising reacting with an olefin and hydrogen peroxide in the presence of the catalyst of claim 11 to produce an epoxide.
13 . The process of claim 12 wherein the catalyst is calcined at a temperature from 200 to 1000° C.
14 . A direct epoxidation process comprising reacting an olefin, hydrogen, and oxygen in the presence of the catalyst of claim 11 and a noble metal.
15 . The process of claim 14 wherein the transition metal zeolite is a titanium zeolite.