FIELD

[0001] The application relates to shaped catalyst extrudates and methods of producing the same.

BACKGROUND

[0002] Fixed bed catalysts are usually formulated as extrudates having particular shapes, diameters, and lengths intended to optimize the catalyst performance for a given application. Extruded catalysts need to be further optimized for mechanical strength, active material loading, reactor packing density, and diffusional characteristics. Typical extrudates used commercially are shaped as cylinders, trilobes, twisted trilobes, or quadralobes (tetralobes). Catalysts with multilobal cross-sections have a higher surface-to-volume (or specific volume (S/V)) ratio than cylindrical extrudates of the same diameter. When used in a fixed bed unit, these multilobe- shaped catalyst particles help reduce diffusional resistance, create a more open bed, and reduce pressure drop. Maximizing S/V can be beneficial to diffusion-limited reactions.

SUMMARY

[0003] A catalyst material comprising elongated particles having a novel shape having an expanded trilobe or expanded quadralobe cross-section is disclosed. The shapes of the catalyst particles are such that the surface to volume ratio of the particles exceeds the surface to volume ratio of a cylindrical particle of the same length and the same effective diameter by at least 10%. Generally, each particle has a cross-section comprising a central triangular or rectangular portion having a part-circular lobe at each vertex, wherein the center of the part circle of each lobe and diameter of each lobe are such that adjacent lobes do not intersect.

[0004] An extrusion die having a plurality of openings through which a catalyst material paste can be extruded, each opening independently having a cross-section as described above is also disclosed, as well as methods for making particles or pieces of a catalyst material by extruding a catalyst material paste through such an extrusion die.

[0005] A method for making a catalyst material is also provided. The method includes

i) mixing a binder, a crystal of an active material that is a zeolite or MCM-41 or a mixture of any two of them, water and optionally one or more elemental metal precursors to form an extrudable paste;

iia) extruding the paste through a die having an expanded trilobe-shaped cross-section to form a green catalyst extrudate having an expanded trilobe-shaped cross-section, for example of a first expanded trilobe design disclosed above or a second expanded trilobe design as disclosed above, to form a green catalyst extrudate having an expanded trilobe cross-section; or iib) extruding the paste through a die having an expanded quadralobe-shaped cross- section to form a green catalyst extrudate having an expanded quadralobe-shaped cross-section; and

iii) calcining the extrudate to form a calcined extrudate catalyst material having an elongated shape and an expanded expanded trilobe-shaped cross-section or an expanded quadralobe-shaped cross-section.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figures 1 A and IB show a first expanded trilobe design; Figure 1 A shows the geometric elements from which the cross-section is constructed. Figure IB shows the outline and resulting cross-section of the first expanded trilobe design.

[0007] Figures 2A and 2B show a second expanded trilobe design; Figure 2A shows the geometric elements from which the cross-section is constructed. Figure 2B shows the outline and resulting cross-section of the second expanded trilobe design.

[0008] Figures 3A and 3B show a traditional trilobe design; Figure 3A shows the geometric elements from which the cross-section is constructed. Figure 3B shows the outline and resulting cross-section of the traditional trilobe design.

[0009] Figures 4A and 4B show a traditional quadralobe design; Figure 4A shows the geometric elements from which the cross-section is constructed. Figure 4B shows the outline and resulting cross-section of the traditional quadralobe design.

[0010] Figure 5 shows both of the geometric elements from which the cross-section is constructed and resulting cross-section of the traditional cylindrical design.

[0011] Figure 6 is a photograph of an extrusion die having a plurality openings with an expanded trilobe cross-section.

[0012] Figures 7 A and 7B show an expanded quadralobe design; Figure 7 A shows the geometric elements from which the cross-section is constructed. Figure 7B shows the outline and resulting cross-section of the expanded quadralobe design.

[0013] Figure 8 shows a photograph of extruded MCM-41/V300 catalyst pieces prepared in Example 6.

