United States Patent (19) 11) 4,115,424

Unland et al. (45) Sep. 19, 1978

(54) ZEOLITE CATALYST 56) References Cited

U.S. PATENT DOCUMENTS
75 Inventors: Mark L. Unland; George E. Barker, 3,598,879 8/1971 Kmecak et al. ................. 252/432X
both of St. Louis, Mo. 3,674,425 7/1972 Robson ............................ 252/455 Z
3,780, 125 12/1973 Takacs. ... 252/455 Z
3,962,364 6/1976 Young ...... ... 252/437 X
73 Assignee: Monsanto Company, St. Louis, Mo. 4,009,217 2/1977 Uitti................................. 260/669 R
Primary Examiner-Carl F. Dees
(21) Appl. No.: 753,041 Attorney, Agent, or Firm-Joseph D. Kennedy; John D.
Upham
22 Filed: Dec. 22, 1976 57 ABSTRACT
An improved alkylation catalyst is provided exempli
(51) Int. Cl’........................ B01J 21/02; B01J 27/34; fied by a type X or Y zeolite with cesium, rubidium or
B01J 29/06 potassium cations, and with a boron or phosphorous
(52) U.S. C. .................................... 252/432; 252/437; component added. The catalyst is useful in producing
252/455 Z; 260/669 R styrene from toluene and methanol.
(58) Field of Search ................... 252/432, 437, 455 Z; 12 Claims, No Drawings
260/669 R, 671 C
 4,115,424 2
1.
tures appropriate for alkylations can be used, for exam
ZEOLITE CATALYST ple about 350° C. to about 500 C. or so, but preferred
temperatures are about 400° C. to 475 C. Higher tem
: This invention relates to particular modified zeolite peratures can be used, but tend to degrade reactants,
catalysts and their uses: in alkylation of toluene to sty 5 and are not necessary as high conversions can be at
rene and ethylbenzene. . . . . tained in the stated ranges. The reactants can be
brought into contact with the catalyst in usual manner,
BACKGROUND OF THE INVENTION generally as a stream of reactants conducted over or
Various alumina-silicate catalysts have been known through a bed of catalyst. The contact time can be var
for various alkylations of aromatic compounds, such as 10 ied over a wide range, but will generally be selected to
the X- or Y- type zeolites described in U.S. Pat. No. obtain an acceptable conversion per pass at the reaction
3,251,897. The alkylation of toluene with methanol in temperature. For example, ranges of gas hourly space
the presence of a cation exchanged zeolite has been velocities from 50 to 5,000 hr or more are operable,
described by Yashima et al in the Journal of Catalysis, and good conversions can often be obtained even at
Vol 26, 303-312 (1972), with styrene and ethylbenzene 15 reasonably high space velocities such as 500 to 1,500
included in products produced. hror so. The reaction in general will occur as long as
quantities of both methanol and toluene are present, in
SUMMARY OF THE INVENTION ranges, for example, of 0.5 to 20 or more moles toluene
It has now been found that certain additives result in per mole methanol. However, since only one methanol
improvement of particular zeolite catalysts for the pro 20 molecule is needed, and to minimize side reactions, the
duction of styrene and ethylbenzene in alkylation reac toluene is generally used in excess, often for example, in
tions. The improved zeolite catalysts have boron or the range of 2 to 10 or 20 or more moles toluene per
phosphorous incorporated therein, with the zeolite mole methanol.
