METHOD FOR OBTAINING A SPHERICAL CATALYST AND ISOBUTANE ALKYLATION CATALYST WITH ISOBUTENE Russian patent published in 2018 - IPC B01J29/08 B01J37/30 C07C2/58 

FIELD: technological processes.

SUBSTANCE: invention relates to the preparation of isobutane alkylation catalysts with isobutene and can be used in the technology for the production of isobutane alkylation catalysts with alkenes and also for the production of isomerization catalysts. Method for the preparation of a spherical isobutane alkylation catalyst with isobutene based on zeolite of NaNH₄Y type with a residual sodium oxide content of not more than 0.8 wt%, including impregnation with stirring of zeolite crystals with an aqueous solution of lanthanum nitrate in an amount providing a lanthanum content in the zeolite of 3.0 wt%, mixing the resultant slurry with a second slurry obtained by peptizing with an aqueous solution of nitric acid to pH of 2–3 in an aluminum hydroxide powder of pseudo-boehmite modification, introducing sulfated tetragonal zirconia with a content of 5 wt% of SO₄^2- and natural silicate into the slurry mixture when mixing the powder, granulation of the molding composition, wilting granules at room temperature (18–24) h, drying with a temperature rise of 2 degrees per minute and exposure at 110±10 °C for at least 5 hours and calcination with a temperature rise of 10 degrees per minute and a exposure speed of 280±10 °C for not less than 4 hours and at 510±10 °C for at least 4 hours. Powders of the zeolite and aluminum hydroxide of the pseudo-boehmite modification, sulfated zirconia have a particle size of less than 10 mcm. Sulphated coarse mesoporous powder θ-Al₂O₃, containing 5 wt% of SO₄^2-, and zirconium silicate ZrSiO₄, with particles smaller than 10 mcm are introduced into the molding mass when mixing. Molding mass is granulated by spherical formation by spheronization on a planetary granulator, with the following ratio of components in the molding mass, % by weight: zeolite of NaNH₄Y type with a residual sodium content of not more than 0.8 wt% – (17.5–21.5), lanthanum nitrate – (1.25–1.55), aluminum hydroxide (pseudo-boehmite) – (21.4–23.8), sulfated zirconium oxide – (7.8–10.5), sulfated θ-Al₂O₃ – (4.2–6.3) and zirconium silicate ZrSiO₄ – (1.5–2.6), nitric acid – (0.40–0.45), water – up to 100. Catalyst prepared by said method comprises a zeolite of the NaLaHY type with a residual sodium oxide content of not more than 0.8 wt% and a modified with 3.0 wt% of lanthanum, aluminum γ-oxide, sulfated tetragonal zirconium oxide containing 5 wt% of SO₄^2-, natural silicate and further includes sulphated θ-Al₂O₃, containing 5 wt% of SO₄^2-. Natural silicate is ZrSiO₄. Catalyst components are in the following weight ratio, %: zeolite of the NaLaHY type (35–42), aluminum γ-oxide – (30–32), sulfated zirconium oxide – (15–19), aluminum oxide – (30–32), sulphated aluminum θ-oxide – (8–12), zirconium silicate – (3–5).

EFFECT: improved catalyst properties; increased plasticity of the molding mass and strength of granules; presence of the developed volume of large mesopores facilitating the transport of reactants to the active zeolite centers in the catalyst granules and the removal of reaction products from the volume of the catalyst granules; decreased catalyst coking; high conversion and selectivity of alkylation; high mechanical abrasion and crushing strength.

2 cl, 1 tbl