DETAILED DESCRIPTION OF THE INVENTION

[0014] A new design of extrusion die insert which enables production of mechanically strong extruded catalysts with at least 10% or at least 20% higher surface area to volume ratio (S/V) compared to traditional trilobes is disclosed. Application of this new design to making catalyst materials can significantly enhance activity of fixed bed catalysts in variety of refining applications, e.g. hydrocracking, lubes aromatics saturation, and others. [0015] Presently disclosed are "expanded trilobe" and "expanded quadralobe" extrudates which provide step-up S/V, e.g. at least 10% increase or at least a 20% increase, when compared to conventional trilobe extrusions (by e.g. at least 10% or 20%), cylinders (e.g. at least 10%, 20%, or at least 40% or at least 50%) or quadralobes (e.g. at least 10%, at least 20% or at least -25 or at least -30%). The expanded trilobe design was also optimized to not only provide increased specific volume but also good mechanical strength of the finished catalyst material.

Exemplary extrusions were performed with a range of active materials: MCM-41, or MCM-22, USY or ZSM-48 zeolite crystals, and different binders, e.g. Versal™-300 or Pural NG™. MCM- 41 extrusions showed similar side crush strength as cylinders, but have about 50% higher surface/volume ratio.

[0016] The design of the expanded trilobe is based on the cross-sectional depictions shown in Figures 1A and IB and Figures 2A and 2B. For comparison, Figures 3-5 also show cross- sectional diagrams of traditional trilobes (Figs. 3A and 3B), traditional quadralobes (Figs. 4A and 4B) and cylinders (Fig. 5). "D" in Fig. 3A, Fig. 4A and Fig. 5 is the effective diameter of the traditional trilobe cross-section, the traditional quadralobe cross-section and the cylinder cross- section, respectively.

[0017] Based on the geometric designs depicted in Figures 1-5, the specific surface areas can be calculated for different length-to-diameter ratios as well as different effective diameters of the extrudates. The external surface area is the sum of the area of the two ends of the extrudate and the area of the side. Tables 1-3 show summary results of calculations for 3 typical catalyst diameters. The calculations show the effect of changing the ratio of lobe diameter to the

extrudate diameter. Typical pieces of catalyst material have L/D = 2.0 or L/D = 2.5. The data in Tables 1-3 show that the first expanded trilobe design ("expanded trilobe 1") provides at least a 10% increase, or at least a 20% increase in S/V when compared to a traditional trilobe design, and even greater increase when compared to other geometries.

Table 1. Specific volumes comparison for 1/8 inch diameter extrudates.

S/V

D=

/8 in Cylinder Quadralobe Trilobe Expanded Trilobe 1 Expanded Trilobe 2

Lobe Lobe Lobe Lobe D/Extrudate D D/Extrudate D D/Extrudate D D/Extrudate D

L/D d/D = 0.3 d/D = 0.2 d/D = 0.3 d/D = 0.2

8 34 41 44 55 58 75 78

4 36 43 46 57 60 77 80 2.5 38 46 49 60 63 80 82

2 40 47 50 61 64 81 84

1 48 55 58 69 72 89 92

Table 2. Specific volumes comparison for 1/16 inch diameter extrudates.

S/V

D=

/16 in Cylinder Quadralobe Trilobe Expanded Trilobe 1 Expanded Trilobe 2

Lobe Lobe Lobe Lobe D/Extrudate D D/Extrudate D D/Extrudate D D/Extrudate D

L/D d/D = 0.3 d/D = 0.2 d/D = 0.3 d/D = 0.2

8 68 82 86 110 116 150 156

4 72 86 93 114 120 154 160

2.5 77 91 97 119 125 159 164

2 80 94 101 122 128 162 168

1 96 110 117 138 144 178 184

Table 3. Specific volumes comparison for 1/20 inch diameter extrudates.

S/V

D=

/20 in Cylinder Quadralobe Trilobe Expanded Trilobe 1 Expanded Trilobe 2

Lobe Lobe Lobe Lobe D/Extrudate D D/Extrudate D D/Extrudate D D/Extrudate D

L/D d/D = 0.3 d/D = 0.2 d/D = 0.3 d/D = 0.2

8 85 103 111 138 145 188 195

4 90 108 116 143 150 193 200

2.5 96 114 122 149 156 199 206

2 100 118 126 153 160 203 210

1 120 138 146 173 180 223 230

[0018] The expanded trilobe 1 design has been further demonstrated using a die insert based on the geometric design from Figure 1. Figure 6 shows a photo of the die insert. [0019] The expanded quadralobe is based on similar design principle as the expanded trilobes. Each apex of a square is located in the mid point between center of the circle and its periphery. Figure 7 shows a representation of one such design and Table 4 shows summary results calculations for 1/16 inch effective diameter extrudates with a ratio of lobe diameter to effective diameter of 0.3.