being a crystalline aluminosilicate of the faujasite struc Methylations of toluene can produce some methanol
ture with SiO/Al2O mole ratio in the range of about 2 25 decomposition products, and over some catalysts are
to about 8, and with some portion of the aikali metal capable of producing various xylenes or other alkylated
present being potassium, rubidium, cesium, or mixtures aromatics, as well as some polymer, aromatization and
thereof. The zeolites utilized are exemplified by X- and coke materials, along with the styrene and ethylbenzene
Y-type zeolites, and cesium is the preferred cation, with sought in the process of the present invention. The
a major amount of the sodium or other cation generally 30 present invention provides a means of directing the
present being replaced by the cesium. The improved process toward production of styrene and ethylben
catalysts can be utilized in an improved process for zene, and to some extent particularly toward styrene. It
producing styrene and ethylbenzene by alkylation of is obvious that there is economic advantage in directing
toluene with alkylating agents such as methanol, with the process to desired product at the expense of waste
improved selectivity to such products and/or higher 35 or less desired product. The use of the present improved
ratio of styrene to ethylbenzene in the product. Proce catalysts increases the selectivity to styrene and ethyl
dures are provided for incorporating the boron orphos benzene, i.e., it increases the amount of these products
phorous components. obtained per unit of methanol which has reacted. Also,
or in some cases alternatively, it increases the amount of
DETAILEDINVENTION
DESCRIPTION OF THE styrene in the desired products, i.e., the ratio of styrene
to styrene plus ethylbenzene. Both styrene and ethyl
Styrene is a commodity chemical sold and utilized in benzene are useful products and sought in the present
extremely large volume for producing polystyrene and invention. However, the usual use for ethylbenzene is to
other products. Hence any process for producing sty prepare styrene by dehydrogenation, and therefore
rene is of great interest if it offers a potential advantage 45 styrene is the more valuable product and there is some
in cost or in availability of reactant materials. Toluene advantage in directing the process toward styrene at the
and methanol are potentially attractive source materials expense of ethylbenzene.
for production of styrene, and the present invention In the methylation process of the present invention,
provides an improved process for producing styrene improved zeolite catalysts containing phosphorus and
from such materials. Zeolites have previously been 50 boron components are utilized. Those with a boron
employed for alkylation of toluene to styrene, but zeo component are preferred, exhibiting marked improve
lites are capable of catalyzing a variety of reactions, and ment in selectivity to styrene and ethylbenzene, as well
therefore generally produce a variety of materials along as improvement in the ratio of styrene in such products.
with the desired alkylation product. In the present in The phosphorus component tends to have a stronger
vention a catalyst is provided which gives improved 55 effect upon the ratio of styrene than upon selectivity,
selectivity to the desired styrene and ethylbenzene but nevertheless provides an advantage.
products, often with a high ratio of styrene in such In methylation reactions employing the present cata
products. The catalysts also in general have good activ lyst, it is not necessary to employ any diluents as the
ity, in many cases giving higher conversions than previ reactants can simply be conducted over the catalyst. A
ously known zeolite catalysts for such reactions. closed system is utilized, thereby avoiding possible ad
In the production of styrene and ethylbenzene, the verse effects of air, moisture, etc. but it is not necessary
present catalysts can be employed under conditions to rigidly exclude such materials by removing all traces
generally used in alkylation reactions, such as those from the system. Over a period of time the catalyst is
used in methylation of toluene with other zeolite cata subject to loss of activity from carbon deposition etc.
lysts, with the selection of particular conditions being 65 and can be regenerated by heating in air to remove the
influenced by such considerations as activity and tem carbon.
perature stability of the particular catalyst, desired con Zeolites are known for the alkylation of toluene to
version and attainable product selectivity. Tempera styrene and ethylbenzene, arid in general zeolites suit
 4,115,424
3 4.
able for such reaction can be modified as taught herein The present improved catalysts include a boron or
to provide the improved catalysts of the present inven phosphorus element or compound. The additional com
tion. For example, the X- or Y-type zeolites described ponent serves as a promoter to cause some reactions to
in the aforesaid U.S. Pat. No. 3,251,897, or the zeolites be favored at the expense of others. A small amount of
described in the aforesaid Journal of Catalysts publica the boron or phosphorus is sufficient, but the effective
tion, including those for which original sources are amounts are not narrowly critical. While extremely
cited therein. As taught herein, the modification will small amounts will have some effect, an amount suffi
include a cation exchange to provide potassium, rubid cient to approach optimum effectiveness will preferably
ium, or cesium ions, if not already present, and the be used. Excess over the optimum can be used, but large
incorporation of boron or phosphorus into the Zeolite. O excesses will not give any additional benefit, and may
In general suitable zeolites will be of the faujasite struc tend to cause unnecessary loss of catalyst activity be
ture with an SiO/Al2O3 mole ratio in the range of about cause of diluent or other effect. Generally the amounts
2 to about 8. A number of zeolites having higher silica employed will not be in excess of 5% by weight of the
to alumina ratios, such as 12 or much higher, have re boron or phosphorus, on an elemental basis, and usually
cently been advanced for various aromatization and 15 in the range of about 0.1% to about 2% by weight. The
alkylation reactions, but in general do not appear suit amounts have reference to the amount in the catalyst,
able for use in the present invention. With regard to rather than the amounts used in the preparation, which
structural classification, those zeolites with a double often are much larger, depending upon method of prep
6-ring or faujasite structure are generally suitable for aration.