Table 4. Specific volumes comparison for 1/16 inch diameter extrudates with expanded quadralobe design.

[0020] The present disclosure describes a catalyst material (extrudate) comprising elongated shaped particles or pieces having an expanded trilobe or expanded quadralobe cross-sectional shape such that the surface to volume ratio of the particles exceeds the surface to volume ratio of a cylindrical particle or piece of the same length and the same effective diameter (i.e. diameter of the cylinder) by at least 10% or by at least 20%. The increase can be as much as 30%, or 40% or even as much as 2-fold or 2.5-fold. The data in Tables 1-4 illustrate the range of improvement obtained by a variety of cross-section geometries disclosed herein and include comparison to a cylindrical, traditional trilobe and traditional quadralobe cross-sections.

[0021] The catalyst material can be one in which each particle or piece of the extrudate has a cross-section that comprises a central triangular or rectangular portion having a part-circular lobe at each vertex, and wherein the center of the part circle of each lobe and diameter of each lobe are such that adjacent lobes do not intersect. The central rectangular portion can be a square portion.

[0022] Referring to Figs. 2A and 2B, the particle or piece of extruded catalyst material can be one in which the cross-section of each particle occupies the space of an expanded trilobe of a first design that is encompassed by the outer edges of three equidiameter outer circles each centered on a vertex of a equilateral triangle centered on the longitudinal axis of the particle and wherein the length of each side of the equilateral triangle is greater than the diameter of each circle, the cross-sectional area of the particle being composed of the area of the equilateral triangle and the area of each of the circles not including the sector overlapping the central triangle.

[0023] In these instances, such a particle or piece of catalyst material (extrudate) can be one in which the effective diameter (D in Fig. 2A) of the elongated shaped particle is equal to the length of a side of the equilateral triangle plus the diameter of an outer circle and in which the lobe diameter (d in Fig. 2A) is equal to the diameter of the equidiameter outer circles and having a ratio of the lobe diameter to the effective diameter of from 0.1 to 0.4 or from 0.2 to 0.3.

[0024] Alternatively, referring to Figs. 7A and 7B, the extruded particle or piece of catalyst material can be one having an expanded quadralobe cross-section comprising four protrusions each extending from and attached to a central position, wherein the central position is aligned along the longitudinal axis of the particle, the cross-section of the particle occupying the space encompassed by the outer edges of four equidiameter outer circles around a central square, each of the four outer circles being centered at a point (c in Fig. 7A) equidistant along the bisector of the central square (b in Fig. 7A) from the edge of the outer circle to the vertex of the square and the length of one side of the central square being greater than 1.5x the diameter of one of the outer circles (d in Fig. 7A), the cross-sectional area of the particle being composed of the area of the central square and the area of each of the circles not including the sector overlapping the central square.

[0025] Such a particle or piece of catalyst material (extrudate) having an expanded quadralobe cross-section can be one which the effective diameter (D in Fig. 7A) of the elongated shaped particle is equal to the diameter of a circle circumscribing the cross-section of the particle and in which the lobe diameter (d in Fig. 7A) is equal to the diameter of the equidiameter outer circles, the catalyst material having a ratio of the lobe diameter to the effective diameter of fromO. l to 0.4 or from 0.2 to 0.3.

[0026] In a third alternative, referring to Figs. 1 A and IB, the particle or piece of catalyst material (extrudate) can be one having a second of an expanded trilobe cross-section ("expanded trilobe 2") comprising three protrusions, extending from and attached to a central position, wherein the central position is aligned along the longitudinal axis of the particle, the cross- section of the particle occupying the space encompassed by the outer edges of three equidiameter outer circles, an effective circumference of the particle being the circumference of a circle (C in Fig. 1 A) encompassing all three of the equidiameter outer circles and being centered on the longitudinal axis of the particle, the equidiameter outer circles being disposed so that all of the outer circles lie within the effective circumference of the particle and such that the vertices of an equilateral triangle are located at the point where the circumference of each outer circle meets the circle defining the effective circumference of the particle, twice the diameter of the equidiameter outer circles being less than the length of a side of the equilateral triangle, the cross-sectional area of the particle being composed of the area of the equilateral triangle and the area of each of the circles not including the sector overlapping the central triangle.

[0027] A particle or piece of catalyst material having such a second expanded trilobe design can be one in which the effective diameter of the elongated shaped particle is equal to the length of a line (D in Fig. 1 A) drawn from the circumference of an outer circle, through the center of the outer circle and through the center of an adjacent outer circle to the circumference of the outer circle, such that the effective diameter of the elongated shaped particle is greater than the length of a side of the equilateral triangle, and in which the lobe diameter (d in Fig. 1 A) is equal to the diameter of the equidiameter outer circles, the catalyst material having a ratio of the lobe diameter to the effective diameter of from 0.1 to 0.4 or from 0.2 to 0.3.

[0028] In any of the above alternatives, the length of the elongated shaped particle can be from 1 to 10 times the effective diameter of the elongated shaped particle.

[0029] In any of the above alternatives, additionally or alternately, the catalyst material can be one in which an active catalyst material is a zeolite or MCM-41, or a mixture of any two or more of these (e.g. MCM-41 and a zeolite, or a mixture of any two or more zeolites).

[0030] Additionally or alternately, the catalyst material can be one in which the amount of zeolite or MCM-41 is from 1-99% by weight of the catalyst material. In the case of mixed catalysts, the proportions of each zeolite (and of MCM-41, if applicable) can be in any ratio.

[0031] Additionally or alternately, the catalyst material can be one that further comprises at least one noble metal, at least one Group 6 metal, at least one Group 8-10 base metal, or a combination of any two or three of these metals. Platinum and palladium, in group 10, are examples of noble metals. Molybdenum and tungsten are examples of Group 6 metals. Cobalt and Nickel are examples of Group 8-10 base metals.

[0032] In any of the catalyst materials disclosed, the amount of the metal(s) can be from 1 - 10% by weight of the catalyst material.

[0033] In any of the catalyst materials disclosed the active material can be a zeolite ZSM-5, ZSM-11, ZSM-12, ZSM-22, ZSM-23, ZSM-35, ZSM-48, ZSM-50, ZSM-57, ZSM-58, Beta, Mordenite, MCM-68, or a MCM-22 family material, or a mixture of two or more thereof. A MCM-22 family material can be selected from the group consisting of MCM-22, PSH-3, SSZ-25, MCM-36, MCM-49, MCM-56, ERB-1, EMM-10, EMM-10-P, EMM-12, EMM-13, UZM-8, UZM-8HS, ITQ-1, ITQ-2, ITQ-30, or a mixture of two or more thereof. [0034] Any catalyst material presently described can further comprise a binder that is alumina, zirconia, titania, silica, ceria or a mixture of any two or more these binders.

[0035] Any catalyst material presently described can further comprise a dopant. The dopant can be, for example, magnesia, phosphorous, lanthanum or a mixture of any two or more of these. The amount of the dopant is that typically used in the art.

[0036] A catalyst material according to the present disclosure can be formed by a method comprising:

i) mixing a binder, a crystal of an active material that is a zeolite or MCM-41 or a mixture of any two of them, water and optionally one or more elemental metal precursors to form an extrudable paste;

iia) extruding the paste through a die having an expanded trilobe-shaped cross-section to form a green catalyst extrudate having an expanded trilobe-shaped cross-section, for example of a first expanded trilobe design disclosed above or a second expanded trilobe design as disclosed above, to form a green catalyst extrudate having an expanded trilobe cross-section; or iib) extruding the paste through a die having an expanded quadralobe-shaped cross- section to form a green catalyst extrudate having an expanded quadralobe-shaped cross-section; and

[0037] calcining the extrudate to form a calcined extrudate catalyst material having an elongated shape and an expanded expanded trilobe-shaped cross-section or an expanded quadralobe-shaped cross-section.