use herein. Such zeolites characteristically have pore 20 The particular form of the boron orphosphorus com
diameters in excess of 6 angstroms, which is appropriate ponent has not definitely been ascertained, but it has
for admission of methanol and toluene, and to allow exit been found effective and apparently boron or phospho
of styrene and ethylbenzene. The X- and Y-type Zeo rus components retained in the catalyst, if not in proper
lites have been found very suitable for modification and form, are converted into effective form either in the
use herein, with the X-type being particularly preferred. 25 catalyst preparation or under use conditions. Presum
Type X has a typical oxide formula Na2O.Al2O3.2.5Si ably boron and phosphorus are in some oxide form, and
O6HO with SiO/Al2O3 in the range of 2.0-3.0. Type there is some evidence that the boron is actually bonded
Y has a typical oxide formula NaO.AlO4.8SiO2.8.9- to the zeolite. Thus preparation methods are used which
HO with SiO/Al2Orange from 3.0-6-0. Type L. Zeo result in retention of the boron or phosphorus in the
lites and natural faujasite materials are examples of 30 zeolite, and various compounds and procedures have
other zeolites having appropriate pore size and struc been found suitable for this purpose. The boron and
ture for use herein. In general, zeolites having suitable phosphorus components can be added to the zeolite
properties can be utilized, whether obtainable as natural during cation exchange procedures, or in subsequent
materials or prepared synthetically, and can be obtained treatments. After the boron or phosphorus component
from commercial sources or prepared by appropriate 35 has been incorporated, there appears to be some poten
laboratory crystallization procedures. tial loss by leaching or exchange, so it is generally pre
The zeolites utilized herein are modified to have po ferred to avoid excessive washing or similar procedures
tassium, rubidium or cesium ions present, individually subsequent to incorporation of the boron or phospho
or together. Usual ion exchange procedures can be rus. Also it will be undesirable to subject the catalyst to
employed to replace the sodium, hydrogen or other ions treatments known to cause loss of cations by exchange
of the zeolite with the desired cations. If equivalent with hydrogen or other ions. Moreover, the selection of
zeolites could be prepared directly with the desired solvents for exchange or impregnation procedures has
cations, the zeolites could be utilized herein, but present an influence on retention of the components in the cata
practice is to prepare the zeolites by ion exchange pro lyst. Solutions or slurries of boron or phosporus com
cedures. In theory, 81% of sodium on type X and 71% 45 pounds in such solvents as acetone, methanol, etc. can
on type Y is exchangeable, and it will ordinarily be be used. Alternatively, the boron or phosphorus can be
desirable to exchange 50% or more for potassium, ru incorporated by physical admixture of the oxides or
bidium or cesium. Smaller portions, for example 20 or other liquid or solid compounds into the zeolite, gener
30% or more, will have some effect and provide im ally in powdered or other particulate form. Various
proved catalysts as taught herein, but the improvement 50 forms of the compounds can be used, e.g. sodium or
is generally enhanced with increasing percentage potassium tetraborate, BO, boric acid, tripentyl bor
change, up to 60% or so. Above about 60%, improve rate, trimethoxy borate, phosphoric acid and its esters,
ment is not apparent, and the usual exchange proce e.g. trimethoxyphosphate, KPO, etc. Other forms of
dures do not readily produce exchanges above 65% or boron orphosphorus can readily be selected which can
so or closely approach the theoretical. For the catalysts 55 conveniently be employed to result in incorporation of
herein, cesium is the preferred cation for the Zeolite. boron or phosphorus into the catalyst. In general any
The boron and phosphorus additives have a desired methods of contacting the catalyst with boron orphos
effect on the rubidium and potassium exchanged materi phorus in a form resulting in retention in the catalyst are
als, which in some aspects is very marked, but the ce suitable. While the catalyst will generally be prepared in