[0038] Calcining can be performed in an inert atmosphere, such as nitrogen, or in air.

[0039] Further processing can include additional steps, e.g. ion exchange, another calcination step, another incipient wetness metals impregnation, reduction steps. For example, the calcining step in making the catalyst material can be followed by one or more steam treatment and/or ion exchange steps and/or washing steps performed as is typical in the art. Ammonium nitrate is an exemplary exchange salt.

[0040] In such methods for making an elongated particle or piece of catalyst material the extrudate paste can be one comprising active catalyst material that is a zeolite or MCM-41. In these methods, the amount of zeolite or MCM-41 can be from 1-99% by weight of the catalyst material.

[0041] In any of these methods, the extrudate paste can further comprise a binder that is alumina, zirconia, titania, silica, ceria or a mixture of any two or more of these binders.

[0042] In addition, the extrudate paste can further comprise a dopant, that can be magnesia or phosphorous. [0043] Additionally or alternatively, the extrudate paste used in any of these methods can be one including one or more elemental precursors. Such an elemental metal precursor can be an organic or inorganic salt of at least one noble metal, an organic or inorganic salt of at least one Group 6 metal, an organic or inorganic salt of at least one Group 8 to Group 10 metal, an organic or inorganic salt of at least one Group 8 to Group 10 non-noble metal, or a mixture of any two or three of these. Platinum and palladium, in group 10, are examples of noble metals. Molybdenum and tungsten are examples of Group 6 metals. Cobalt and Nickel are examples of Group 8-10 base metals.

[0044] The elemental metal precursor can be added to extrudate paste in an amount that provides from 0.1-10% or 0.5 to 10%, or 0.2% to 5%, or 0.2 to 2%, 0.5-5%, or 0.2-2% by weight of each of the elemental metals desired in the calcined catalyst material. The amount of each metal in the calcined catalyst material can be determined independently. The total amount of metal in the calcined catalyst material can be in the range 0.01 - 25%, 0.1-20%, 0.1-10%, 0.1- 5%, 0.5-20%, 0.5-10%, 1-10%, 2-10%, 2-6% or 5-10%.

[0045] Additionally or alternatively, the extrudate paste used in any of these methods can be one in which the elemental metal precursor is an organic or inorganic salt of nickel,

molybdenum, cobalt, tungsten, platinum or palladium, or a mixture of two or more of these.

[0046] In any of these instances, the elemental metal precursor can added in an amount that provides an amount by weight of the elemental metal in the calcined catalyst material as described above.

[0047] The present disclosure also provides an extrusion die comprising a plurality of openings configured for forcing through a material to be extruded, each opening having an expanded trilobe cross-section encompassed by the outer edges of three equidiameter outer circles each centered on a vertex of a equilateral triangle centered on the longitudinal axis of the particle and wherein the length of each side of the equilateral triangle is greater than the diameter of each circle, the cross-sectional area of the particle being composed of the area of the equilateral triangle and the area of each of the circles not including the sector overlapping the central triangle;

[0048] Alternatively the plurality of openings in the extrusion die can have an expanded trilobe cross-section comprising three protrusions, extending from and attached to a central position, wherein the central position is aligned along the longitudinal axis of the particle, the cross-section of the particle occupying the space encompassed by the outer edges of three equidiameter outer circles, an effective circumference of the particle being the circumference of a circle encompassing all three of the equidiameter outer circles and being centered on the longitudinal axis of the particle, the equidiameter outer circles being disposed all of the outer circles lie within the effective circumference of the particle and such that the vertices of an equilateral triangle are located at the point where the circumference of each outer circle meets the circle defining the effective circumference of the particle, twice the diameter of the equidiameter outer circles being less than the length of a side of the equilateral triangle, the cross-sectional area of the particle being composed of the area of the equilateral triangle and the area of each of the circles not including the sector overlapping the central triangle.

[0049] In a third alternative, the plurality of openings in the extrusion die can have an expanded quadralobe cross-section comprising four protrusions each extending from and attached to a central position, wherein the central position is aligned along the longitudinal axis of the particle, the cross-section of the particle occupying the space encompassed by the outer edges of four equidiameter outer circles around a central square, each of the four outer circles being centered at a point equidistant along the bisector of the central square from the edge of the circle to the vertex of the square and the length of one side of the central square being greater than 1.5x the diameter of one of the outer circles, the cross-sectional area of the particle being composed of the area of the central square and the area of each of the circles not including the sector overlapping the central square.

[0050] The plurality of openings of the extrusion die can be independently any cross-section shape, in any ratio among them, so long as at least one has a cross-section shape as described above. In some instances all of the openings of the extrusion die will have a cross-section shape as described above. The plurality of cross-section shapes can be all the same, or every cross- section shape can be different.

[0051] The extrusion die will be of a size typically used in the art of making extruded catalyst materials and will be made of materials usually used in the art to form such extrusion dies.

[0052] A catalyst material according to the present disclosure can be made by a method comprising mixing a binder, a crystal of an active catalyst material, and water to form an extrudable paste, and extruding the paste through a die as described above.

[0053] The mixing step can further include one or more elemental metal precursors as described above.

Examples

Example 1: Preparation of MCM-41/Versal™-300 extrudates with 1/16" cylinder insert (Comparative 1) [0054] 65 parts (basis: calcined 538 °C) of small pore MCM-41 crystal were mixed with 35 parts of pseudoboehmite alumina of Versal™-300 (basis: calcined 538 °C) in a muller. Sufficient water was added to produce an extrudable paste on a 1" extruder. The mix of calcined MCM-41, pseudoboehmite alumina, and water containing paste was extruded with 1/16" cylinder and dried in a hotpack oven at 121 °C overnight. The dried extrudate was calcined in air @ 500 °C to decompose and remove the organic template. Calcined extrudates show surface area of about 700 m ² /g and crush strength of - 45 lbs/in.

Example 2: Preparation of MCM-41 /Vers al™-300 extrudates with 1/16" expanded trilobe insert

[0055] 65 parts (basis: calcined 538 °C) of small pore MCM-41 crystal were mixed with 35 parts of pseudoboehmite alumina of Versal™-300 (basis: calcined 538 °C) in a muller. Sufficient water was added to produce an extrudable paste on a 1" extruder. The mix of calcined MCM-41, pseudoboehmite alumina, and water-containing paste was extruded with 1/16" expanded trilobe inserts and dried in a hotpack oven at 121 °C overnight. The dried extrudate was calcined in air @ 500 °C to decompose and remove the organic template. Calcined extrudates have a surface area of ~ 750 m ² /g and crush strength of 44 lbs/in. These are similar to the properties of the cylindrical catalyst pieces of Example 1 and with much higher specific surface area (S/V).

Example 3: Preparation of MCM-49/V-300(80/20) extrudates with 1/20" traditional quadralobe insert (Comparative 2)

[0056] 80 parts (basis: calcined 538 °C) of MCM-49 crystal with Si/A12 of - 19/1 synthesized from US Patent No. 4,954,325 were mixed with 20 parts alumina (basis: calcined 538 °C) in a muller. The mixture of 49, alumina, and water was extruded into 1/20" traditional quadrulobe pieces and then dried at 121 °C overnight. The dried extrudate was calcined in nitrogen @ 538 °C to decompose and remove the organic template. The N2 calcined extrudate was humidified with saturated air and exchanged with 1 N ammonium nitrate to remove sodium (spec: < 500 ppm Na). After ammonium nitrate exchange, the extrudate was washed with deionized water to remove residual nitrate ions prior to drying. The ammonium exchanged extrudate was dried at 121 °C overnight and calcined in air at 538 °C. H-formed catalyst showed typical surface area of - 500 m ² /g and Alpha of > 600.