sium zeolite even without additional additive, is gener advance of use, it is considered feasible to introduce
ally better, and with the additive boron or phosphorus boron orphosphorus into the catalyst along with alkyla
gives superior selectivity to styrene and ethylbenzene tion process reactants, as by adding a volatile boron or
or a better ratio of styrene, and often better activity as phosphorus compound to the reactants and contacting
well. At times it may be convenient or desirable to the catalyst zeolite material therewith, or by introduc
employ a mixture of cations, such as a mixture of rubid 65 ing such boron or phosphorus compound with inert
ium and cesium, and, of course the common prepara diluent prior to introduction of the reactants. As illus
tions generally result in a mixture of a minor amount of trated herein, the boron or phosphorus component can
sodium with one of the other cations. s conveniently be incorporated by inclusion in an ion
 5
4,115,424 6
exchange solution, or by subsequently utilizing a solu toluene, with very good selectivity to styrene and ethyl
tion of such component as a slurrying medium for cata benzene. In procedures utilizing 14 different samples of
lyst particles or as an impregnating medium to be ab such catalyst, in reacting methanol with toluene at 410
sorbed in the catalyst. The media for incorporating the C. to about 60% conversion of the methanol, the aver
boron and phosphorus do not necessarily have to com 5 age selectivity to styrene plus ethylbenzene was 50%,
pletely dissolve the boron or phosphorus material, and with the ratio of styrene to styrene plus ethylbenzene
in fact may often contain suspended solids. being 38%. This compares to a selectivity of 39.7% and
The catalyst is generally dried following impregna ratio of 21% for a control catalyst having cesium in a
tion or other liquid treatment procedures, as by heating type X zeolite, prepared by the same procedure but
at about 100 C. for a sufficient time, but such procedure 10 without the boron component. Considered on a basis of
can be omitted. The catalyst can be activated by calcin 80% conversion, the selectivity for the boron-contain
ing, i.e., heating to elevated temperatures, usually as ing catalyst is 48.4%, compared to 35.2% for the con
high as the contemplated reaction-use temperature, and trol catalyst.
often higher. Activation temperatures in the general EXAMPLE 2
range of 400 to 650° C. or so can be used, ordinarily in 15
a stream of air or inert gas. It is preferred to activate in Catalyst samples were prepared by an ion exchange
a flowing stream to mitigate possible adverse effects of procedure as described in Example 1, but without boric
water being removed, but this precaution is not essential acid in the exchange solution. Boric acid was then
to the preparation of the present improved catalyst. The added to the catalyst by slurrying the cesium zeolite
heating will cause fusion and/or decomposition of many 20 obtained from 20 grams of zeolite X, with a solution of
boron or phosphorus compounds, thereby possibly re a measured amount of boric acid in 100 grams of metha
sulting in closer association with the zeolite. nol. The slurry was stirred for 5 to 10 minutes or so, and
The present catalyst is adaptable to use in the various the catalyst solids were separated and treated as in Ex
physical forms in which catalysts are commonly used, ample 1. The catalyst was then used to methylate tolu
as particulate material in a contact bed, or a coating 25 ene be reaction of toluene and methanol supplied in
material on monolithic structures, generally being used about 5:1 mole ratio and contacting the catalyst at a bed
in a form to provide high surface area. The catalyst can temperature of 410°C. The results are reported in Table
if desired be composited with various catalyst binder or 1.
support materials which do not adversely affect the Table 1
catalyst or the reactions in which the catalyst is to be 30
employed. Toluene Methylation
The present catalysts are well suited for use in the Cesium zeolite with HBO. Added (methanol)
methylation of toluene to styrene. However, the cata HBO
in solution Con- Selectivity
lysts are also contemplated as having utility in various Catalyst (grams) version (S -- EB) Ratio S. Coke
condensation type reactions. Acidic zeolite catalysts, 35 AB 0
1
46
44
46
S4.4
30
35
36.5
46.8
5.