Example 4: Preparation of MCM-49/V-300(80/20) with 1/16" expanded trilobe insert

[0057] 80 parts (basis: calcined 538 °C) of MCM-49 crystal with Si/A12 of - 19/1 synthesized from US Patent No. 4,954,325 were mixed with 20 parts alumina (basis: calcined 538 °C) in a muller. The mixture of MCM-49, alumina, and water was extruded into a 1/16" expanded trilobe insert and then dried at 121 °C overnight. The dried extrudate was calcined in nitrogen @ 538 °C to decompose and remove the organic template. The N2 calcined extrudate was humidified with saturated air and exchanged with 1 N ammonium nitrate to remove sodium (spec: < 500 ppm Na). After ammonium nitrate exchange, the extrudate was washed with deionized water to remove residual nitrate ions prior to drying. The ammonium exchanged extrudate was dried at 121 °C overnight and calcined in air at 538 °C. H-formed catalyst showed surface area of - 500 m ² /g and Alpha of 860.

Example 5: Preparation of MCM-49/V-300(80/20) with 1/20" expanded trilobe insert

[0058] 80 parts (basis: calcined 538 °C) of MCM-49 crystal with Si/A12 of - 19/1 synthesized from US Patent No. 4,954,325 were mixed with 20 parts alumina (basis: calcined 538 °C) in a muller. The mixture of MCM-49, alumina, and water was extruded into a 1/20" expanded trilobe insert and then dried at 121 °C overnight. The dried extrudate was calcined in nitrogen @ 538 °C to decompose and remove the organic template. The N2 calcined extrudate was humidified with saturated air and exchanged with 1 N ammonium nitrate to remove sodium (spec: < 500 ppm Na). After ammonium nitrate exchange, the extrudate was washed with deionized water to remove residual nitrate ions prior to drying. The ammonium exchanged extrudate was dried at 121 °C overnight and calcined in air at 538 °C. H-formed catalyst showed surface area of - 490 m ² /g and Alpha of 850.

Examples 6, 7, and 8: CAP testing

[0059] Those catalysts prepared in Examples 3, 4, and 5 were tested for benzene alkylation with propylene in a 300 ml autoclave. The finished catalyst was transferred into a catalyst basket and then dried in an oven at 260° C. for about 16 hours. This catalyst basket was then transferred into a 300 ml autoclave quickly with minimum exposure to ambient atmosphere. The catalyst was then purged with dry nitrogen for 2 hours at 181° C inside the reactor to remove air and moisture from the reactor. One hundred fifty six grams of benzene was transferred to the reactor under nitrogen and equilibrated with the catalyst for 1 hour at 130° C. Twenty eight grams of propylene was transferred into reactor under 2170 KPa-a of nitrogen pressure. The reaction started as soon as propylene was added and a constant pressure of 2170 KPa-a nitrogen blanketed the autoclave. The reaction was allowed to run for four hours and propylene was completely consumed during this period. Small samples of liquid were withdrawn from the autoclave at regular interval for analysis of propylene, benzene, cumene (IPB), diisopropylbenzene(s) (DIPB), and triisopropylbenzene(s) (TIPB), using gas chromatography. Catalyst performance was assessed by a kinetic activity rate parameter base on propylene and benzene conversion. Cumene selectivity was calculated from the weight ratio of DIPB/cumene (expressed as percentage). The calculation method was as referenced in WO 03/006160.

[0060] The results are shown in the following Table 5. Catalysts having an expanded trilobe cross-section show higher CAP, than those having a traditional quadralobe cross-section consistent with their higher S/V ratio.

Table 5. CAP activity of exemplary catalysts

Catalyst Activity Selectivity DIPB/Cumene (%)

Example 3 - 280 17.5

Example 4 293/338 17.8

Example 5 364 17.0

Example 9: Preparation of Pt/Pd (0.1/0.3 wt%) coated MCM-41/Versal™-300 catalysts

[0061] 65 parts (basis: calcined 538 °C) of small pore MCM-41 crystal were mixed with 35 parts of pseudoboehmite alumina of Versal™-300 (basis: calcined 538 °C) and novel metal precursors (Platinum tetraamine nitrate and Palladium tetraamine nitrate solutions) in a muller. Sufficient water was added to produce an extrudable paste on a 1" extruder. The mix of calcined MCM-41, pseudoboehmite alumina, metal precursor, and water containing paste was extruded with 1/16" cylinder (3A) and Trilobe inserts(3B, Figure 9) and dried in a hotpack oven at 121 °C overnight. The dried extrudate was calcined in air @ 450 and 500 °C to decompose and remove the organic template.