9.4
which have various known uses, can often be converted C 2 5 55.0 41 520 13.0
to basic catalysts by ion exchange with such ions as D 3 62 49.0 67 47.3 8.7
cesium. Such basic catalysts tend to convert methanol, E 4. 64 49.4 66 48.6 20.9
apparently through an intermediate, to carbon monox
ide, rather than to dimethylether. Borate modification In the above table, and for other data reported herein,
of the catalyst makes it slightly less basic, but it retains conversion
selectivity to carbon monoxide in methanol reactions. of methanolisinbased on methanol, and is the percentage
the reactant stream which has been con
Thus the catalyst may be useful in various reactions of verted to other compounds. Selectivity (S -- EB) is the
methanol involving production of carbon monoxide as
an intermediate. The catalyst may also find use in other 45 percentage of methanol converted which is found as
reactions of toluene involving activation such that reac conversion ofethylbenzene.
styrene and So is the selectivity at 80
tion occurs at the methyl group rather than on the ring. to styrene plus ethylbenzene,Ratio
the methanol. is styrene compared
on a mole percentage
The following examples are illustrative of the inven basis. "Coke' is a relative number, indicating the ten
tion.
50 dency of the catalyst to form carbon, with higher values
EXAMPLE1 indicating more carbon.
A zeolite catalyst with cesium cation and boron addi in The data indicates that the presence of boron results
tive was prepared as follows. One liter of an aqueous zene as well as aninincrease
improvement selectivity to styrene and ethylben
solution was prepared containing 75 grams CsCH and product. Conversions areinalso the ratio of styrene in that
increased, indicating
50 grams HBO. Twenty grams of a type X zeolite 55
(Linde SK20) was ion exchanged with a 300 ml portion good activity even at a temperature of only 410 C.
of the solution with stirring at about 100 C. for 2 hours. Such converions are obtainable at gaseous hourly space
The exchange procedure was repeated for 3 hours with velocities of 950 hr, and faster space velocity will
another 300 ml. portion of the solution. The procedure generally lower conversions, while slower space veloci
was then repeated overnight using the remaining 400 60 ties raise conversions. The improved selectivity and
ml. solution. The solid zeolite was then dried at 100 C. therefore higher yield of styrene was obtained despite
in air for 4 hours. The resulting solid powder was the higher carbon formation indicated by the coke in
pressed under pressure into 1 inch disks, which were dex.The results in the methylation -
reactions herein are
then crushed and screened into 8 x 30 mesh particles. 65 largely reported on the basis of methanol, as the yields
The catalyst can then be activated by heating to about
reaction temperature, or approximately 450° C., in inert based on toluene are generally very high, while the
gas, such as a flowing nitrogen stream, or in air. The methanol is the reactant with a tendency to undergo
thus prepared catalyst is suitable for methylation of side or decomposition reactions and with regard to
 4,115,424
7 8
which improvement over previously known procedures Table 4
is sought. Methylation of Toluene
EXAMPLE 3 Cesium Zeolites with Phosphorous or Boron
Cat- Add- Con- Selectivity
Catalysts were prepared as in Example 2, but utilizing 5 alyst Zeolite itive version (S -- EB) Ratio Ss. Coke
acetone as the solvent in the slurrying operation, rather N X HPO, 99 35.2 42 41.4. 14.7
O Y HPO, 85 26.5 70 - --
than methanol. The catalyst was then used to methylate P X HBO 100 44.3 34 46.8 9.9
toluene with methanol at 950 hr space velocity as in Q
R
Y
X
HBO,
one
64
100
37.4
25.0
71
1
37.4
34.4
4.1
6.0
Example 2, but at a temperature of 450° C., with results O
S Y None 93 16.5 3 17.7 3.3
as reported in Table 2.
Table 2 Active catalysts are formed from both X and Y type
Toluene Methylation zeolites, and both phosphorus and boron have a benefi
Cesium zeolite with HBO. Added (Acetone) cial effect on selectivity of the catalysts.
HBO, 15
in solution Con- Selectivity EXAMPLE 6
Catalyst (grams) version (S -- EB) Ratio Ss. Coke
F O 99 29.4 8 41.6 7.4 A type X zeolite was treated in an ion exchange pro
G 0.5 98 44.9 27 46.9 13.8 cedure to produce a cesium exchanged zeolite, and 21.5
H
I
1.0
2.0
97
92
46.8
43.7
43
76
48.6
46.9
12.5
7.2
grams of the particulate material was physically mixed
20 with 1 gram of boric acid. The material was pressed into
disks which were then broken into particulate material
The presence of boron again improves selectivity to and activated as catalyst by heating in the reactor. At a
styrene and ethylbenzene, and the ratio of styrene in the temperature of 410 C., the material was effective for
product. Also the coke formation was lower than with methylation of toluene, giving selectivity of 49.1% to
some other catalysts. Referring particularly to catalyst 25 styrene plus ethylbenzene with a 42% ratio of styrene,
I, the conversion, selectivity and ratio were all high, conversion of 69% and a coke index of 10.8.
resulting in a very good styrene monomer yield, 33% EXAMPLE 7
per pass. Acetone has advantage as a solvent for addi
tion of boron or other components subsequent to the Portions of a cesium zeolite catalyst were physically
zeolite preparation, as it has less tendency than more 30 admixed with measured amounts of boric acid, to incor
polar solvents to cause ion exchange or similar reactions porate a specified amount of boric acid into 21-22
which result in loss of cations. grams or so of zeolite, and the catalysts were activated
and utilized for methylation of toluene with methanol in
EXAMPLE 4 a mole ratio of 5.25 to 1,950 hr gaseous hourly space
Cesium exchanged zeolite X was prepared as in Ex 35 velocity, and temperature of 410° C. Results are re
ample 1, but without boron additive. Twenty gram ported in Table 5.
portions of the zeolite were used. The resulting cesium Table 5
zeolite was then impregnated with a boron compound Methylation of Toluene
Cesium Zeolite - Boric Acid Mixture
by treating the zeolite with approximately an equal Weight
weight of methanol, containing one gram of a boron Boric Acid Selectivity
compound. The zeolite was then vacuum dried and (grams) Conversion (S -- EB) Ratio S80 Coke
activated for catalytic use. Results for reaction of meth 1
2
53
37
52.4
53.5
35
44
50.6
46.8
8.9
5.5
anol and toluene at 410 C. and under previously de 5 16 43.1 70 40 1.8
scribed conditions are reported in Table 3. 45
Table 3
Toluene Methylation EXAMPLE 8
Cesium Zeolite with Boron Compound Impregnated Procedures are known in which catalysts have been
Boron Con- Selectivity prepared from type X zeolite by ion exchange to have
Catalyst Compound version (S -- EB) Ratio So Coke 50
J None 67 34.9 17 33.3 6.7
rubidium or potassium ions. Procedures as described in
K. HBO, 68 44.6 55 44.8 16.5 Example 1 can be employed. Similar exchanges were
L BO 60 440 80 45.9 16.1 run in which phosphoric acid had been added to the
M NaBO 77 43.3 27 43.3 10.6 alkali hydroxide exchange solution (to pH 10). The
55
catalysts were activated and employed in a reaction of
The various forms of added boron resulted in improved toluene and methanol at 5.25/1 mole ratio at 410 C.,
selectivity. and 950 hrspace velocity. Results, along with those
for reference catalysts, are reported in Table 6.
EXAMPLE 5 Table 6
Catalysts were prepared from type X (Linde SK20) Toluene Methylation
and type Y (Linde SK 40) zeolites, by exchange with Catalyst Catalyst with HPO,
cesium hydroxide in water. Additional catalysts were Con- Selectivity
Cation Additive version (S -- EB) Ratio So Coke
prepared under the same conditions, but with phos Cs None 61 44.6 27 39.5 8.3
phoric or boric acid added in the exchange solution, to Cs HPO, 62 44.4 66 414 14.7
bring it to a pH of 10. The catalysts were employed in 65 Rb HPO, 43
Rb None 61 28.2
42.6
24
44
26.7
32.7
7.9
6.6
the reaction of methanol and toluene at 950 hr gase K O 57 21.4 37 21.0 7.6
ous hourly space velocity and 450° C., with results K HPO, 45 21.1 60 21.6 6.0
reported in Table 4.
 4,115,424 10
9
The results were fairly good with all of the catalysts, and at 400° C. An effluent sample was taken after 17
including those with potassium and rubidium as cation, minutes, and an additional sample after 37 minutes, with
and the phosphoric acid improved the ratio of styrene in results as follows:
the product. Table 9
Rubidium and potassium zeolite catalysts were pre 5
Selectivity
pared as in Example 8, from X type zeolite, but with Time Conversion (S + EB) Ratio Coke
boric acid (to pH10) in the alkali metal hydroxide ex 17 nin, 100 41.9 75 15
change solution. The catalysts were employed in the 37 min. 100 36.5 77 8
reaction of toluene and methanol (5.25:1 mole ratio in
feed) at 410 C, and 950 hr. Results, along with those 10
The results indicate the boron-containing catalyst
of reference catalysts, are reported in Table 7. was successfully used for reacting trioxane and toluene
Table 7 to form styrene and ethylbenzene. The trioxane utilized
Methylation of Toluene was s-trioxane, m.p. 58-60' C, mol. wt. 90.08.
Catalyst with HBO After the reaction with trioxane, the coke was burned
Catalyst Con-Selectivity 15
Cation Additive version (S -- EB) Ratio So Coke off the catalyst for 38 minutes (16 millimoles coke) and
Cs None 61 44.6 27 39.5 8.3 the catalyst was then utilized for reacting toluene and
Cs HBO 58 51.9 29 49.8 9.2 methanol (5.25/1 mole ratio) at 400 C., with a sample
Rb
Rb
Ole
HBO
61
40
28.2
40.2
24
31
26.7
36.5
7.9
6.0
after 5 minutes showing 49% conversion, 53.5% selec
K One 57 21.4 37 21.0 7.6 20 tivity, a ratio of 43%, and coke 9.8.
K HBO 44 22.5 62 24.6 7.3 In the production of styrene and ethylbenzene ac
cording to the present invention formaldehyde, or
The boric acid resulted in improved catalysts, note the forms or derivatives of formaldehyde producing form
improvement in So in each case over the reference aldehyde in situ can be employed and are contemplated
catalyst. 25 in the use of formaldehyde described herein. Also it will
In the conversion of toluene to styrene and ethylben be recognized that various industrial sources of metha
zene over the catalysts of the present invention, reac nol or formaldehyde are available, as for example meth
tants other than methanol can be used. Such reactants anol produced in a methanol reformer from carbon
are for convenience termed "methylating' agents monoxide and hydrogen obtained in a cracking process.
herein, although styrene does not actually differ from 30 What is claimed is:
toluene by a methyl group. Methanol and formalde 1. A catalyst comprising a crystalline aluminosilicate
hyde, or various forms or sources of formaldehyde can zeolite of the faugasite structure with SiO/Al2O mole
be used, e.g. trioxane, methylal, paraformaldehyde, or ratio in the range of about 2 to about 8 and including
commercial formaldehyde solutions such as Formcel potassium, rubidium or cesium cations or combinations
formaldehyde solution (55% formaldehyde, 10% water 35 thereof, and containing boron orphosphorus or combi
and balance methanol). nations thereof.
2. The catalyst of claim 1 containing boron.
EXAMPLE 9 3. The catalyst of claim 1 in which the zeolite in
A boron-containing catalyst was prepared in accor cludes cesium cation.
dance with the procedure of Example 1, but employing 4. The catalyst of claim 3 containing boron.
a type X zeolite prepared in the laboratory and very 5. The catalyst of claim 1 in which boron has been
similar to SK20 zeolite used in Example 1. The catalyst introduced by addition of boric acid.
was employed under the usual conditions in the reaction 6. The catalyst of claim 1 in which boron has been
of methanol and toluene (5.25 moles/1 mole) with re introduced by addition of an oxide of boron.
sults as follows 45 7. The catalyst of claim 1 in which potassium, rubid
Table 8 ium or cesium cations have been introduced into a type
Selectivity X or Y zeolite by ion exchange procedures to have at
Temperature Conversion (S -- EB) Ratio least 50% of the potential alkali metal content as such
450 C 98 48.3 10 cations,
430' C 85 54.2 18 50 8. The catalyst of claim 7 in which cesium is at least
40' C 60 58.3 24 60% of the potential alkali metal.
9. The catalyst of claim 8 in which the zeolite is type
The effluent sample for the 450 C. readings was X.
taken after the feed was on stream for ten minutes, the 10. The catalyst of claim 8 containing boron.
430 C. sample after an additional 17.5 minutes, and the 55 11. The catalyst of claim 10 in which boron is present
410 C. sample after an additional 17.5 minutes. in an amount of 0.1% to 2% by weight of the catalyst.
The boron-containing catalyst described above was 12. The catalyst of claim 1 in which boron or phos
utilized in a reaction of trioxane with toluene. A feed of phorus are present in amounts no greater than 5% by
30 moles toluene/1 mole s-trioxane (10/1 mole tolue weight of the catalyst.
k sk sk
ne/CHO) was employed at the usual space velocity 60

65